QFR No - 8000896052
Defect Details
| NC No. | 8000896052 |
| NC Date | 17/10/2024 |
| 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 |
1. Problem Description
| Defect Description | Dent mark |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 41 |
| 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 |
576
|
0
|
0
|
330
|
0
|
906
|
| Check Qty |
576
|
0
|
0
|
330
|
0
|
906
|
| NG Qty |
41
|
0
|
0
|
29
|
0
|
70
|
| Scrap | 70 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL end and In-house material verify and rejected at ETL end also at in-house stage. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Casting inward=>CNC Setup=>Drilling =>Powder Coating=>Powder Coating Inward=>VMC Setup=>De-burring=>Final Inspection=>Packing and Dispatch. |
4. Process Details
| Process / Operation | VMC machining |
| Outsource | No |
| Machine / Cell | VMC Cell |
| Machine / Cell No. | VMC Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine paramter required not as per control plan | Verify the machine parameter as clamping pressure found ok. | O |
| Tool | Required tooling for part production not as per standard. | Verify the toolong for production and found adequate. | O |
| Material | Material specifications not as per drawing. | Verify the material specification with MTC and found as per drawing. | O |
| Man | Final inspector not as per skill matrix. | Verify the skill matrix for final inspector as well as packing person found as per skill matrix. | O |
| Method | Deburring not done as per work instruction given. | Verify the deburring method by operator and found inadequate. | X |
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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Dent damage issue on the parts. |
| Why 2 | Clamping pressure not as per control plan specifications. |
| Why 3 | Part handling not done as per material handling WI. |
| Why 4 | De-burring process not done properly as per WI. |
| Why 5 | |
| Root Cause (Occurance) | De-burring process not done properly as per WI. |
Root Cause Analysis (Outflow)
| Why 1 | Dent damage issue on the parts. |
| Why 2 | Parts skipped by inspector during final inspection. |
| Why 3 | During material packing dent damage issue. |
| Why 4 | Awareness not available to inspector as well as packing person for dent damage issue. |
| Why 5 | |
| Root Cause (Outflow) | Awareness not available to inspector as well as packing person for dent damage issue. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Training and awareness given to final inspector as well as packing person for dent damage issue. | Mr.Yogesh Sonune | 18/10/2024 | 18/10/2024 | Completed |
| Occurance | Training given to operator of de-burring process for de-burring should be done as per WI display. | Mr. Sudarshan Kadam | 18/10/2024 | 18/10/2024 | 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) |
Operator not aware about dent damage issue on the parts. 1164_Occurance_Before.pptx |
| Occurance (After) |
Training and awareness given to operator for de-burring on the parts. 1164_Occurance_After.pptx |
| Outflow (Before) |
No any awareness about dent damage issue observed on the parts. 1164_Outflow_Before.pptx |
| Outflow (After) |
Training and awareness given to final inspector for dent damage issue observed on the parts also Q alert display for the raise concern by ETL. 1164_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 |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |