QFR No - 8000862973
Defect Details
| NC No. | 8000862973 |
| NC Date | 14/02/2024 |
| NC Submission Date | |
| Part No. | F2LY02502B |
| Part Name | SOCKET HEADED BOLT - RE J1A |
| Supplier Name & Code | 100846-SANGKAJ ENGINEERING PVT.LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-PLATING THICKNESS FOUND NOT OK |
1. Problem Description
| Defect Description | Pinch bolt - J1C plating thickness found 6 to 8 microns against 8 microns minimum |
| Detection Stage | Customer End |
| Problem Severity | Aesthetic |
| NG Quantity | 6200 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | sepl.quality@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6200
|
0
|
0
|
0
|
0
|
6200
|
| Check Qty |
6200
|
0
|
0
|
0
|
0
|
6200
|
| NG Qty |
6200
|
0
|
0
|
0
|
0
|
6200
|
| Scrap | 0 |
| Rework | 6200 |
| Under Deviation | 0 |
| Containment Action |
|---|
| rework done on all part |
3. Process Flow
| Process Flow Description |
|---|
| Wire Draw - Cold Forging - Thread Rolling - HT - Plating - F.I. - Dispatch. |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | Plating |
| Machine / Cell No. | Auto Line |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Due to excess loading in a batch qty | Cause Verfied | 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 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Thickness at lower side |
| Why 2 | Current fluctuation observed |
| Why 3 | Current not properly distributed |
| Why 4 | Due to excess loading in a batch qty ( 50 Kg against 40 Kg ) |
| Why 5 | Manually batch quantity taken on weighting scale |
| Root Cause (Occurance) | Manually batch quantity taken on weighting scale |
Root Cause Analysis (Outflow)
| Why 1 | Plating Thickness at lower side |
| Why 2 | Not detected at final inspection. |
| Why 3 | Measurement variation observed. |
| Why 4 | in DFT meter plating thickness not get proper reading. |
| Why 5 | |
| Root Cause (Outflow) | in DFT meter plating thickness not get proper reading. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Online weighting interlock system implementation | Krishna Industries | 15/03/2024 | 07/03/2024 | Completed |
| Outflow | Now every batchwise samples is getting checked by XRF . | Krishna Industries | 16/02/2024 | 16/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Now every batch-wise samples is getting checked by XRF |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 30 Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Manualy batch quantity taken on weighting scale 679_Occurance_Before.pptx |
| Occurance (After) |
We are implementing the online weighting interlock system with over load alarm /buzzer 679_Occurance_After.pptx |
| Outflow (Before) |
We checked batch wise thickness on in house thickness tester 679_Outflow_Before.xlsx |
| Outflow (After) |
Now every batch wise samples is getting checked by XRF. 679_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Plated Parts. |
12. Document Review
| Documents | ControlPlan, PokayokeCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 567 |
| Reason for submission | Found ok |