QFR No - 8000787718
Defect Details
| NC No. | 8000787718 |
| NC Date | 17/05/2022 |
| NC Submission Date | |
| Part No. | 550LG06202 |
| Part Name | SEAT PIPE -K23A/PRFH-006 |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | HIGHT U/SIZE.-TOTAL LENGTH LESS ISSUE |
1. Problem Description
| Defect Description | KON seat pipe total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | nqppngc1jzrocztqb5vn0rur.xlsx |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | qaharshad@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
550
|
4325
|
6875
|
| Check Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. 100 % sorting done at ETL 2. 100 % sorting done for HEC FG & WIP stock with Identification mark on box |
3. Process Flow
| Process Flow Description |
|---|
| "10 - Raw Material Annealed and Phosphated "20-A - Cutting & 20-B- Cutting wt. "30-A MOS Application 30 -B Multistation Draw "40-A- Head Formation "40-B Inward/Incoming Inspection "50 - Rough Grinding "60-A CNC Head Turning , Facing. 60-B Facing & Boring 60-C Tapping "70A - Punching "70B- Chamfering "80-A - Finish grinding 80-B Buffing "90-A- De-burr 90-B- Final/Visual Inspection "100-A ID Cleaning Diesel 100-B - Ultrasonic cleaning "110-A- Visual Inspection Q gate 110-B - Rust oil Application "120 - Packing & Dispatch |
4. Process Details
| Process / Operation | Inspection & Packing |
| Outsource | No |
| Machine / Cell | Packing section |
| Machine / Cell No. | 120 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Mix up while packing process | At Packing station mix part found | X |
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 | Model mix up |
| Why 2 | During length process parts mix up |
| Why 3 | Various models Length checking done at same station |
| Why 4 | No any provision |
| Why 5 | |
| Root Cause (Occurance) | Various models Length checking done at same station |
Root Cause Analysis (Outflow)
| Why 1 | Model Mix up |
| Why 2 | Various models Length checking done at same station |
| Why 3 | After length checking process no check point |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | After length checking process no check point |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.At Final inspection station separate inspection table with checking length gauge proved 2.100% inspection done for length 3."Q" Gate station added before packing 4.Total box weight done to ensure no mix up | Ashish M & Pravin Jadhav | 25/05/2022 | 09/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1.At Final inspection station separate inspection table with checking length gauge proved 2.`Q` gate provided to ensure mix up concern 3. Total Box weight mention on each box |
| 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) |
Only One station for checking total length 125_Occurance_Before.jpg |
| Occurance (After) |
Three inspection station provided for total length checking 125_Occurance_After.jpg |
| Outflow (Before) |
No provision for Q Gate 125_Outflow_Before.jpg |
| Outflow (After) |
Mix up checking station added ( Q gate) 125_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Final Inspection & packing area total length station |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | Packing WI |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Reviewed 1000 number no issue found ok |