QFR No - 8000884639
Defect Details
| NC No. | 8000884639 |
| NC Date | 30/07/2024 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | WELDING NOT OK-IMPROPER WELDING |
1. Problem Description
| Defect Description | Adjuster improper welding defects issue |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 1386 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | nukwu5cfxpybz1b4adopzotb.jpg |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
2000
|
1000
|
4000
|
| Check Qty |
1000
|
0
|
0
|
2000
|
1000
|
4000
|
| NG Qty |
10
|
0
|
0
|
50
|
10
|
70
|
| Scrap | 0 |
| Rework | 70 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1- Stock checked at Nice end . 2- Training provided to inspection team about visual defects 3- Quality gate implemented to control the out flow of parts. 4-One point lesson displayed at quality table . |
3. Process Flow
| Process Flow Description |
|---|
| 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 1st 80 FLAIRING 2nd 90 ID SIZING 100 SIDE GRINDING & BUFFING 110 REROUNDING 120 BROACHING 130 HEAD GRINDING 140 OUTSIDE MOVEMENT FOR PLATING 150 STORAGE & RQC INSP. OF PLATED MATERIAL 160 FINAL INSPECTION 170 PACKING & DISPATCH |
4. Process Details
| Process / Operation | WELDING |
| Outsource | No |
| Machine / Cell | MIG WELDING |
| Machine / Cell No. | 10,11 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | UNSKILLED MANPOWER WAS DEPUTED AT WELDING | SKILLED MANPOWER WAS AVAILABLE AND SKILL MATRIX VERIFIED | O |
| Material | WRONG MATERIAL USED | MTC VERIFIED | O |
| Machine | HIGHER/LOWER CAPACITY MACHINE USED | MACHINED VERIFIED AND FOUND OK | O |
| Tool | Gap of Joint is over size | Gap not maintained during rounding | X |
| Method | PROCESS PARAMETER CHANGED | CHECKED AND FOUND OK | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | BY DVC |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | VISUAL |
7. Root Cause Analysis (Occurance)
| Why 1 | Part crack at one side from gap due to One side welding was not proper in part gap |
| Why 2 | One side welding was over fill and other side was uneven welding |
| Why 3 | Gap of Joint is over size |
| Why 4 | Gap not maintained during rounding |
| Why 5 | Error in Rounding operation |
| Root Cause (Occurance) | 1-Gap of Joint is over size 2-Error in Rounding operation |
Root Cause Analysis (Outflow)
| Why 1 | Defective part passed at customer end |
| Why 2 | Defective part not detected by inspector |
| Why 3 | Inspector was not followed the WI |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Defective part not detected by inspector |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 200% inspection started | Nice Steel Ind. | 31/07/2024 | 01/08/2024 | Completed |
| Occurance | Die design changed and now Gap to be provided in tapper in die | Nice Steel | 01/08/2024 | 01/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 200% visual inspection started |
| Inspection Method | Other |
| Other Inspection Method | 200% |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 200% |
10. Evidance of Countermeasure
| Occurance (Before) |
Tool design 980_Occurance_Before.png |
| Occurance (After) |
Tool design 980_Occurance_After.png |
| Outflow (Before) |
NO DOCUMENT 980_Outflow_Before.png |
| Outflow (After) |
OPL 980_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NOT APPLICABLE |
12. Document Review
| Documents | WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | still we are receiving the welding issues |