QFR No - 8000878523
Defect Details
| NC No. | 8000878523 |
| NC Date | 15/06/2024 |
| NC Submission Date | |
| Part No. | 550BZ01402 |
| Part Name | CAP OIL LOCK - DF01 |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | RUSTY- |
1. Problem Description
| Defect Description | CAP OIL LOCK RUST ISSUE |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 616 |
| 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 |
6000
|
0
|
0
|
0
|
12000
|
18000
|
| Check Qty |
6000
|
0
|
0
|
0
|
12000
|
18000
|
| NG Qty |
616
|
0
|
0
|
0
|
0
|
616
|
| Scrap | 0 |
| Rework | 616 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material Check at the Customer End and Warehouse End |
3. Process Flow
| Process Flow Description |
|---|
| RM inward - store - Parting Piot Drill on Traub Machine - Bottom Side Chamfer -Semi finish Inward - CNC ( Counter ID Machining ) - OD Grinding - Plating - Final Inspection - Packing - Dispatch |
4. Process Details
| Process / Operation | Warehouse Loading - Unloading Handling Problem |
| Outsource | Yes |
| Machine / Cell | Narsapura Warehouse |
| Machine / Cell No. | Narsapura Warehouse |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Finish material Not Proper Packing | Yes , at Transport and Godown material not proper handling | 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 | Rusty |
| Why 2 | Finish Good Material Wet at warehouse |
| Why 3 | Finish Good Lying On Shop floor |
| Why 4 | Packing Bag Torn of finish good |
| Why 5 | Finish Material Improper Material Handling |
| Root Cause (Occurance) | Packing Bag Torn of finish good Material During Store Area as it is material collect by godown man and Dispatch. |
Root Cause Analysis (Outflow)
| Why 1 | Rusty |
| Why 2 | Finish Good Material More No. of days lying at transport Godown |
| Why 3 | Inform To godown person |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Finish Good Material More No. of days lying at transport Godown |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1)Improper Material Handling .2)Finish Good Material More No. of days lying at transport Godown | Mahavir QA | 25/06/2024 | 26/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1)Packing as per Customer Standards. 2) HDPE white, Heavy thickness and clean Gunny bags use for outer coating packing. |
| Inspection Method | Other |
| Other Inspection Method | Packing Visual Obs |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Finish Good Packing Bag Torn at warehouse during Material Handling .2)Low Thickness Poly Bag 873_Occurance_Before.gif |
| Occurance (After) |
1)Inner poly bag thickness increases up to 100mic gauge Instead of 75Microm for Tearing problems avoid Suitable to Material Handling. 2)HDPE white , Heavy thickness and clean Gunny bags use for outer coating packing. 873_Occurance_After.jpg |
| Outflow (Before) |
Finish Good Material More No. of days lying at transport godown 873_Outflow_Before.xlsx |
| Outflow (After) |
As per the attached packing standard
443_Outflow_After.xlsx 873_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Cap Oil Lock Models |
12. Document Review
| Documents | ControlPlan, PFMEA, PackingStd |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 15000 |
| Reason for submission | reviewed 2 lots found ok |