QFR No - 8000889489
Defect Details
| NC No. | 8000889489 |
| NC Date | 02/09/2024 |
| NC Submission Date | |
| Part No. | F2AV00302B |
| Part Name | BELLOW-B104B |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CUT MARK |
1. Problem Description
| Defect Description | CUT MARK |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 9 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
1000
|
0
|
2000
|
| Check Qty |
1000
|
0
|
0
|
1000
|
0
|
2000
|
| NG Qty |
9
|
0
|
0
|
0
|
0
|
9
|
| Scrap | 9 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Sorting all stock |
3. Process Flow
| Process Flow Description |
|---|
| Rm inward - Mixing - Moulding -Final Inspection. |
4. Process Details
| Process / Operation | Moulding |
| Outsource | No |
| Machine / Cell | Cell |
| Machine / Cell No. | cell number 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Verification of Compound as per control plan. | Found match with control plan & production report. Checked one month data & found okay | O |
| Tool | Less material flow in cavity | Leakage in mould cavity | X |
| Machine | Process parameter of moulding not followed | Found matched with control plan & automatic PLC control | O |
| Method | Mix up during packing | offline packing | X |
| Man | Un skill Inspector | Skill level verified found L3 & Required L3 | O |
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 | Flow mark |
| Why 2 | Less material flow in cavity |
| Why 3 | leakage in mould cavity. |
| Why 4 | Mould plate parallelism not okay |
| Why 5 | |
| Root Cause (Occurance) | Mould plate parallelism not okay |
Root Cause Analysis (Outflow)
| Why 1 | Flow mark |
| Why 2 | Skipped from Fores quality |
| Why 3 | Not checked part mixed in okay part after quality inspection |
| Why 4 | Offline box packing |
| Why 5 | |
| Root Cause (Outflow) | Offline box packing |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | `Online packing implemented | Pande | 25/08/2024 | 15/07/2024 | Completed |
| Occurance | Mould leakage removed by making plate parallelism okay. | Ravi | 11/07/2024 | 26/06/2024 | 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) |
Mould parallelism not okay 1056_Occurance_Before.pdf |
| Occurance (After) |
Mould parallelism okay 1056_Occurance_After.pdf |
| Outflow (Before) |
Offline packing 1056_Outflow_Before.pdf |
| Outflow (After) |
Online packing 1056_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Cell no 1 |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |