QFR No - 8000875383
Defect Details
| NC No. | 8000875383 |
| NC Date | 24/05/2024 |
| NC Submission Date | |
| Part No. | S2DC06502B |
| Part Name | INNER DUST COVER (L=86) |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | EXCESS MATERIAL-MATIRAL DEFT |
1. Problem Description
| Defect Description | Do Spot |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 1140 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | planthead.aurangabad@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2600
|
0
|
0
|
985
|
0
|
3585
|
| Check Qty |
2600
|
0
|
0
|
985
|
0
|
3585
|
| NG Qty |
1140
|
0
|
0
|
48
|
0
|
1188
|
| Scrap | 1188 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Checked 100 % parts available at ETL line & in stores on 25.5.2024. Also checked 100 % stock available at inhouse FG stores on 25.5.2024 |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of Material, Inward inspection, Storage, Material issue, Master batch mixing, Injection molding, Deflashing & Inspection, Final Inspection, Packaging & labelling, Pre dispatch Inspection, Dispatch |
4. Process Details
| Process / Operation | Injection Moulding |
| Outsource | No |
| Machine / Cell | Injection Moulding Cell |
| Machine / Cell No. | IMM-07 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Sampling inspection | Verified & found that visual defects are checked on sampling basis at FI | X |
| Man | Awareness lacking about the defect | Verified that operator, In process inspectors & final inspectors lacks the awareness about the defe | X |
| Machine | Injection speed is high | Verified as per C.P.& OCS found OK as per standard specification | O |
| Machine | Barrel Temp low/High | Verified as per C.P.& OCS found OK as per standard specification | O |
| Machine | Back pressure is low | Verified as per C.P. & OCS found OK as per standard specification | O |
| Method | RM preheating not done | Verified as per CP & OCS found that preheating not required | O |
| Material | RM grade not OK | Checked with MTC and found OK as per specification | O |
| Tool | Air trapped / Air vent inefficient | Verified mold vent condition on punch side and found rust /dirt inside air vents are not clean | X |
| Machine | Machine not working in OK condition | Verified and found that Machine working in OK condition | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | plan |
7. Root Cause Analysis (Occurance)
| Why 1 | Bubbles observed on the part surface |
| Why 2 | Air not coming out of the mold during molding process |
| Why 3 | Air trapped inside the system during the process |
| Why 4 | Air vents are not fully open/ cleaned |
| Why 5 | Cleaning done during PM is not effective |
| Root Cause (Occurance) | Air vent cleaning done during PM is not effective |
Root Cause Analysis (Outflow)
| Why 1 | Bubbles observed on the part surface |
| Why 2 | Defective part skipped from operator & inspectors |
| Why 3 | Less awareness of operator & inspectors about the defect |
| Why 4 | Point not added in In-process inspection check sheet, set up approval report & Inspection standard sheet |
| Why 5 | |
| Root Cause (Outflow) | Less awareness of operator & inspectors about the defect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Air vent cleaning done by chemical WD-40 | Mr. Ganesh Mhaske | 30/05/2024 | Completed | |
| Occurance | During PM of mold, air vent cleaning by chemical WD-40 is now introduced to enhance the effectiveness of cleaning ,point added in mold PM check sheet | Sandeep Roday | 30/05/2024 | Completed | |
| Outflow | Point added in In-process check sheet, Set up approval report, Control Plan, PFMEA | Sandeep Roday | 31/05/2024 | Completed | |
| Outflow | Training provided to operator & inspectors about the defect through OPL & Inspection standard sheet | Sandeep Roday | 30/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % Visual inspection at Final stage for bubble defect |
| 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) |
Air vent cleaning not by chemical in Mould PM check sheet 819_Occurance_Before.png |
| Occurance (After) |
Air vent cleaning by chemical point added in Mould PM check sheet 819_Occurance_After.png |
| Outflow (Before) |
Point of Bubble checking not addressed in Inspection standard check sheet 819_Outflow_Before.png |
| Outflow (After) |
Point of Bubble checking addressed in Inspection standard check sheet & OPL displayed 819_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, InspCheckSheet |
| Specify Other Document | Set up Approval Repo |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | no any concern observed after action taken. |