QFR No - 8000865072
Defect Details
| NC No. | 8000865072 |
| NC Date | 29/02/2024 |
| NC Submission Date | |
| Part No. | S2AB00512B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | PLATING NOT OK-PLATING PEEL OFF |
1. Problem Description
| Defect Description | Plating Peel off found in adjuster |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 7 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 3iisml0gioq3mxwcs2srfye1.jpg |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
1000
|
2000
|
2000
|
1000
|
7000
|
| Check Qty |
1000
|
1000
|
2000
|
2000
|
1000
|
7000
|
| NG Qty |
1
|
1
|
0
|
2
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material segregated |
3. Process Flow
| Process Flow Description |
|---|
| 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 80 ID SIZING 90 SIDE GRINDING 100 BROACHING 110 SINGLE GROOVE MATCHING 120 HEAD GRINDING 130 OUTSIDE MOVEMENT FOR PLATING 140 STORAGE & RQC INSP. OF PLATED MATERIAL 150 FINAL INSPECTION 160 PACKING & DISPATCH TO CUSTOMER |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | Semi Nickle drug out process |
| Machine / Cell No. | Semi Nickle drug out |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Semi bright drug out water level low | Water level checked and found | X |
| Method | Process was not followed | All process checked and found implementedd | O |
| Machine | Low capacity tank | Semi bright drug out level was low | X |
| Tool | Wrong jig/ hanger used | Hanger checked and found ok | O |
| Man | Unskilled manpower | Skilled manpower available and skill matrix verified | O |
| Material | Wrong chemical used | All chemical checked as per TDS data sheet and found OK | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | File test |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 pcs each |
7. Root Cause Analysis (Occurance)
| Why 1 | Peel off |
| Why 2 | Part peel off from bright layer |
| Why 3 | Bright layer was not bond on part |
| Why 4 | Semi bright layer was oxidize |
| Why 5 | Part was not completely in the DM water during semi bright drug out due to Semi Bright drug out water level was low |
| Root Cause (Occurance) | Part was not completely in the DM water during semi bright drug out due to Semi Bright drug out water level was low |
Root Cause Analysis (Outflow)
| Why 1 | Defective part passed at customer end |
| Why 2 | Defective part not detected |
| Why 3 | Later peel-off problem generated in part |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Later peel-off problem generated in part |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Training provided to all | Veekay | 10/03/2024 | 20/03/2024 | Completed |
| Occurance | Semi Bright drug out water level increased | Veekay | 12/03/2024 | 20/03/2024 | Completed |
| Outflow | File test frequency revised | Veekay | 06/03/2024 | 20/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | File test frequency revised . |
| Inspection Method | Other |
| Other Inspection Method | File test frequency |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20 per lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Water level was low at semi bright drug out 693_Occurance_Before.pptx |
| Occurance (After) |
Water level increased at semi bright drug out 693_Occurance_After.pdf |
| Outflow (Before) |
File test done in 5 pcs each lot 693_Outflow_Before.png |
| Outflow (After) |
File test done 20 pcs each lot 693_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Adjuster HF delux |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |