QFR No - 8000894023
Defect Details
| NC No. | 8000894023 |
| NC Date | 01/10/2024 |
| NC Submission Date | |
| Part No. | 530DA00507 |
| 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 PEEL OFF |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 106 |
| Is Defect Repeatative? | Yes |
| 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 |
208
|
0
|
0
|
0
|
0
|
208
|
| Check Qty |
208
|
0
|
0
|
0
|
0
|
208
|
| NG Qty |
106
|
0
|
0
|
0
|
0
|
106
|
| Scrap | 106 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Available lot Qty 208 Nos Segregated for peel off Issue by heating Method. |
3. Process Flow
| Process Flow Description |
|---|
| RM+Forming +Piercing+Vibro+Powder coating+final Inspection+Dispatch |
4. Process Details
| Process / Operation | Powder Caoting |
| Outsource | Yes |
| Machine / Cell | Tulja Enterprises |
| Machine / Cell No. | Powder Coating L |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Excess Powder Coating at OD edge | Due to new coater powder coating observed excess on part Edge | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | DFT meter Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | DFT Chech |
7. Root Cause Analysis (Occurance)
| Why 1 | TSL Powder Coating Peel off at Edge |
| Why 2 | Powder Coating Thickness Observed More on part Edge |
| Why 3 | Excess powder observed ( more than 120Micron )observed on Edge |
| Why 4 | New Coater in place of regular coater absentism |
| Why 5 | No new coater powder spraying training for powder DFT 60 to 70 |
| Root Cause (Occurance) | Excess powder coating on part and its Edge |
Root Cause Analysis (Outflow)
| Why 1 | TSL Powder Coating Peel off at Edge |
| Why 2 | Not detected at final Inspection stage |
| Why 3 | Sampling basis DFT verification |
| Why 4 | visual method of 100% Inspection not followed |
| Why 5 | |
| Root Cause (Outflow) | Sampling basis DFT verification |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Inspection frequency increased for DFT verification and 100& visual inspection followed for Excess coating on Edge | Mr.Vishal | 15/10/2024 | Completed | |
| Occurance | Training provided to available coater for Powder Coating thickness within 60-70 Micron | Mr.Mahendra Patil | 15/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection Qty increased for DFT Inspection also 100% powder verification at edge for excess powder coating |
| Inspection Method | Other |
| Other Inspection Method | Double sampling |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 20/100 |
10. Evidance of Countermeasure
| Occurance (Before) |
Excess Coating 1126_Occurance_Before.pdf |
| Occurance (After) |
No Excess Coating training provided to coater. 1126_Occurance_After.jpg |
| Outflow (Before) |
No Training to Coater, Coater Training provided 1126_Outflow_Before.pdf |
| Outflow (After) |
Training Provided to Coater 1126_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Other Locator also |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Final Training |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | After taking action no powder coating peel off observed on part. |