QFR No - 8000889507
Defect Details
| NC No. | 8000889507 |
| NC Date | 02/09/2024 |
| NC Submission Date | |
| Part No. | F2FQ00307B |
| Part Name | HOLDER HANDLE LOWER P/C (XF-521) |
| Supplier Name & Code | 201092-PRANEEL INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | DENT MARK-DENT DAMAGE, PIN HOLE |
1. Problem Description
| Defect Description | DENT DAMAGE |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 16 |
| 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 |
350
|
0
|
0
|
0
|
200
|
550
|
| Check Qty |
350
|
0
|
0
|
0
|
200
|
550
|
| NG Qty |
27
|
0
|
0
|
0
|
30
|
57
|
| Scrap | 57 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL end and In-house sagrigation done and NG parts rejected at both location. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Casting Inward=>CNC Setup=>Powder Coating=>VMC setup=>De-burring=>Final Inspection=>Packing and Dispatch. |
4. Process Details
| Process / Operation | VMC Machining |
| Outsource | No |
| Machine / Cell | VMC Machine |
| Machine / Cell No. | VMC Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Clamping pressure not as per CP. | Verify clamping pressure as per CP and found OK. | O |
| Tool | Toolings used for part production is not as per standard. | Verify the toolings used for part production and found adequate. | O |
| Man | Unskilled manpower for inspection. | Verify skill matrix for inspector and found skilled person. | O |
| Method | Inspection method not as per standard. | Verify inspection method and found inadequate. | X |
| Material | Material not as per specifications. | Verify matertial composition and found as per specifications. | 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 | Pin hole observed on the parts after powder coating. |
| Why 2 | Powder used for the process contains trapped air and moisture. |
| Why 3 | Degreesing bath deep time for surface cleaning is found low for cleaning the parts. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Degreesing bath deep time for surface cleaning is found low for cleaning the parts. |
Root Cause Analysis (Outflow)
| Why 1 | Pin hole observed on the parts after powder coating. |
| Why 2 | Skipped from final inspection stage. |
| Why 3 | Final inspector was unable to identify pin hole defect properly. |
| Why 4 | Due to low lux level inspector was unable to identify the pin hole issue. |
| Why 5 | |
| Root Cause (Outflow) | Due to low lux level inspector was unable to identify the pin hole issue. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | New high power LED tube installed at final inspection stage to increase the optimal lux level. | Mr. Yogesh Sonune | 12/09/2024 | 12/09/2024 | Completed |
| Occurance | Degreesing bath deep time for surface cleaning increases from 5-7 min to 7-9 min for cleaning the parts. | Mr.Dhawale | 11/09/2024 | 12/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | --- |
| 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 Degree sing bath time 5-7 min available for part cleaning process. 1064_Occurance_Before.jpeg |
| Occurance (After) |
After Degree sing bath time 7-9 min done for part cleaning process. 1064_Occurance_After.jpeg |
| Outflow (Before) |
Lux level on the final inspection found low for inspection and no awareness about pin hole on the parts. 1064_Outflow_Before.pptx |
| Outflow (After) |
Lux level increase on the final inspection for visual inspection also awareness and training given to inspector. 1064_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Handle Holder Upper |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Q-alert,Training rec |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |