QFR No - 8000861163
Defect Details
| NC No. | 8000861163 |
| NC Date | 30/01/2024 |
| NC Submission Date | |
| Part No. | 550LZ00102 |
| Part Name | SPACER L 50-PRF001 |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIAMETER OVER SIZE-OVALITY & 33±0.1 GRUE OD OVER SIZE |
1. Problem Description
| Defect Description | Groove OD over size |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 114 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | planthead.aurangabad@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1400
|
0
|
0
|
0
|
0
|
1400
|
| Check Qty |
1400
|
0
|
0
|
0
|
0
|
1400
|
| NG Qty |
114
|
0
|
0
|
0
|
0
|
114
|
| Scrap | 114 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Immediately visited customer end for problem identification & 100% checking of all available stock at customer end completed |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of raw material, Inward inspection , storage, Material issue, Injection molding, Machining, Deflashing & final inspection, Packing & labelling, Pre dispatch inspection, despatch |
4. Process Details
| Process / Operation | Injection Molding |
| Outsource | No |
| Machine / Cell | Injection molding machine |
| Machine / Cell No. | IM-5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Sampling Inspection at Final Inspection stage & on machine | Verified that at FI inspection by gauge on sampling basis & operator was checking after every hour | X |
| Method | Part clamping not correct | Verified that part clamping on machine was not correct | X |
| Man | Operator having less awareness | Varified & found that operator was having less awareness about the issue | X |
| Tool | Tool not ok / wear out | Verified that there was no problem in tool | O |
| Material | Use of improper material | Veried that material used was as per specifications | O |
| Machine | Improper Cooling time in Injection moulding | Verified and found that cooling time was as per specified | O |
| Machine | Jaw wear out in machining | Verified and found that jaw condition was ok | O |
| Method | Process parameters not followed | Verified that process parameters were as specified | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Aslot size |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove OD O/S - Req Specification 33.95+/- 0.1 mm & found oval |
| Why 2 | While machining for groove equal material not removed from part OD |
| Why 3 | Due to part clamping was not centered in jaws |
| Why 4 | Flashes not removed from part before clamping |
| Why 5 | Manual error |
| Root Cause (Occurance) | Flashes on part were not removed by the operator prior its loading for machining ( Manual error) |
Root Cause Analysis (Outflow)
| Why 1 | Groove OD O/S - Req Specification 33.95+/- 0.1 mm & found oval |
| Why 2 | Part skipped from machine & Final inspection stage |
| Why 3 | Inspection on sampling basis on machine by operator & by inspector at FI |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection on sampling basis on machine by operator & by inspector at FI |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Training provided to operator on removing flashes from part , prior to loading on machine | Production | 24/02/2024 | 24/02/2024 | Completed |
| Outflow | 1. Parts are checking 100% with GO Gauge for groove OD at FI with Identification mark. 2. Now 100% parts are checked by gauge (groove OD 33.95 +/-0.1 mm) by operator on machine. 3. Displayed OK/NG samples at work station & also displayed OPL. | QA HOD | 24/02/2024 | 24/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1. Parts are checking 100% with GO Gauge for groove OD at FI by inspector with Identification mark. 2. Now 100% parts are checked by gauge (groove OD 33.95 +/-0.1 mm) by operator on machine |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Operator having less awareness about the issue 656_Occurance_Before.xlsx |
| Occurance (After) |
Training provided to the operator ( Training Record) 656_Occurance_After.pdf |
| Outflow (Before) |
Inspection on Sampling basis with gauge on machine by operator & at Final inspection by inspector 656_Outflow_Before.xlsx |
| Outflow (After) |
100% Inspection with gauge by operator on machine & by inspector at FI 656_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not Applicable |
12. Document Review
| Documents | |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 11000 |
| Reason for submission | after action implementation no any parts found defective. |