QFR No - 8000854744
Defect Details
| NC No. | 8000854744 |
| NC Date | 12/12/2023 |
| NC Submission Date | |
| Part No. | B2SU00702O |
| Part Name | BRAKE HOSE TUBE CLAMP 1(NTORQ) |
| Supplier Name & Code | 100151-EXCELL PRESSINGS |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | PLATING NOT OK-PLATING NOT OK |
1. Problem Description
| Defect Description | PLATING NOT OK-PLATING NOT OK |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 164 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | excellpressings.qc@gmail.com |
| Plant Head/CEO Email ID | yogesh_vaidya42@gmail.com |
| MD Email ID | excellpressings@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
2000
|
1000
|
4000
|
| Check Qty |
1000
|
0
|
0
|
2000
|
1000
|
4000
|
| NG Qty |
164
|
0
|
0
|
0
|
0
|
164
|
| Scrap | 0 |
| Rework | 164 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All the lots are checked at ETL end and our end. |
3. Process Flow
| Process Flow Description |
|---|
| After pressings operation, the material is given for plating to M/S Krishna Industries.Then at final inspection 100% visual inspection is being carried out. |
4. Process Details
| Process / Operation | Plating operation |
| Outsource | Yes |
| Machine / Cell | KI _ WATT TANK NO 02 |
| Machine / Cell No. | KI _ WATT TANK NO 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Current supply issue on jigs | Rectifier wires loose contact so that causes for current fluctuations | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Thickness observed below 8 micron |
| Why 2 | Current fluctuations observed |
| Why 3 | Jigs copper getting hot |
| Why 4 | V block getting loosed |
| Why 5 | Monthly maintenance was not done to V block |
| Root Cause (Occurance) | Current fluctuation due to over heat cathode contacts |
Root Cause Analysis (Outflow)
| Why 1 | Visul found ok |
| Why 2 | Thickness was not checked |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Thickness was not checked after plating operation |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Current supply issue caused to lower the thickness | M/S Krishna Industries | 19/12/2023 | 20/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Every lot thickness will be checked at Krishna Industries and Excell pressings |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
10. Evidance of Countermeasure
| Occurance (Before) |
V block get damaged 616_Occurance_Before.jpg |
| Occurance (After) |
V block repaired 616_Occurance_After.jpg |
| Outflow (Before) |
Not Ok plating part 616_Outflow_Before.jpg |
| Outflow (After) |
Ok plating part 616_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | At Krishna Industries, process flow chart is followed on every stage |
12. Document Review
| Documents | ControlPlan, JHCheckSheet, InspCheckSheet |
| Specify Other Document | FFPA checksheet |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | No defect found in latest lot |