QFR No - 8000890966
Defect Details
| NC No. | 8000890966 |
| NC Date | 13/09/2024 |
| NC Submission Date | |
| Part No. | B2KN01103O |
| Part Name | RESERVOIR CAP RAW CASTING |
| Supplier Name & Code | 100865-HI TECH ARAI PVT LTD UNIT XI |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BUFFING DEFECT-LETTER MARKING NT OK |
1. Problem Description
| Defect Description | BUFFING DEFECT-LETTER MARKING NT OK |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 978 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | rajeshwaran.m@hitecharai.com |
| Plant Head/CEO Email ID | sundararaman.v@hitecharai.com |
| MD Email ID | spm32@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
28000
|
5000
|
0
|
0
|
3000
|
36000
|
| Check Qty |
28000
|
5000
|
0
|
0
|
3000
|
36000
|
| NG Qty |
978
|
200
|
0
|
0
|
0
|
1178
|
| Scrap | 1178 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| ETL End – 978 Qty rejected by ETL . Available stock at Supplier end verified and sorting out. |
3. Process Flow
| Process Flow Description |
|---|
| Casting - fettling |
4. Process Details
| Process / Operation | Casting |
| Outsource | No |
| Machine / Cell | Diecasting machice |
| Machine / Cell No. | 125T |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Insert Chip off | Insert verification | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 / 2hrs |
7. Root Cause Analysis (Occurance)
| Why 1 | Letter damage issue observed |
| Why 2 | Due to material stuck at letter area |
| Why 3 | Due to insert chip off |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Letter damage issue happened due to insert chip off issue. |
Root Cause Analysis (Outflow)
| Why 1 | Letter damage issue observed |
| Why 2 | Due to lack of awareness |
| Why 3 | Due to after powder coating only identification |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Due to after powder coating only identification |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Insert send to reforming | Mr.Balakrishnan | 05/09/2024 | 05/09/2024 | Completed |
| Outflow | Briefing the quality requirement for fettling operator, inspector & ware house in-charge based on defect details and actual part | Rajeshwaran / Mane | 06/09/2024 | 06/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection on 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) |
Defect Photo 1094_Occurance_Before.jpg |
| Occurance (After) |
Correction Photo 1094_Occurance_After.jpg |
| Outflow (Before) |
No 100% inspection 1094_Outflow_Before.jpg |
| Outflow (After) |
To conduct 100% inspection 1094_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All reservoir Cap |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | nil |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | Improvement found. |