QFR No - 8000853049
Defect Details
| NC No. | 8000853049 |
| NC Date | 28/11/2023 |
| NC Submission Date | |
| Part No. | S2HT49207B |
| Part Name | OUTER SPRING SILVER- AAGM |
| Supplier Name & Code | 100186-SAGAR SPRINGS PRIVATE LIMITED |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | POWDER COATING NOT OK-RUBBING MARK |
1. Problem Description
| Defect Description | RUBBING MARK AND SCRATCH MARK IN AAGM SILVER OUTER SPRING |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 490 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | dhsnflow3mtppp15idcmtd4b.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@sagarsprings.com |
| Plant Head/CEO Email ID | ajai.singh@sagarsprings.com |
| MD Email ID | sagar@sagarsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1980
|
0
|
0
|
280
|
0
|
2260
|
| Check Qty |
1980
|
0
|
0
|
280
|
0
|
2260
|
| NG Qty |
490
|
0
|
0
|
0
|
0
|
490
|
| Scrap | 0 |
| Rework | 490 |
| Under Deviation | 0 |
| Containment Action |
|---|
| SSPL represntative visited ETL verify the problem and segregated spring at ETL end 490 nos recall to sagar springs and will be recovered |
3. Process Flow
| Process Flow Description |
|---|
| coil-tempring,end grinding-shot pinning-tempring-sq connection Htchecking-pre-treatment-powder coating-inspection-packing-dispatch |
4. Process Details
| Process / Operation | Packing |
| Outsource | No |
| Machine / Cell | Packing |
| Machine / Cell No. | 130 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Person negligence on spring handling | Found persons are aware and handling it properl | O |
| Material | Powder deffective | Found powder is OK as problem is not 100% | O |
| Method | Packing method is not adequate | Spring is packed in box which is tight which result in to rubbing mark | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Rubbing mark on silver spring |
| Why 2 | Spring outer surface is get rubbed hardly |
| Why 3 | Spring is packed in corrugated box with 30 nos honey comb interlock is tight |
| Why 4 | Bin for spring is not available as regular bins area short in height while spring height is more |
| Why 5 | |
| Root Cause (Occurance) | Spring pack in corrugated box which is tight and same bin for particular spring is not available |
Root Cause Analysis (Outflow)
| Why 1 | Spring with rubbing mark move to customer |
| Why 2 | Rubbing mark generated after packing hence it is not detected |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Rubbing mark generate after packing in corrugated box |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Bin with proper height with plastic insert will be developed and same will be introduced for packing | Powder Coating Supervisor | 31/12/2023 | 28/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | As rubbing mark is in packing hence packing mode is change so there is no need in change in inspection method |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Earlier springs was dispatched in corrugated box which remain tight and generate black rubbing mark on spring Outer surface 601_Occurance_Before.pdf |
| Occurance (After) |
Started packing and dispatch spring in Plastic with PP interlock to avoid rubbing mark 601_Occurance_After.pdf |
| Outflow (Before) |
Spring is checked and rubbing mark generates after packing hence it not get detected 601_Outflow_Before.pdf |
| Outflow (After) |
One point lesson given to inspector and started sampling checking of packed spring 601_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All powder coated spring with metallic silver paint |
12. Document Review
| Documents | ControlPlan, PackingStd |
| Specify Other Document | Packing std |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |