QFR No - 8000865087
Defect Details
| NC No. | 8000865087 |
| NC Date | 29/02/2024 |
| NC Submission Date | |
| Part No. | B2BK06823O |
| Part Name | CALIPER BODY-PAINTED - ATHER FR |
| Supplier Name & Code | 206460-TULJA ENTERPRISES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | POWDER COATING NOT OK-AFTER 100% INSP. POWDER COATING UNCOVER, |
1. Problem Description
| Defect Description | POWDER COATING NOT OK-AFTER 100% INSP. POWDER COATING UNCOVER, |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 217 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality.tulja@gmail.com |
| Plant Head/CEO Email ID | tuljaenterprises.e124@gmail.com |
| MD Email ID | tuljaenterprises.e124@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15126
|
0
|
0
|
0
|
0
|
15126
|
| Check Qty |
1363
|
0
|
0
|
0
|
0
|
1363
|
| NG Qty |
217
|
0
|
0
|
0
|
0
|
217
|
| Scrap | 0 |
| Rework | 217 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Given training to painter how paint critical area during painting process. |
3. Process Flow
| Process Flow Description |
|---|
| Inward Inspection-PT process-WDO-PC-Baking-Final Inspection-Packing & Dispatch |
4. Process Details
| Process / Operation | Coating |
| Outsource | No |
| Machine / Cell | Wagner coating Gun |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operatoer | due to unskilled operator | 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 | During coating skip critical area. |
| Why 2 | No awareness to operator about how to cover all critical area by coating. |
| Why 3 | Skill level 2 operator was appointed |
| Why 4 | Unskilled operator |
| Why 5 | |
| Root Cause (Occurance) | Unskilled operator |
Root Cause Analysis (Outflow)
| Why 1 | NG material mix up in Finish Good. |
| Why 2 | Both location was near each other |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | OK/Not OK material mix up |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Given training to coating operator for critical parts area | production /Quality | 05/03/2024 | 05/03/2024 | Completed |
| Outflow | Define OK/Not OK material location away from each other. | Prod.& Inspector | 04/03/2024 | 04/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change required,due to mix up by loading person. |
| 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) |
Skill level 2 operator 697_Occurance_Before.xlsx |
| Occurance (After) |
Given training to operator 697_Occurance_After.pdf |
| Outflow (Before) |
OK/Not OK material location near each other 697_Outflow_Before.xlsx |
| Outflow (After) |
Define OK/Not OK location 697_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |