QFR No - 8000896118
Defect Details
| NC No. | 8000896118 |
| NC Date | 17/10/2024 |
| NC Submission Date | |
| Part No. | F2FQ00507B |
| Part Name | HOLDER HANDLE P/C-XF-1C1 |
| Supplier Name & Code | 100001-ANANT ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | B/H INSIDE BORE-BLOW HOLE,CUT MARK |
1. Problem Description
| Defect Description | CUT MARK |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 70 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandkulkarni@anantgroup.co.in |
| Plant Head/CEO Email ID | pramodgosavi@anantgroup.co.in |
| MD Email ID | ashwinjoshi@anantgroup.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
205
|
160
|
365
|
| Check Qty |
0
|
0
|
0
|
203
|
152
|
355
|
| NG Qty |
0
|
0
|
0
|
2
|
8
|
10
|
| Scrap | 10 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Under cut part segregated at our end and scraped separately for the same. ICA mark started back side on part surface for the confirm free from cut mark on part. |
3. Process Flow
| Process Flow Description |
|---|
| Raw material Inspection=Melting=Spectro=Metal transfer to holding furnace=Degassing=Die preparation=Casting=Riser cutting=Inspection=Buffing=Heat treatment=Inspection=Powder coating=Inspection=Machining=deburring=Pre-Washing=Final Inspection=Packing Dispatched |
4. Process Details
| Process / Operation | Casting=HT=PC=M/C |
| Outsource | No |
| Machine / Cell | Plat Form number 03 |
| Machine / Cell No. | Machine Number 04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled manpower | Skill matrix verified and found ok | O |
| Method | Buffing process | Buffing process done by manual, some part profile not matched during buffing | X |
| Material | Material not ok | Material grade check and found as per specification. | O |
| Machine | Machine condition not ok | Machine condition verified and PM done as per defined frequency | O |
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 | cut mark observed on part |
| Why 2 | Cut mark observed on part due to buffing not done properly |
| Why 3 | Buffing not done properly due to buffing process is manual |
| Why 4 | Buffing process is manual due to some part profile not match process |
| Why 5 | |
| Root Cause (Occurance) | Buffing process is manual due to some part profile not match in process |
Root Cause Analysis (Outflow)
| Why 1 | Cut mark observed on part |
| Why 2 | Cut mark part skipped by inspector |
| Why 3 | Part skipped by inspector due to part not catch by inspector at final stage |
| Why 4 | cut mark part not catch by inspector due to eyes sequence not followed |
| Why 5 | Eyes sequence not followed due to operator negligence |
| Root Cause (Outflow) | Eyes sequence not followed due to operator negligence |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Q- alert displayed | Nisar | 19/10/2024 | 19/10/2024 | Completed |
| Outflow | Awareness training given to all Inspector regarding customer complaint. | Nisar A | 20/10/2024 | 20/10/2024 | Completed |
| Occurance | Q alert and defect matrix displayed | Nisar A. | 19/10/2024 | 19/10/2024 | Completed |
| Occurance | Start to five numbers part check in every hrs in buffing process. | Ambar | 22/10/2024 | 22/10/2024 | Completed |
| Occurance | Training has given to all buffing operator regarding customer complaint | Nisar A. | 20/10/2024 | 20/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No any change in process |
| 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) |
Q- alert display 1173_Occurance_Before.pdf |
| Occurance (After) |
Training given to al regarding customer complaint 1173_Occurance_After.pdf |
| Outflow (Before) |
Q alert displayed 1173_Outflow_Before.pdf |
| Outflow (After) |
Awareness training given to al inspector regarding customer complaint 1173_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All holder and bracket |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | No Any |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |