QFR No - 8000787717
Defect Details
| NC No. | 8000787717 |
| NC Date | 17/05/2022 |
| NC Submission Date | |
| Part No. | F1LG00902B |
| Part Name | SEAT PIPE -K86A |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | HIGHT U/SIZE.-TOTAL LENGTH LESS ISSUE |
1. Problem Description
| Defect Description | K0LA seat pipe total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | nqppngc1jzrocztqb5vn0rur.xlsx |
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 |
15000
|
0
|
0
|
7000
|
0
|
22000
|
| Check Qty |
15000
|
0
|
0
|
0
|
0
|
15000
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all the material at ETL. |
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. |
4. Process Details
| Process / Operation | CNC Boring & Facing |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | NP/CNC/014 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator Negligence. | Operator found to be non-negligent. | O |
| Man | Operator Unaware. | Operator found to be aware about the Operation. | O |
| Material | Material Hardness Less/More. | Material Hardness found to be ok. | O |
| Method | NG setting part mixed. | No locked Red Bin present at work station. | X |
| Material | Other model mixed during processing. | Verified found OK . | O |
| Method | CNC vernier not calibrated. | Calibration certificate | O |
| Method | Usage of open Red Bins. | During Gemba visit open Red Bins observed to be present at work station. | X |
| Method | CNC Stopper design inadequate. | Verified found 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 | 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 | Lock & Key type rejection bins to be implemented at work station (Only part drop down and not pick up from Bin). | Mr Mohinderpal | 26/05/2022 | Completed | |
| Occurance | Quality Alert to be displayed at work station. | Mr Lokesh | 20/05/2022 | Completed | |
| Outflow | Quality alert to be displayed at final inspection | Mr. Lokesh | 20/05/2022 | Completed | |
| Outflow | Sampling plan to be doubled at final inspection. | Mr. Gurpreet | 23/05/2022 | Completed | |
| Occurance | Setting NG part to be damaged by shift supervisor. | Mr Lokesh | 27/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling to be doubled. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | doubled |
10. Evidance of Countermeasure
| Occurance (Before) |
Usage of open Red Bin. 126_Occurance_Before.jpg |
| Occurance (After) |
Lock & Key type rejection bins to be implemented. 126_Occurance_After.jpg |
| Outflow (Before) |
As per Sampling plan. 126_Outflow_Before.jpg |
| Outflow (After) |
Sampling doubled. 126_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar models. |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No. |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | reviewed 5000 number no issue found ok |