QFR No - 8000782620
Defect Details
| NC No. | 8000782620 |
| NC Date | 03/04/2022 |
| 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 | NOT AS PER SPECIFICATION-TOTAL LENGTH UNDER SIZE I.E. 148.89 MM |
1. Problem Description
| Defect Description | Total Length Under Size |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| 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 |
20000
|
7000
|
15000
|
0
|
0
|
42000
|
| Check Qty |
20000
|
7000
|
15000
|
0
|
0
|
42000
|
| NG Qty |
4
|
3
|
0
|
0
|
0
|
7
|
| Scrap | 7 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Lock & Key type rejection bins to be implemented at work station. |
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 | CNC Boring & Facing |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | NP/CNC/013 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Quality Inspector negligent | Quality Inspector found to be non-negligent and performed his duty with diligence | O |
| Method | Operator located part incorrectly | Verified found OK | O |
| Method | Other model mixed during processing | Verified found OK | O |
| Man | Opeartor located part incorrectly | Verified found OK | O |
| Method | CNC Stopper design inadequate | Verified found OK | O |
| Method | CNC vernier not calibrated | Verified found OK | O |
| Method | NG setting part mixed | Verified found not OK | X |
| Method | Usage of open Red Bins | 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 | Asper plan |
7. Root Cause Analysis (Occurance)
| Why 1 | Total length undersize |
| Why 2 | NG Setting part with length undersize passed |
| Why 3 | NG Setting part mixed in OK parts |
| Why 4 | Usage of open Red Bins |
| Why 5 | |
| Root Cause (Occurance) | Usage of open Red Bins |
Root Cause Analysis (Outflow)
| Why 1 | Total Length undersize |
| Why 2 | Could not be detected at Final Inspection |
| Why 3 | Skipped in Sampling at Final Inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Skipped in Sampling at Final Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Training to be provided to line supervisor and all line operators | Mr Gurpreet | 11/04/2022 | Completed | |
| Occurance | Lock & Key type rejection bins to be implemented at work station (Only part drop down and not pick up from Bin) | Mr Mohinderpal | 12/04/2022 | Completed | |
| Occurance | Quality Alert to be displayed at work station | Mr. Lokesh | 04/04/2022 | Completed | |
| Outflow | 100% marking after total length inspection to be done | Mr. Ankush | 07/04/2022 | Completed | |
| Outflow | Quality alert to be displayed at final inspection | Mr. Lokesh | 04/04/2022 | Completed | |
| Occurance | Setting NG part to be damaged by shift supervisor. | Mr. Gursewak Singh | 07/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling plan is doubled |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | double |
10. Evidance of Countermeasure
| Occurance (Before) |
Open Red Bin 41_Occurance_Before.png |
| Occurance (After) |
Lock & Key type rejection bins at work station (Only part drop down and not pick up from Bin) 41_Occurance_After.jpg |
| Outflow (Before) |
As per Sampling Plan 41_Outflow_Before.jpg |
| Outflow (After) |
Sampling Plan Doubled 41_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable all similar parts |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |