QFR No - 8000886662
Defect Details
| NC No. | 8000886662 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2GA02302B |
| Part Name | PROTECTION COVER-XF1D1-XF1C1 |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-DUST MARK |
1. Problem Description
| Defect Description | Dust Mark |
| Detection Stage | Customer End |
| Problem Severity | Aesthetic |
| NG Quantity | 694 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | planthead.aurangabad@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
14000
|
0
|
0
|
1000
|
0
|
15000
|
| Check Qty |
14000
|
0
|
0
|
1000
|
0
|
15000
|
| NG Qty |
694
|
0
|
0
|
35
|
0
|
729
|
| Scrap | 729 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % inspection at final & firewall workstation with identification mark on it . |
3. Process Flow
| Process Flow Description |
|---|
| Injection Moulding |
4. Process Details
| Process / Operation | Injection Moulding |
| Outsource | No |
| Machine / Cell | IM-04 |
| Machine / Cell No. | IM-4 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Barrel Temp High / Low | verified as per Cp & OCS found ok , As per Standard Specification | O |
| Tool | Air trapped & air vent inefficient open | verifie Air vent blocked due to carbon deposit on air vent surface | X |
| Man | Man Power does not aware about this defect . | verifed that operator , In process inspector & Final Inspector does not about this defect . | X |
| Material | RM Grade not as per CP . | Check with MTC & found ok as per specification | O |
| Method | Sampling Inspection | verified & Found that Defect are checked on sampling basis At FI | X |
| Machine | OPS & control plan not followed by Machine Operator . | verified as per CP & OCS found ok , As per standard specificiation | O |
| Method | RM preheating not done | Verified as per CP & OCS found ok , As per Standard Specification | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Dust marks due to air trapped in tool erratically while injection . |
| Why 2 | Air vent blocked due to carbon deposit formed on air vent surface |
| Why 3 | Carbon deposit formed due to un periodic cleaning during production |
| Why 4 | Air vent cleaning done during Production is not effective . |
| Why 5 | |
| Root Cause (Occurance) | .Air vent cleaning done during Production is not effective . |
Root Cause Analysis (Outflow)
| Why 1 | Dust mark observed on part surface . |
| Why 2 | Defective part skipped from operator & final Inspector . |
| Why 3 | Lack of Awareness of Highlighted defect . |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Lack of Awareness of Highlighted defect . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Air vent cleaning increased from 25 pieces to 15 pieces . | Sandeep Roday | 17/08/2024 | 02/09/2024 | Completed |
| Outflow | Awareness training given to in process inspector & Final Inspector about highlighted defect . | Sandeep Roday | 19/08/2024 | 02/09/2024 | Completed |
| Occurance | Air vent cleaning done by Chemical WD -40 . | Ganesh Mahske | 16/08/2024 | 02/09/2024 | Completed |
| Outflow | Check Point Added in PM sheet & CP & FMEA updated for the same | Sandeep Roday | 21/08/2024 | 02/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection at final stage for Dust Mark |
| 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) |
Air Vent cleaning not By chemical in mould pm check sheet . 1018_Occurance_Before.xlsx |
| Occurance (After) |
PM check Sheet After correction . 1018_Occurance_After.pdf |
| Outflow (Before) |
Dust Mark check point not address in inspection standard . 1018_Outflow_Before.pdf |
| Outflow (After) |
Dust mark check point add in inspection standard . 1018_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | PMCheckSheet, WISOP, InspCheckSheet |
| Specify Other Document | Q alert . |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |