QFR No - 8000873536
Defect Details
| NC No. | 8000873536 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2DZ07203B |
| Part Name | FORK BOLT (K-9207) Ni+Cr Plated |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-PLATING MISSING |
1. Problem Description
| Defect Description | PLATING MISSING |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@npcindustries.in |
| Plant Head/CEO Email ID | anand@npcindustries.in |
| MD Email ID | ajay@npcindustries.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
50000
|
0
|
0
|
0
|
51500
|
| Check Qty |
1500
|
50000
|
0
|
0
|
0
|
51500
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.Raw Material 2. Blanking 3. Hex Punching 4. Flattening 5. CNC Turning, Chamfering & threading 6. Buffing 7. Plating 8.Final Inspection. |
3. Process Flow
| Process Flow Description |
|---|
| 10 - Raw Material 20 - Cutting and Forging(1st) 30-Forging(2nd) 40-Annealing 50-Phosphating 60 - Forging(3rd) I.D 70-Forging(4th) Hex 80 - CNC(1st) 90 - CNC(2nd) 100 - CNC(3rd) 110 - CNC drilling and Chamfering 120 - Final inspection 130 - Packing & Dispatch 140 - Buffing-1st 150 - Buffing 2nd 160 - Plating |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | Plating plant |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Plating chemicals composition was not as per spec. | After verification we found OK | O |
| Man | Untrained Operator | After verification we found operator was aware about process and responsibilities | O |
| Method | Plating time duration less | After verification we observed plating time duration as per std. | O |
| Method | PC position holding method NG | During verification we found Jig holder was damage | X |
| Method | Skipped during final inspection | after verification we found part was skipped at final inspection. | X |
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 | The bolt was not correctly positioned during the plating process. |
| Why 2 | The jig point, which is supposed to hold the bolt securely, was not clean. |
| Why 3 | The jig cleaning process was either inadequate or not performed regularly. |
| Why 4 | There was no clear protocol or schedule for cleaning the jig points. |
| Why 5 | WI did not include guidelines for the regular cleaning of jig points. |
| Root Cause (Occurance) | WI did not include guidelines for the regular cleaning of jig points. |
Root Cause Analysis (Outflow)
| Why 1 | Plating NG in fork bolt. |
| Why 2 | Defected part could not detect |
| Why 3 | The part was skipped at final Q-gate. |
| Why 4 | NG and OK pc was put at the same color of bin. |
| Why 5 | |
| Root Cause (Outflow) | NG and OK pc was put at the same color of bin. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Locked red bin implement at the Final Q gate | Nikhil Jain | 11/05/2024 | 11/05/2024 | Completed |
| Outflow | Q-alert to be displayed at final Q gate | Mr. Deepak | 08/05/2024 | 07/05/2024 | Completed |
| Occurance | Regular cleaning of jig points to be added in WI | Nikhil Jain | 10/05/2024 | 09/05/2024 | Completed |
| Outflow | Blue bin used for without checked material and Green bin used for Checked material. | Nikhil Jain | 15/05/2024 | 11/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Same color of bin to be replaced with different color for different purpose. |
| 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) |
WI did not include guidelines for the regular cleaning of jig points. 788_Occurance_Before.jpg |
| Occurance (After) |
updated wi to be updated 788_Occurance_After.jpg |
| Outflow (Before) |
NG and OK pc was put at the same color of bin. 788_Outflow_Before.jpeg |
| Outflow (After) |
NG pcs put in orange bin and OK pc was put in Blue bin and red bin implement 788_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Similar parts |
12. Document Review
| Documents | PMCheckSheet, PFMEA, WISOP |
| Specify Other Document | Na |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |