QFR No - 8000878520
Defect Details
| NC No. | 8000878520 |
| NC Date | 15/06/2024 |
| NC Submission Date | |
| Part No. | F2PH00902B |
| Part Name | VALVE RETAINER (C101B) |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | RUSTY- |
1. Problem Description
| Defect Description | VALVE RETANIER RUST ISSUE |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 1004 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | bhpnhqxb2aqiqeo31315nure.gif |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | production@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3200
|
1200
|
0
|
0
|
0
|
4400
|
| Check Qty |
3200
|
0
|
0
|
0
|
0
|
3200
|
| NG Qty |
1004
|
0
|
0
|
0
|
0
|
1004
|
| Scrap | 0 |
| Rework | 1004 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM inward - store - Parting - Semi finish Inward - CNC ( Counter ID Machining ) - OD Grinding- Plating - Final Inspection - Packing - Dispatch - Transport- warehouse |
4. Process Details
| Process / Operation | Packing |
| Outsource | No |
| Machine / Cell | Packing Area |
| Machine / Cell No. | Final Packing Area |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | n incorrect curing machine was used for the plating drying process | During Curing Process The correct drying machine was used. | O |
| Method | During Finish Good material Handling at Narsapura Warehouse | n the warehouse, the bag became weak during the handling of the finished material, and due to the ba | X |
| Man | skilled manpower of warehouse | Regular man power of ware house | O |
| Tool | Manual handling | In the warehouse, finished material is placed on the floor and dragged to the location | X |
| Material | Without Process Material Mix With finish Material | After defect analysis, the material was found to be fully plated | 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 | Visual |
7. Root Cause Analysis (Occurance)
| Why 1 | RUSTY- |
| Why 2 | The warehouse ground floor was rough |
| Why 3 | Finished goods were handled without a trolley |
| Why 4 | The packing bag was torn during the handling of finished goods |
| Why 5 | |
| Root Cause (Occurance) | Finished goods were handled without a trolley |
Root Cause Analysis (Outflow)
| Why 1 | RUSTY- |
| Why 2 | There is no awareness among the warehouse-deputed manpower regarding the handling of finished goods. |
| Why 3 | There are no material handling work instructions displayed in the warehouse area |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | There are no material handling work instructions displayed in the warehouse area. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Display work instructions in the warehouse at the finished goods loading and unloading area. | Quality Head And Warehouse Incharge. | 06/09/2024 | 09/09/2024 | Completed |
| Occurance | Trolley Arrange At Ware House | Warehouse Owner | 09/09/2024 | 10/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspect the material condition and packing condition during the handover to the customer from the warehouse |
| 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) |
Finished goods were handled without a trolley 871_Occurance_Before.docx |
| Occurance (After) |
Trolley Arrange At Ware House 871_Occurance_After.jpg |
| Outflow (Before) |
There are no material handling work instructions displayed in the warehouse area. 871_Outflow_Before.docx |
| Outflow (After) |
Display work instructions in the warehouse at the finished goods loading and unloading area. 871_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Warehouse Materials |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 20000 |
| Reason for submission | verified after received 4 lots found ok |