QFR No - 8000857899
Defect Details
| NC No. | 8000857899 |
| NC Date | 08/01/2024 |
| NC Submission Date | |
| Part No. | 520HL00202 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 100176-GKN SINTER METALS PRIVATE LIMI |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-HEAVY RUSTY |
1. Problem Description
| Defect Description | Heavy rusty |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1300 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Rajendra.Sethiya@gknpm.com |
| Plant Head/CEO Email ID | Pratik.Dharangaonkar@gknpm.com |
| MD Email ID | Rajesh.Mirani@gknpm.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7500
|
12000
|
0
|
0
|
0
|
19500
|
| Check Qty |
7500
|
12000
|
0
|
0
|
0
|
19500
|
| NG Qty |
400
|
0
|
0
|
0
|
0
|
400
|
| Scrap | 400 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All stock lying at ETL segregated , Quality alert raised at Concerned Area |
3. Process Flow
| Process Flow Description |
|---|
| Forming - Sintering - Barreling - Steam Treatment - PDI |
4. Process Details
| Process / Operation | Steam Treatment |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Inspection Standard not available | Inspection standard verified, available at concerned area | O |
| Man | Untrained Operator | Operator skill matrix is ok | O |
| Material | Parts Metallurgy NG | Parts are OK to the metallurgical check and found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Rust observed on part`s surface |
| Why 2 | Part got rust as it came in contact with Moisture |
| Why 3 | Insufficeint protection for parts getting Rust due to Monsoon season |
| Why 4 | Parts been handled in MS Basket not covered with VCI Bags |
| Why 5 | |
| Root Cause (Occurance) | As during Mansoon season part came in contact with Moisture due to which part got Rusted during Storage. |
Root Cause Analysis (Outflow)
| Why 1 | Rust observed on part`s surface |
| Why 2 | Didn’t get detected during Final Inspection |
| Why 3 | Part got rust after Dispatch/Storage |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | During In-process & Final Inspection parts found OK & got rusted during Storage at warehoue. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | During Mansoon season parts to be handled in VCI Bags in MS Baskets to ensure parts doesn’t came in contact with moisture. | Vijay Thorat | 17/02/2024 | Completed | |
| Outflow | After action implementation 100nos samples to be kept for Observation, which need to check once a week for 4months. | Rohan G | 29/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | After action implementation 100nos samples to be kept for Observation, which need to check once a week for 4months. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
No polybags for MS basket 628_Occurance_Before.pdf |
| Occurance (After) |
During Monsoon season parts to be handled in VCI Bags in MS Baskets to ensure parts doesn’t came in contact with moisture. 628_Occurance_After.pdf |
| Outflow (Before) |
NA 628_Outflow_Before.pdf |
| Outflow (After) |
NA 628_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PFMEA, WISOP, AuditCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Found ok |