QFR No - 8000893531
Defect Details
| NC No. | 8000893531 |
| NC Date | 27/09/2024 |
| NC Submission Date | |
| Part No. | F2MF02702B |
| Part Name | Spring guide Ø26 - 690 smc trial |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIAMETER OVER SIZE-O D OVER SIZE 21.0.2 |
1. Problem Description
| Defect Description | OD Over Size |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 102 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | planthead.aurangabad@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
0
|
0
|
500
|
0
|
1700
|
| Check Qty |
1200
|
0
|
0
|
500
|
0
|
1700
|
| NG Qty |
106
|
0
|
0
|
18
|
0
|
124
|
| Scrap | 124 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % inspection at final & firewall workstation with identification mark on it . |
3. Process Flow
| Process Flow Description |
|---|
| Injection Moulding |
4. Process Details
| Process / Operation | Injection Moulding |
| Outsource | No |
| Machine / Cell | IMM09 |
| Machine / Cell No. | IMM09 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Mould Cooling Time High/low | Checked with CP & OCS and found high | X |
| Machine | Barrel Temperature High/Low | verified as per Cp & OCS found ok , as per Standard Specification | O |
| Method | Sampling Inspection | Verified & Found that Defect are checked on sampling basis at FI | X |
| Machine | OPS & control plan not followed by Machine Operator | Verified as per CP & OCS found ok , as per standard specificification. | O |
| Material | RM Grade not as per CP | Check with MTC & found ok as per specification | O |
| Man | Man Power does not aware about this defect . | Verifed that operator , In process inspector & Final Inspector aware of this defect. | O |
| Method | Checking method for OD checking | Verified as per CP/OCS and found checking method inadequate for OD Checking | X |
| Tool | Mould Cooling Water flow rate at Cooling Outlet | Verified as per Tool PM checksheet and found as per specification. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Part OD Oversize |
| Why 2 | Because of part not shrink as per material property |
| Why 3 | Because of mould cooling time kept high |
| Why 4 | Introduce the chiller system instead of normal water |
| Why 5 | Because of in In-process cooling time was not optimum |
| Root Cause (Occurance) | Because of in In-process cooling time was not optimum with reference to Chiller application. |
Root Cause Analysis (Outflow)
| Why 1 | Because Part not detect in final inspection |
| Why 2 | Part dimensionally check on sampling basis |
| Why 3 | Checking method Inadequate for OD checking |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Checking method Inadequate for OD checking . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Reduced the cooling time by 26 ± 3 second during normal water use (without chiller) and cooling time 24 ± 3 sec. during chiller use. Process Validation to be done with ref to Chiller application. | Vishnu | 10/10/2024 | 05/10/2024 | Completed |
| Occurance | Given training to operator to check the part in process for OD by gauge and given instruction for not to run the production if he found any out of tolerance etc. | Yogesh Aharwal | 08/10/2024 | 05/10/2024 | Completed |
| Outflow | Displayed the Quality alert and limit sample at work Place for inspection reference | Yogesh Aharwal | 10/10/2024 | 05/10/2024 | Completed |
| Outflow | Given on job training to Inspector to check the parts 100% for OD by OD checking gauge and Given instruction not to pass the out of spec part also | Yogesh Aharwal | 10/10/2024 | 05/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection at firewall through Plug Gauge. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Process Cooling time as per OCS with normal cooling water 1119_Occurance_Before.pdf |
| Occurance (After) |
Training record with part checking with Plug gauge and Revised OCS with cooling time tolerance. 1119_Occurance_After.pdf |
| Outflow (Before) |
OD checking on sampling in OCS 1119_Outflow_Before.pdf |
| Outflow (After) |
Revised OCS , Quality Alert 1119_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Similar Spring Guide having insert Moulding |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | Quality Alert, OCS |
13. Effectiveness Of Action
| Reviewed Quantity | 250 |
| Reason for submission | No any issue observed in this lot. |