QFR No - 8000874401
Defect Details
| NC No. | 8000874401 |
| NC Date | 15/05/2024 |
| NC Submission Date | |
| Part No. | S2HT03607B |
| Part Name | OUTER SPRING POWDER COATED |
| Supplier Name & Code | 100186-SAGAR SPRINGS PRIVATE LIMITED |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | POWDER COATING NOT OK-POWDER COATING NOT OK |
1. Problem Description
| Defect Description | Heavy powder coating defect |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 2 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | smnodm11zr4stedlcpv3uset.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@sagarsprings.com |
| Plant Head/CEO Email ID | ajai.singh@sagarsprings.com |
| MD Email ID | sagar@sagarsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4080
|
0
|
0
|
2000
|
0
|
6080
|
| Check Qty |
4080
|
0
|
0
|
2000
|
0
|
6080
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection check ETL Halol plant |
3. Process Flow
| Process Flow Description |
|---|
| coiling. tempring ,grinding, shot peening, 2nd tempring, scragging, checking &correction, powdercoating |
4. Process Details
| Process / Operation | Powder coating |
| Outsource | No |
| Machine / Cell | Powder coating |
| Machine / Cell No. | Powder coating |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Deffective powder not get stick properly | Powder get well stick with spring, check spring after coating | O |
| Man | Painter intervention in spring path after coating | Barricade is presence and except painter no body is entering in booth while coating | O |
| Method | Spring not hange properly | Spring hanged are incorrect postion and inclination observed | 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 | NO |
7. Root Cause Analysis (Occurance)
| Why 1 | Powder coating not ok |
| Why 2 | The spring had collapsed from the wall of the booth or oven |
| Why 3 | Due to Some hooks were not strong enough to hold the spring |
| Why 4 | Due to excessive use of hooks |
| Why 5 | |
| Root Cause (Occurance) | Due to excessive use of hooks hence spring had collapsed from the wall of the booth or oven. |
Root Cause Analysis (Outflow)
| Why 1 | Powder coating not ok spring move to customer end. |
| Why 2 | Not ok part put with ok part on final inspection table. |
| Why 3 | Due to rejection bin away from the table. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not ok part put with ok part on final inspection table by final inspector. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | On job training given to inspector for the same. | RGM / HKR - QA | 17/05/2024 | 17/05/2024 | Completed |
| Occurance | The frequency for using the hook will be determined | supervisor | 27/05/2024 | 19/05/2024 | Completed |
| Outflow | Closed mouth rejection bin will be provided on each final inspection table. | Supervisor | 27/05/2024 | 19/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Closed mouth rejection bin (Lock & Key) will be provided on each final inspection table. |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | NO |
10. Evidance of Countermeasure
| Occurance (Before) |
How often to use the hook was not determined in work instraction 803_Occurance_Before.pdf |
| Occurance (After) |
Decided to Use the hook only 3 times only update work instraction. 803_Occurance_After.pdf |
| Outflow (Before) |
open mouth rejection bin away from final inspection table 803_Outflow_Before.jpg |
| Outflow (After) |
Closed mouth Rejection bin privided on each final inspection tabel so operater rejected part not mixup with ok part. 803_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | all powder coated springs |
12. Document Review
| Documents | WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |