QFR No - 8000886625
Defect Details
| NC No. | 8000886625 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2DZ07203B |
| Part Name | FORK BOLT (K-9207) Ni+Cr Plated |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-RUSTY |
1. Problem Description
| Defect Description | Rusty - Not as per specification |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 77 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@npcindustries.in |
| Plant Head/CEO Email ID | anand@npcindustries.in |
| MD Email ID | ajay@npcindustries.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
750
|
1800
|
0
|
0
|
0
|
2550
|
| Check Qty |
750
|
1800
|
0
|
0
|
0
|
2550
|
| NG Qty |
77
|
13
|
0
|
0
|
0
|
90
|
| Scrap | 0 |
| Rework | 90 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% visual inspection of available qty. |
3. Process Flow
| Process Flow Description |
|---|
| 1-Raw Material Receipt 2- Cutting & Forging 1st 3-Annealing 4-Phosphating 5-Forging - 2nd 6-CNC1st 7-CNC 2nd 8-Thread Rolling 9-Drilling 10-Buffing 11-Head Polishing 12-Plating 13-Final Inspection 14-Packing & Dispatch |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | Plating Set Up |
| Machine / Cell No. | Plating Tank |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator unaware about process | Operator found to be aware about the process | O |
| Method | Incoming material for plating rusty | Incoming material for Plating observed to be rusty | X |
| Man | Plating operator negligent | Operator found to be not negligent | O |
| Material | Material not as per drawing | Material observed as per drawing | O |
| Method | NG part could not be detected at final inspection | It was observed that NG part skipped final inspection | 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 | Incoming material for Plating observed to be rusty |
| Why 2 | Rusted material received by Plating Supplier |
| Why 3 | Parts became rusted during transit |
| Why 4 | Parts not dipped in RPO before dispatch |
| Why 5 | |
| Root Cause (Occurance) | Parts not dipped in RPO before dispatch |
Root Cause Analysis (Outflow)
| Why 1 | NG parts could not be detected at Final Inspection |
| Why 2 | NG parts got skipped at Final Inspection |
| Why 3 | No rust observed at the time of dispatch |
| Why 4 | Curing time not given to parts before dispatch |
| Why 5 | |
| Root Cause (Outflow) | Curing time not given to parts before dispatch |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Quality Alert to be displayed at Final Dispatch Station at NP Nabha | Mr Thakur | 12/08/2024 | 12/08/2024 | Completed |
| Occurance | Parts to be dipped in RPO before disptach to Plating Supplier | Mr Thakur | 27/08/2024 | 26/08/2024 | Completed |
| Occurance | WI for RPO dipping of parts to be displayed at Final Dispatch Station | Mr Thakur | 27/08/2024 | 26/08/2024 | Completed |
| Outflow | Curing time of 24 hrs to be given to parts before dispatch | Mr Ganesh | 22/08/2024 | 22/08/2024 | Completed |
| Outflow | Quality Alert to be displayed at M/s Zumtara | Mr Ganesh | 13/08/2024 | 13/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| 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) |
Parts not dipped with RPO before dispatch 1016_Occurance_Before.jpg |
| Occurance (After) |
Parts dipped with RPO before dispatch 1016_Occurance_After.jpg |
| Outflow (Before) |
100% inspection but no marking 1016_Outflow_Before.jpg |
| Outflow (After) |
100% marking after inspection 1016_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |