QFR No - 8000886610
Defect Details
| NC No. | 8000886610 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2FQ00307B |
| Part Name | HOLDER HANDLE LOWER P/C (XF-521) |
| Supplier Name & Code | 201092-PRANEEL INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | DENT MARK-DENT DAMAGE |
1. Problem Description
| Defect Description | Dent Mark & Damage |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 35 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@praneelgroup.com |
| Plant Head/CEO Email ID | praneelindustries@rediiffmail.com |
| MD Email ID | anilpatil@praneelgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1216
|
0
|
0
|
100
|
0
|
1316
|
| Check Qty |
1216
|
0
|
0
|
100
|
0
|
1316
|
| NG Qty |
35
|
0
|
0
|
20
|
0
|
55
|
| Scrap | 55 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL end and at in-house sagrigation done and NG parts are scrap at both location. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Casting inward=>CNC Setup=>Powder Coating=>Powder Coating Inward=>VMC Setup=>De-burring=>Final Inspection=>Packing and Dispatch. |
4. Process Details
| Process / Operation | VMC Machining |
| Outsource | No |
| Machine / Cell | VMC Machining |
| Machine / Cell No. | VMC Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Inadequate clamping method while machining. | Verify the method of loading and unloading during machine found inadequate. | X |
| Machine | Clamping pressure for part load not as per specifications. | Verify the clamping pressure and found as per required specifications. | O |
| Man | Skilled person not available | Verify the skill matrix found as per skill matrix. | O |
| Material | Material specification not as per required. | Vewrify the material found ok. | O |
| Tool | Tooling for manufacturing the part not as per specification. | Verify the machining tool and found Ok. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Dent mark-Dent Damage observed on the part. |
| Why 2 | Clamping pressure not as per required specification on the machine. |
| Why 3 | Clamping not done properly during the machining. |
| Why 4 | Damage during the machining after parts unloading observed. |
| Why 5 | |
| Root Cause (Occurance) | Damage during the machining after parts unloading observed. |
Root Cause Analysis (Outflow)
| Why 1 | Dent mark-Dent Damage observed on the part. |
| Why 2 | Parts skipped by inspector during the visual inspection. |
| Why 3 | Awareness not available about dent and damage issue. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Awareness not available about dent and damage issue. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Awareness and training provided for visual inspection of the material for dent and damage issue. | Mr.Yogesh Sonune | 19/08/2024 | 19/08/2024 | Completed |
| Occurance | Training given to operator for air should be blow on the fixture and resting area to remove the burr. | Mr.Chandrakant Nanher | 19/08/2024 | 19/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | --- |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
No any work instruction for fixture cleaning in the machine work instruction. 1004_Occurance_Before.pdf |
| Occurance (After) |
Instruction for fixture cleaning with clamping and resting area added in the machine work instruction. 1004_Occurance_After.pdf |
| Outflow (Before) |
No awareness about dent and damage issue observed at ETL end. 1004_Outflow_Before.pdf |
| Outflow (After) |
Training and awareness provided for the dent and damage issue observed on the parts. 1004_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Handle Holder Upper |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Q alert,Training rec |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |