QFR No - 8000781361
Defect Details
| NC No. | 8000781361 |
| NC Date | 24/03/2022 |
| 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-WRONG MODEL FOUND |
1. Problem Description
| Defect Description | Wrong Model Part |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 252 |
| 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 |
8000
|
0
|
0
|
0
|
0
|
8000
|
| Check Qty |
8000
|
0
|
0
|
0
|
0
|
8000
|
| NG Qty |
250
|
0
|
0
|
0
|
0
|
250
|
| Scrap | 0 |
| Rework | 250 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Bar coding to be done in NP&Co. Plant itself |
3. Process Flow
| Process Flow Description |
|---|
| 1.RM Receipt 2. Cutting 3.Multistation Draw 4. Head Formation 5. Rough Grinding 6. Punching 7. CNC Head Turning & Chamfering 8. CNC Boring & Facing 9. Thread M8x1.25 Tapping 10. Chamfering-1 11. Chamfering-2 12. ID Deburring 13. Finish Grinding 14. Final Inspection 15. ID Cleaning 16. Oiling 17. Packing & Dispatch 18. Transportation. |
4. Process Details
| Process / Operation | Transportation |
| Outsource | Yes |
| Machine / Cell | ---- |
| Machine / Cell No. | ---- |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | In process Operator negligent | In process operator was not found to be negligent . | O |
| Method | Mix up during cleaning | After verification it was observed that parts were not mixed at cleaning station | O |
| Method | Mix up during Packing | After verification it was observed that parts were not mixed during Packing | O |
| Method | Mix up at final Inspection | No linkage with defect | O |
| Method | Material identification missing | Material identification with Tags observed to be followed regularly and on all the material | O |
| Man | Quality Inspector negligent | Quality Inspector was not found to be negligent. | O |
| Method | Mix up by transport | After verification it was observed that material boxes got mixed during transportation. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | asper plan |
7. Root Cause Analysis (Occurance)
| Why 1 | MIX UP OTHER MODEL-WRONG MODEL FOUND |
| Why 2 | Mixing of boxes during transportation |
| Why 3 | Collecting different customers material simultaneously at one time |
| Why 4 | Wrong Barcoding done in Transportation Hub |
| Why 5 | |
| Root Cause (Occurance) | Wrong Barcoding done in Transportation Hub |
Root Cause Analysis (Outflow)
| Why 1 | MIX UP OTHER MODEL-WRONG MODEL FOUND |
| Why 2 | Could not be detected at Packing Station |
| Why 3 | No inspection activity before supply to customer |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No inspection activity before supply to customer |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Single Seat Pipe model to be packed at one time | Mr. Ankush | 21/04/2022 | Pending | |
| Occurance | Transport personnels to be contacted for making them aware of the defect | Mr. Kamaldeep | 21/04/2022 | Pending | |
| Occurance | Quality Alert & WI to be displayed at Packing Station | Mr. Lokesh | 29/03/2022 | Pending | |
| Occurance | Bar Coding to be done from Nabha Plant itself | Mr. Kamaldeeep | 21/04/2022 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | ------ |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | asper plan |
10. Evidance of Countermeasure
| Occurance (Before) |
Bar coding done in Transportation Hub 23_Occurance_Before.jpeg |
| Occurance (After) |
Bar Coding to be done in N.P. & Co. Nabha Plant itself 23_Occurance_After.jpeg |
| Outflow (Before) |
Multiple model seatpipes inspected simultaneously 23_Outflow_Before.jpeg |
| Outflow (After) |
Single model seat pipe will be inspected at one time 23_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |