QFR No - 7000831106
Defect Details
| NC No. | 7000831106 |
| NC Date | 14/04/2022 |
| NC Submission Date | |
| Part No. | 550LG06702 |
| Part Name | SEAT PIPE-(HMS-30 & HMP-30) |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | THREADING NOT OK-Half thread and Go gauge not qualified |
1. Problem Description
| Defect Description | Half Thread observed |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 61 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@npcindustries.in |
| Plant Head/CEO Email ID | anand@npcindustries.in |
| MD Email ID | ajay@npcindustries.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
10000
|
0
|
0
|
0
|
0
|
10000
|
| Check Qty |
10000
|
0
|
0
|
0
|
0
|
10000
|
| NG Qty |
14
|
0
|
0
|
0
|
0
|
14
|
| Scrap | 14 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all the parts at ETL end. |
3. Process Flow
| Process Flow Description |
|---|
| 1. Raw Material 2.Cutting 3.Multistation Draw 4.Head Formation 5.Rough Grinding 6.Punching 7.CNC Head Turning 8.CNC Boring & Facing 9.Tapping 10.Chemfering-1&2 11.Finish Grinding 12.Final Inspection 13. Cleaning 14.Oiling. |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping Machine |
| Machine / Cell No. | NPC/TPM/012 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Chips in thread | Verified ok | O |
| Method | Pre Tapping Bore dia u/s | Verified ok | O |
| Method | Tap Wear Out | Verified not ok | X |
| Material | Material Hardness less / more | Verified ok | O |
| Man | Operator negligency at inprocess | Verified not ok | X |
| Method | Minor Dia u/s | Verified ok | O |
| Method | Dents in thread | Verified ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Asper plan |
7. Root Cause Analysis (Occurance)
| Why 1 | M8 GO TPG not answering |
| Why 2 | Wearout tapping tool used in process. |
| Why 3 | Operator was less awareness about the tapping tool |
| Why 4 | New operator appointed and training gap observed |
| Why 5 | |
| Root Cause (Occurance) | New operator appointed and training gap observed |
Root Cause Analysis (Outflow)
| Why 1 | M8 GO TPG not answering |
| Why 2 | Could not be detected at Final Inspection |
| Why 3 | Skipped in Sampling at Final Inspection |
| Why 4 | Less quantity in our Sampling at Final Inspection |
| Why 5 | |
| Root Cause (Outflow) | Less quantity in our Sampling at Final Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | TPG Inspection to be done after every 60pcs(or 10minutes) by operator. | Mr. Paramjeet | 20/04/2022 | Completed | |
| Occurance | Quality Alert to be displayed at Work Station | Mr. Lokesh | 14/04/2022 | Completed | |
| Outflow | Increase sampling size at Final inspection. | Mr. Gurpreet Singh | 14/06/2022 | Completed | |
| Outflow | Quality alert to be displayed at final inspection area | Mr. Lokesh | 14/04/2022 | Completed | |
| Occurance | Training to be provided to new operator about the process any new station. | Mr. Gurpreet | 18/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Increase sampling plan at final inspection |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | increase p |
10. Evidance of Countermeasure
| Occurance (Before) |
Operator unaware 54_Occurance_Before.jpg |
| Occurance (After) |
Training to be provided to new operator about the process any new station. 54_Occurance_After.jpg |
| Outflow (Before) |
As per sampling plan. 54_Outflow_Before.jpg |
| Outflow (After) |
Increase sampling size at Final inspection. 54_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar model |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | No. |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |