QFR No - 8000862169
Defect Details
| NC No. | 8000862169 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | 520AT00302 |
| Part Name | BEARING CONE ELIMINATOR |
| Supplier Name & Code | 100264-SAI INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-SCALING OBSERVED |
1. Problem Description
| Defect Description | Scaling observed |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 186 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | info@sai-industries.com |
| Plant Head/CEO Email ID | info@sai-industries.com |
| MD Email ID | umesh.honap@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
800
|
640
|
0
|
1000
|
640
|
3080
|
| Check Qty |
800
|
640
|
0
|
1000
|
640
|
3080
|
| NG Qty |
186
|
0
|
0
|
0
|
0
|
186
|
| Scrap | 0 |
| Rework | 186 |
| Under Deviation | 0 |
| Containment Action |
|---|
| In ETL found 186 nos. Scaling on Track side face out of 800 Nos. Logistic 640 nos. finish stock verify to Scaling on Track side face found all are ok & marked green dot on o/d 51 In SAI - 1000 nos. finish stock for inhouse verification found all are ok.Mark green dot on o/d 51 |
3. Process Flow
| Process Flow Description |
|---|
| Blank - Drilling - CNC Ist set up - CNC IInd set up - Heat Treatment - Vibro Finishing/Cleaning - O/D Grinding - I/D & Hard Track - Final Inspection - Packing & Dispatch. |
4. Process Details
| Process / Operation | Vibro Finishing/Cleaning |
| Outsource | No |
| Machine / Cell | Vibro |
| Machine / Cell No. | SI/VB/01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Uneven media(Media warn out) use in vibro cleaning. | Verify Media Size & Shape | O |
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 | Scaling on Track side face observed |
| Why 2 | In Line Inspection not addressed the above defect. |
| Why 3 | Some parts clean properly some part not clean. |
| Why 4 | Uneven media(Media warn out) use in vibro cleaning. |
| Why 5 | |
| Root Cause (Occurance) | Uneven media(Media warn out) use in vibro cleaning. |
Root Cause Analysis (Outflow)
| Why 1 | Scaling on Track side face observed. |
| Why 2 | In Final Inspection not detect the above defect. |
| Why 3 | May by mix up in ok qty. |
| Why 4 | Separated parts mix up in ok part during packing stage. |
| Why 5 | |
| Root Cause (Outflow) | Separated parts mix up in ok part during packing stage. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | On job training given to final inspection person as well as packing person. Do not mix up without vibro cleaning part in ok qty. Display OK not ok photo. | Santosh/Tajane | 08/02/2024 | 08/02/2024 | Completed |
| Occurance | We are already implementing Vibro cleaning, which is extra operation after heat treatment . | Santosh/Tajane | 08/02/2024 | 08/02/2024 | Completed |
| Occurance | Replaced warn out Media(stone) immediately. Follow Media changed frequency strictly as per revised work instruction. | Santosh/Tajane | 08/02/2024 | 08/02/2024 | Completed |
| Outflow | OK component marked with Green dot mark on O/D 51. | Devendra | 08/02/2024 | 08/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Warn out Media 667_Occurance_Before.jpg |
| Occurance (After) |
New Media 667_Occurance_After.pdf |
| Outflow (Before) |
Withuot Frequency WI 667_Outflow_Before.pdf |
| Outflow (After) |
With Frequency WI 667_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all Model |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Ok & not ok display |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |