QFR No - 7000891491
Defect Details
| NC No. | 7000891491 |
| NC Date | 20/01/2023 |
| NC Submission Date | |
| Part No. | F1LG00902B |
| Part Name | SEAT PIPE -K86A |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | MIX UP OTHER MODEL-Mix up Other model |
1. Problem Description
| Defect Description | Other model Mixing . |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 250 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | tj5qkjazjfglq5x4xctoxy0m.png |
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 |
4000
|
1250
|
0
|
0
|
0
|
5250
|
| Check Qty |
4000
|
1250
|
0
|
0
|
0
|
5250
|
| NG Qty |
250
|
0
|
0
|
0
|
0
|
250
|
| Scrap | 250 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all parts at ETL, at Warehouse & at NPC Nabha. |
3. Process Flow
| Process Flow Description |
|---|
| Process Flow Description 1.Raw Material 2.Cutting & Chemfering 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 15.Packing &Dispatch |
4. Process Details
| Process / Operation | Final Inspection |
| Outsource | Yes |
| Machine / Cell | ST-01 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | skipped at final inspection | it was observed that parts skipped during sampling at final inspection. | O |
| Method | wrong part mixed during material handing | After verification we found material handling properly as per std. | O |
| Machine | tempered program run in CnC machine | it was observed that no program | O |
| Man | Packing person negligence at in packing | Packing person was not aware | X |
| Tool | Tap Wear Out | after verification we found tap was wear out | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Mix up Other model |
| Why 2 | other model box mixed at dispatch station |
| Why 3 | Dispatch helper was not aware |
| Why 4 | different model boxes were placed at same places |
| Why 5 | No identification point was not available for particular model |
| Root Cause (Occurance) | No identification point was not available for particular model |
Root Cause Analysis (Outflow)
| Why 1 | Mix up Other model |
| Why 2 | other model box mixed at dispatch station |
| Why 3 | No checkpoint was available after packing |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No checkpoint was available after packing |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Give the awareness training for dispatch department | Mr. Gurpreet singh | 25/01/2023 | 23/01/2023 | Completed |
| Outflow | New checkpoint to be added as temporary basis in warehouse | Mr. Ratness | 25/01/2023 | 24/01/2023 | Completed |
| Occurance | identification point should be available for particular model | Mr. Ankush | 22/01/2023 | 21/01/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | new checkpoint add at warehouse |
| 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) |
No identification point was not available for particular model 336_Occurance_Before.jpeg |
| Occurance (After) |
Place is define by identification tag for perticular moidel. 336_Occurance_After.png |
| Outflow (Before) |
No any check point available after packing. 336_Outflow_Before.png |
| Outflow (After) |
New check point establish in warehouse for material check befor dispatch in GIL Sanand Plant. 336_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | K-86 Seat pipe |
12. Document Review
| Documents | |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | Provide evidence for training record and check point sheet added in warehouse |