QFR No - 8000899141
Defect Details
| NC No. | 8000899141 |
| NC Date | 14/11/2024 |
| NC Submission Date | |
| Part No. | F2PA00202B |
| Part Name | BOTTOM CASE RING RE J1A |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CRACK/BROKEN |
1. Problem Description
| Defect Description | CRACK/BROKEN |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 44 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | xd0zclmakc4kyvvbxutjlf4r.jpg |
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 |
1000
|
0
|
0
|
225
|
0
|
1225
|
| Check Qty |
1000
|
0
|
0
|
225
|
0
|
1225
|
| NG Qty |
44
|
0
|
0
|
12
|
0
|
56
|
| Scrap | 56 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Checked all available stock of 1000 no. at ETL end 100% and found 44 no. defective parts. Checked 100% all inhouse FG stock available 225 no. and found 12 no. defective parts |
3. Process Flow
| Process Flow Description |
|---|
| Annealing |
4. Process Details
| Process / Operation | Annealing |
| Outsource | No |
| Machine / Cell | Annealing Tank |
| Machine / Cell No. | ANL -01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | RM Grade not as per CP . Check with | Check with MTC & found ok as per specification | O |
| Machine | Barrel Temp High / Low | Verified as per Cp & OCS found ok , As per Standard Specification | O |
| Tool | Air trapped & air vent inefficient open | Verified the air vent and found ok | O |
| Method | Annealing surface volume in tank in sufficient to dip the parts in medium. | Verified and found due to small tank top parts are getting float in medium . | X |
| Method | RM preheating not done | Verified as per CP & OCS found ok , As per Standard Specification | O |
| Man | Man Power does not aware about this defect . | Verifed that operator , In process inspector & Final Inspector aware about this defect . | O |
| Machine | OCS & control plan not followed by Machine Operator . | Verified as per Cp & OCS found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Parts are getting broken erratically on weld line surface. |
| Why 2 | Parts are not getting fully dipped in annealing medium |
| Why 3 | Due to parts are getting floated above the medium surface |
| Why 4 | Due to Annealing tank size small , parts surface not completely annealed. |
| Why 5 | |
| Root Cause (Occurance) | Due to Annealing tank size small , top parts surface not completely annealed resulting into insufficient annealing . Due to Annealing tank size small , parts surface not completely annealed resulting in breakages erratically. |
Root Cause Analysis (Outflow)
| Why 1 | Parts are getting broken erratically on weld Line surface. |
| Why 2 | Parts are getting skipped from Operator and Final Inspector |
| Why 3 | After annealing process , parts are getting checked on sampling Inspection |
| Why 4 | Lack of awareness of highlighted defect. |
| Why 5 | |
| Root Cause (Outflow) | Lack of awareness of highlighted defect. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Annealing record Register monitoring started | Ganesh mhaske | 22/11/2024 | 22/11/2024 | Completed |
| Occurance | Big Annealing tank to Incorporate so that max parts are getting covered in one annealing cycle. | Ganesh Mhaske | 26/11/2024 | 27/11/2024 | Completed |
| Outflow | Awareness training given to in process inspector & Final Inspector about highlighted defect . | Sandeep Rode | 22/11/2024 | 22/11/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection for part softness after annealing. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Earlier small Annealing tank does not cover part max occupancy per cycle . Parts are getting open in medium due to floating on surface at top side which may be the probable cause . 1224_Occurance_Before.pptx |
| Occurance (After) |
Now Big Size Annealing tank implemented so that max parts are covered per cycle. Annealing Monitoring record started. 1224_Occurance_After.pdf |
| Outflow (Before) |
Earlier Parts Softness & ductility after annealing process was checked at sampling basis. 1224_Outflow_Before.pdf |
| Outflow (After) |
Parts softness and Ductility checking with 100% Inspection with OJT to In process and Firewall Inspectors. 1224_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |