QFR No - 8000887128
Defect Details
| NC No. | 8000887128 |
| NC Date | 16/08/2024 |
| NC Submission Date | |
| Part No. | F2DZ15510B |
| Part Name | FORK BOLT -ACJA FF |
| Supplier Name & Code | 100505-A B AUTOCOMPONENTS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-COLOUR SHADING |
1. Problem Description
| Defect Description | COLOUR SHADING |
| Detection Stage | Customer End |
| Problem Severity | Aesthetic |
| NG Quantity | 9 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | headqaabauto@gmail.com |
| Plant Head/CEO Email ID | kamalabautocomponent@gmail.com |
| MD Email ID | abautocomponent@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
0
|
400
|
2400
|
| Check Qty |
2000
|
0
|
0
|
0
|
400
|
2400
|
| NG Qty |
9
|
0
|
0
|
0
|
0
|
9
|
| Scrap | 9 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Verify the WIP stocks, there is no FG qty. |
3. Process Flow
| Process Flow Description |
|---|
| CNC Turning >VMC Milling >Special process. |
4. Process Details
| Process / Operation | Turning, Milling & Black Anodizing |
| Outsource | Yes |
| Machine / Cell | CNC & VMC & Special process |
| Machine / Cell No. | CNC & VMC & Special |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Part clamp issue | Verified Jig problem found. | X |
| Man | Part Jigging variation | Verified found ok | O |
| Method | Process variation | Process parameters witnessed and found ok. | O |
| Machine | Maintenance overdue. | Preventive Maintenance verification done, found ok | O |
| Machine | Power fluctuation | Verified found ok | O |
| Material | Chemical used | Verified found ok | O |
| Material | Cleaning agents | Verified there is no cleaning agent using. | O |
| Method | Cleaning problem | There is no cleaning required with agent, Only cloth cleaning found ok. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Limit sample visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Shade variation. |
| Why 2 | Due to the Part hold in the jig, improper hold / part shake will create the shade variation in the part. |
| Why 3 | Part holding not rigid in the jigs. |
| Why 4 | Jigs weaker |
| Why 5 | Jigs Life does not monitor. |
| Root Cause (Occurance) | Due to the Part hold in the jig, improper hold / part shake will create the shade variation in the part. |
Root Cause Analysis (Outflow)
| Why 1 | Shade variation |
| Why 2 | Not witnessed during final visual inspection. |
| Why 3 | Due to shade variation not capturing immediately. |
| Why 4 | Shade generation will take time to appear. |
| Why 5 | |
| Root Cause (Outflow) | Shade generation will take time to appear. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Monitor the Jig life through number of Batch processed, also verify the jigs while loading the part. SIR report updated, also revise the supplier inspection reports. | Karan Metals | 04/09/2024 | 02/09/2024 | Completed |
| Outflow | Avoid the immediate dispatches from AB Auto to ETL to avid shade issues. | Rudresh | 04/09/2024 | 02/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % visual after one-week FG WIP Stock. |
| Inspection Method | Other |
| Other Inspection Method | WIP stock maintain |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Monthly verifying the Anodizing processes through check list. 1026_Occurance_Before.pdf |
| Occurance (After) |
Anodizing process verifying each batch by updating the checklist. 1026_Occurance_After.pdf |
| Outflow (Before) |
Same day dispatch after anodizing 1026_Outflow_Before.pdf |
| Outflow (After) |
Minimum one week kept before dispatch after FG. 1026_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Fork bolts & screw caps. |
12. Document Review
| Documents | AuditCheckSheet, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | 05 Problem analysis - Fact verification need to correct as per actual observation against 4M and give judgment `X` for not ok and `O` for OK |