QFR No - 8000893366
Defect Details
| NC No. | 8000893366 |
| NC Date | 27/09/2024 |
| NC Submission Date | |
| Part No. | S2DA00907O |
| Part Name | TOP SPRING LOCATOR |
| Supplier Name & Code | 100161-PREMIER ENGINEERS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | POWDER COATING NOT OK-POWDER COATING PEEL OFF |
1. Problem Description
| Defect Description | POWDER COATING NOT OK-POWDER COATING PEEL OFF |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 1168 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality.premier@sanghavigroup.co.in |
| Plant Head/CEO Email ID | prabhune.girish@sanghavigroup.co.in |
| MD Email ID | sanghavi.rajesh@sanghavigroup.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
0
|
0
|
0
|
0
|
1200
|
| Check Qty |
1200
|
0
|
0
|
0
|
0
|
1200
|
| NG Qty |
1166
|
0
|
0
|
0
|
0
|
1166
|
| Scrap | 1166 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All the material available at Endurance End Segregated by hitting method |
3. Process Flow
| Process Flow Description |
|---|
| RM+Cutting+Forming+Piercing+Vibro+Powder Coating+Final Inspection |
4. Process Details
| Process / Operation | Powder Coating at Krishna Coating |
| Outsource | Yes |
| Machine / Cell | Red wine locator Line |
| Machine / Cell No. | Red wine locator |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | No proper bonding of paint to Locator | At phosphating stage bath concentration not maaintained | X |
| Method | Oil traces on parts | -tank heater not working | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Inspection by nail |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5/100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Coating Peel Off |
| Why 2 | Phosphating observed week |
| Why 3 | Bath concentration observed less |
| Why 4 | regular bath analysis not done |
| Why 5 | Lab chemist not done analysis |
| Root Cause (Occurance) | Phosphating bath concentration not maintained. |
Root Cause Analysis (Outflow)
| Why 1 | Coating Peel Off |
| Why 2 | Part missed from inspector |
| Why 3 | Part peel off not observed during Inspection |
| Why 4 | Sampling basis adhesion verification |
| Why 5 | sampling frequency not increased |
| Root Cause (Outflow) | Due to sampling basis adhesion inspection part could not be cached at final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Phosphating bath concentration maintained, Degreasing heater Started | Mr.Lokahnde | 01/10/2024 | 15/10/2024 | Completed |
| Outflow | Sampling frequency for Adhesion increased, Double sampling started | Mr.Lokhande | 01/10/2024 | 15/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Double sampling inspection for adhesion started |
| Inspection Method | Other |
| Other Inspection Method | Cross Adhesion |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5/100 |
10. Evidance of Countermeasure
| Occurance (Before) |
Phosphating Stage Bath Concentration not maintained and Degreasing Heater not working which is started. 1116_Occurance_Before.pdf |
| Occurance (After) |
Bath Concentration maintained and Heater Started 1116_Occurance_After.pdf |
| Outflow (Before) |
Operator Skill matrix Not Updated 1116_Outflow_Before.pdf |
| Outflow (After) |
Training Provided to Final Inspector 1116_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Brass Gold Locator, Silver Locator |
12. Document Review
| Documents | WISOP |
| Specify Other Document | OPL Implemented |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | AFTER TAKING ACTION POWDER COATING FOUND OK- NO POWDER COATING PEEL OFF OBSERVED. |