QFR No - 8000887123
Defect Details
| NC No. | 8000887123 |
| NC Date | 16/08/2024 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-BIN CONTAMINATION |
1. Problem Description
| Defect Description | BIN CONTAMINATION |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 528 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@sharp-engineers.com |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| Check Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| NG Qty |
528
|
0
|
0
|
0
|
0
|
528
|
| Scrap | 0 |
| Rework | 528 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Clean all pipeline material |
3. Process Flow
| Process Flow Description |
|---|
| RM incoming-Parting and drilling-Milling-CNC 1st-Deburring-CNC 2nd-Finish Drilling--Tapping-Plating-Final Inspection-PDIR-Packing and forwarding |
4. Process Details
| Process / Operation | Dispatch |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New manpower for packaging | Having existing manpower | O |
| Tool | Tool change | Not applicable | O |
| Machine | Machined change | No machine change | O |
| Method | Bin cleaning not done at defined frequency | Bin cleaning not done as per defined frequency | X |
| Method | Bin Received in contamination condition from customer | Received in ok condition | O |
| Material | Material grade change | Material found ok | O |
| Method | other parts Bin used for dispatched | Having Possibilities | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Contamination Bin |
| Why 2 | Oil found in Bin |
| Why 3 | Used other parts Bin for dispatched |
| Why 4 | Shortage of Bins |
| Why 5 | |
| Root Cause (Occurance) | Shortage of Bins |
Root Cause Analysis (Outflow)
| Why 1 | Contamination Bin |
| Why 2 | Bin condition not verified at PDI stage |
| Why 3 | Check Point not available in PDI report |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Check Point not available in PDI report |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Check point added in PDI report | Mr. Omkar Bhange | 20/08/2024 | 20/08/2024 | Completed |
| Occurance | Ordered New 50nos Bins | Mr. Vivek Dewar | 11/09/2024 | 20/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Check point added at PDI stage |
| 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) |
Contamination in Bin 1024_Occurance_Before.png |
| Occurance (After) |
Ordered New 50 Nos Bins 1024_Occurance_After.pdf |
| Outflow (Before) |
Check point not added in PDI report 1024_Outflow_Before.jpeg |
| Outflow (After) |
Check point added in PDI report 1024_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK But preventive action is required |