QFR No - 8000872209
Defect Details
| NC No. | 8000872209 |
| NC Date | 23/04/2024 |
| NC Submission Date | |
| Part No. | B2GQ01823O |
| Part Name | M/CYL BODY RAW POWDER COATED-KHI |
| Supplier Name & Code | 100204-KRISHNA COATING |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | POWDER COATING NOT OK-UNCOVER, DUST, COATING NOT OK |
1. Problem Description
| Defect Description | POWDER COATING NOT OK-UNCOVER, DUST, COATING NOT OK |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 118 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualitykrishnaassociates01@gmail.com |
| Plant Head/CEO Email ID | ravikrishnacoating@gmail.com |
| MD Email ID | krishnacoating@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
0
|
0
|
0
|
0
|
1200
|
| Check Qty |
1200
|
0
|
0
|
0
|
0
|
1200
|
| NG Qty |
118
|
0
|
0
|
0
|
0
|
118
|
| Scrap | 0 |
| Rework | 118 |
| Under Deviation | 0 |
| Containment Action |
|---|
| One dedicated inspection operator allocated at final inspection stage to recheck inspected material and make sure that defective parts should not be dispatched. |
3. Process Flow
| Process Flow Description |
|---|
| Inward + PT + Powder Coating + Baking + Final Inspection + Dispatch |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | No |
| Machine / Cell | powder coating lime |
| Machine / Cell No. | powder coating line |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Inconsistent powder flow through coating gun can causes uncover | Powder flow was not consistent | O |
| Method | Powder coating gun to part distance can cause uncover issue | Powder coating gun to part distance was found ok | X |
| Tool | Damage to any internal or external part of the powder coating gun can cause inconsistent flow | Gun Venturi found damage | 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 | each lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Uncover and dust issue observed with Master Cylinder |
| Why 2 | Inconsistent powder flow causes uncover and dust formation |
| Why 3 | Damaged Venturi causes inconsistent powder flow through powder coating gun. |
| Why 4 | Proper gun maintenance not done by coating operator |
| Why 5 | |
| Root Cause (Occurance) | Proper gun maintenance not done by coating operator that damaged gun Venturi by which powder flow was inconsistent that causes the formation of dust and some area left uncovered. |
Root Cause Analysis (Outflow)
| Why 1 | Defective part skipped by inspection operator at final inspection stage. |
| Why 2 | Operator was not aware of such kind of defects. |
| Why 3 | Proper training was not provided to operator. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Proper training was not provided to operator on issues like Uncover and dust. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Instructions given to the coating operator about gun maintenance and updated gut maintenance check sheet provided to him. | QC / Production Supervisor | 26/04/2024 | 25/04/2024 | Completed |
| Outflow | Training about dust and uncover issue provided to inspection operator at final inspection stage | QC / Production supervisor | 26/04/2024 | 25/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | none |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | each lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Gun maintenance before 763_Occurance_Before.jpg |
| Occurance (After) |
Gun maintenance after 763_Occurance_After.jpg |
| Outflow (Before) |
Training provided 763_Outflow_Before.png |
| Outflow (After) |
training provided 763_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | all parts |
12. Document Review
| Documents | PMCheckSheet |
| Specify Other Document | Gun maintenance |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | No defect observed in latest lot |