QFR No - 8000887428
Defect Details
| NC No. | 8000887428 |
| NC Date | 20/08/2024 |
| NC Submission Date | |
| Part No. | B2FP05313O |
| Part Name | HOLDER BRACKET FINISHED-RE J1 REAR |
| Supplier Name & Code | 201092-PRANEEL INDUSTRIES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | DENT MARK-DENT DAMAGE |
1. Problem Description
| Defect Description | DENT MARK-DENT DAMAGE |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 186 |
| 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 |
420
|
0
|
0
|
130
|
0
|
550
|
| Check Qty |
420
|
0
|
0
|
130
|
0
|
550
|
| NG Qty |
186
|
0
|
0
|
3
|
0
|
189
|
| Scrap | 189 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL end and In-house Finish Good material sagrigation done and NG material rejected. |
3. Process Flow
| Process Flow Description |
|---|
| Raw material inward=>Powder coating=>Powder coating inward=>VMC 1st setup=> VMC 2nd setup=>Final inspection=>Packing and Dispatch. |
4. Process Details
| Process / Operation | Machining |
| Outsource | No |
| Machine / Cell | VMC Machining |
| Machine / Cell No. | VMC Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Material not as per drawing. | Verify the material and found as per drawing. | O |
| Tool | Required tooling not as per specifications. | Verify the tooling on machine,found adequate. | O |
| Method | Packing method not as per packing standard. | Verify the packing standard and found inadequate. | X |
| Machine | Machine clamping pressure not as required. | Verify the machine clamping pressure on machine and found as per CP. | O |
| Man | Unskilled operator and inspector on machine and final inspection. | Verify skill matrix of operator and inspector ,found as per skill matrix. | 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 | samp.plan |
7. Root Cause Analysis (Occurance)
| Why 1 | Holder Bracket REJ1C Rear found dent and damage on the parts. |
| Why 2 | Operator unaware of material handling and packing |
| Why 3 | Unskilled operator of packing. |
| Why 4 | Stage wise material movement is improper |
| Why 5 | |
| Root Cause (Occurance) | Stage wise material movement is improper. |
Root Cause Analysis (Outflow)
| Why 1 | Holder Bracket REJ1C Rear found dent and damage on the parts. |
| Why 2 | Phenomenon skip during visual inspection |
| Why 3 | Inspector not aware about defects occurs. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector not aware about defects occurs. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Stage wise material handling made and display on the shop floor to avoid dent and damage issue on parts. | Mr.Sudarshan Kadam | 26/08/2024 | 26/08/2024 | Completed |
| Outflow | Training and awareness given to Inspector about unknown defects received at ETL End. | Mr.Yogesh Sonune | 24/08/2024 | 24/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection done as per eye sequence chart display on the inspection table. |
| 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) |
Before material handle in the box for machining. 1031_Occurance_Before.jpeg |
| Occurance (After) |
After stage wise material handling display on the shop floor for material handling. 1031_Occurance_After.xlsx |
| Outflow (Before) |
Before awareness not available about raise defects to inspector. 1031_Outflow_Before.jpeg |
| Outflow (After) |
Training and Awareness given to Inspector with Q-Alert display on final inspection table. 1031_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Holder Brackets and shop floor . |
12. Document Review
| Documents | WISOP, PackingStd, InspCheckSheet |
| Specify Other Document | Q-Alert |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | Seen improvement in dent/damage issue. |