QFR No - 8000858545
Defect Details
| NC No. | 8000858545 |
| NC Date | 13/01/2024 |
| NC Submission Date | |
| Part No. | B2BK01723O |
| Part Name | CALIPER BODY POWDER COATING -AVENGER |
| Supplier Name & Code | 100204-KRISHNA COATING |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | POWDER COATING NOT OK-PART REJECTED AFTER 100% INSPECTION AT E |
1. Problem Description
| Defect Description | POWDER COATING NOT OK |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 192 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualitykrishnaassociates01@gmail.com |
| Plant Head/CEO Email ID | ravikrishnacoating@gmail.com |
| MD Email ID | krishnacoating@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3460
|
0
|
0
|
0
|
0
|
3460
|
| Check Qty |
3460
|
0
|
0
|
0
|
0
|
3460
|
| NG Qty |
192
|
0
|
0
|
0
|
0
|
192
|
| Scrap | 0 |
| Rework | 192 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Uncover issue found. After inspection we found Venturi in powder coating gun defective i.e. damaged venturi. We replaced defective venturi with new one. After venturi replacement uncover issue was not observed. |
3. Process Flow
| Process Flow Description |
|---|
| Inward - Pretreatment - Drying - powder Coating- Baking- Final Inspection - dispatch. |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | No |
| Machine / Cell | Powder Coating Line |
| Machine / Cell No. | Powder Coating Line |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Powder Coating Gun defect | Venturi in powder coating gun found damaged | O |
| Man | Inconsistent powder coating by operator | Operator found doing Powder coating ok | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Uncover issue observed in Caliper Body. |
| Why 2 | Powder Gun not proper check for powder coating process |
| Why 3 | Powder flow not proper on the component |
| Why 4 | Defective venturi observed in Powder coating Gun |
| Why 5 | |
| Root Cause (Occurance) | Defective Venturi observed in Coating Gun |
Root Cause Analysis (Outflow)
| Why 1 | Uncover issue observed due to damaged coating Gun Venturi |
| Why 2 | Coating Gun venturi not checked on regular basis |
| Why 3 | Improper gun cleaning |
| Why 4 | Operator was unaware about proper gun cleaning |
| Why 5 | |
| Root Cause (Outflow) | Coating Gun venturi not checked on regular basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Training provided to operator on gun checking and cleaning | supervisor | 15/01/2024 | 14/01/2024 | Completed |
| Occurance | Damaged Venturi replaced with new one. | Supervisor | 15/01/2024 | 14/01/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% a lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Damaged Venturi found as shown in attachment 634_Occurance_Before.jpg |
| Occurance (After) |
New Venturi replaced with old one which was damaged 634_Occurance_After.jpg |
| Outflow (Before) |
Gun Venturi checking was doing once per day 634_Outflow_Before.jpg |
| Outflow (After) |
Gun Venturi Checking daily twice. 634_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Al powder coating Guns |
12. Document Review
| Documents | |
| Specify Other Document | None |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |