QFR No - 8000874634
Defect Details
| NC No. | 8000874634 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | 550HH02302 |
| Part Name | O-RING - K7 |
| Supplier Name & Code | 100131-KAMAL RUBPLAST IND PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | FITTMENT NOT OK.-DIMN. 3.5 +0.1 UNDERSIZE |
1. Problem Description
| Defect Description | DIMN. 3.5 +0.1 UNDERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 40000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | santosh.s@kamalrub.com |
| Plant Head/CEO Email ID | kamalrub@gmail.com |
| MD Email ID | Danish.g@kamalrub.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
40000
|
0
|
0
|
1000
|
0
|
41000
|
| Check Qty |
40000
|
0
|
0
|
1000
|
0
|
41000
|
| NG Qty |
40000
|
0
|
0
|
0
|
0
|
40000
|
| Scrap | 0 |
| Rework | 40000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| The subject item has been shifted to the other plant of Kamal. The part does not belong to Endurance . This will ensure further mix up is not happening . |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receving > Weighing > Mixing (Kneader & Open Mixer) > Lab Testing > Strip Cutting > Moulding > Deflashing > Final inspection(100% Visual) > Packing > PDIR > Dispatch |
4. Process Details
| Process / Operation | As above |
| Outsource | No |
| Machine / Cell | JRD Semi Automatic |
| Machine / Cell No. | P-24 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Look Like Similier | Checked with Go-Nogo gauge | X |
| Method | Similier Part Handling not define | Similier Part Handling already define | O |
| Machine | Machine running Condition not OK | Machine running Condition found - OK | O |
| Tool | Tool identification number not define | Tool identification number already define | O |
| Material | Material not as per Grade | Check Material Grade material Ok as per lab test Report. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | 100% Visual Insp. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Thickness of O Ring 3.5+0.1 (Significant parameter) under size |
| Why 2 | Due to mix of similar dimension Part |
| Why 3 | Part produce at same place |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Similar Part produce at same place |
Root Cause Analysis (Outflow)
| Why 1 | Thickness of O Ring 3.5+0.1 (Significant parameter) Mix with Similar Dimension Part |
| Why 2 | Identification Mis match |
| Why 3 | Due to Similar dimension |
| Why 4 | Location not defined |
| Why 5 | |
| Root Cause (Outflow) | Location not defined |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | The subject item has been shifted to the other plant of Kamal | S. K. Singh | 15/05/2024 | 15/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection and as per sample basis checked by Go-Nogo gauge. |
| Inspection Method | Other |
| Other Inspection Method | Go-Nogo Gauge |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 500 |
10. Evidance of Countermeasure
| Occurance (Before) |
PPT Slide No. 01 811_Occurance_Before.pptx |
| Occurance (After) |
PPT Slide No.02 811_Occurance_After.pptx |
| Outflow (Before) |
PPT 811_Outflow_Before.pptx |
| Outflow (After) |
PPT 811_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | WI |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | 5. Problem Analysis - Need to cover all 4M 8. Countermeasure ( Occurrence , Outflow & System side Actions ) - Need out flow side and system side actions |