QFR No - 7001053895
Defect Details
| NC No. | 7001053895 |
| NC Date | 16/09/2024 |
| 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 | LENGTH UNDERSIZE-Short Lenght ,concentricity found NG |
1. Problem Description
| Defect Description | Total length specification 152-0.2 observation 150.51 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1500 |
| 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 |
6000
|
10000
|
18000
|
15000
|
5000
|
54000
|
| Check Qty |
6000
|
10000
|
18000
|
15000
|
5000
|
54000
|
| NG Qty |
1500
|
525
|
0
|
0
|
0
|
2025
|
| Scrap | 2025 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregate all material at both end |
3. Process Flow
| Process Flow Description |
|---|
| Process Flow Description 1.0 Raw Material 2.0 Cutting 3.0 Drawing 4.0 Head Formation 5.0 Rough Grinding 6.0 Punching 7.0 CNC Head Turning 8.0 CNC Boring & Facing 9.0 Tapping 10.0 Chamfering 11.0 ID Deburring 12.0 Finish Grinding 13.0 Final Inspection 14.0 Cleaning 15.0 Oiling 16.0 Packing &Dispatch. |
4. Process Details
| Process / Operation | CNC Head Turning |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC-12 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Instrument /Gauge not Callibrated | No linkage with defect observed. | O |
| Man | Process Operator Negligence | No linkage with defect observed. | O |
| Man | Final Q-gate Inspector Negligence | No linkage with defect observed. | O |
| Method | Wrong Setting | No linkage with defect observed. | O |
| Material | Wrong material mixed | No linkage with defect observed. | O |
| Method | Tool was damage | After verification we found tooling method was inadequate | X |
| Method | NG parts skipped at final Q-gate | Verified found NOT OK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As per std |
7. Root Cause Analysis (Occurance)
| Why 1 | Total length less & concentricity found NG |
| Why 2 | The CNC machine cut more material than necessary, making the part shorter than the required length. |
| Why 3 | Seatpipes were mispositioned, leading to incorrect length measurement during clamping. |
| Why 4 | metallic chip was stuck in the stopper, increasing the apparent length of the part. |
| Why 5 | The stopper design allowed chips to accumulate and interfere with accurate part positioning. |
| Root Cause (Occurance) | The stopper design allowed chips to accumulate and interfere with accurate part positioning. |
Root Cause Analysis (Outflow)
| Why 1 | Total length less & concentricity found NG |
| Why 2 | Defected part did not detected during inspection. |
| Why 3 | Parts were skipped during the Inspection. |
| Why 4 | The sampling Inspection method followed for Concentricity & Visual Inspection method use for length gauge with the help of flat plat |
| Why 5 | Sampling Quantity was less for concentricity & Visual inspection method was inadequate for total length . |
| Root Cause (Outflow) | Sampling Quantity was less for concentricity & Visual inspection method was inadequate for total length . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Q-Alert to be displayed at CNC work stations . | Mr. Princ | 17/09/2024 | 16/09/2024 | Completed |
| Occurance | Training to be given for correct part placement. | Mr. Harwinder | 17/09/2024 | 16/09/2024 | Completed |
| Occurance | The stopper is designed to be modified to eliminate areas where chips can rest or become stuck | Mr. Mohinder toti | 25/09/2024 | 23/09/2024 | Completed |
| Outflow | Q- Alert to be displayed at the final Inspection | Mr. Princ | 17/09/2024 | 16/09/2024 | Completed |
| Outflow | 100% length inspection to be started with the help of length gauge & Sampling qty doubled for concentricity. | Mr. Vinay tiwari | 19/09/2024 | 18/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling Qty doubled for concentricity & 100 % length inspection started. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
The stopper design allowed chips to accumulate and interfere with accurate part positioning. 1098_Occurance_Before.jpeg |
| Occurance (After) |
The stopper is designed to be modified to eliminate areas where chips can rest or become stuck . 1098_Occurance_After.jpeg |
| Outflow (Before) |
Sampling Quantity was less for concentricity & Visual inspection method was inadequate for total length . 1098_Outflow_Before.jpeg |
| Outflow (After) |
100% length inspection to be started with the help of length gauge & Sampling qty doubled for concentricity. 1098_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar models |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Total length specification 152-0.2 observation 150.51 mm |