QFR No - 8000789590
Defect Details
| NC No. | 8000789590 |
| NC Date | 31/05/2022 |
| NC Submission Date | |
| Part No. | 550LG06202 |
| Part Name | SEAT PIPE -K23A/PRFH-006 |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | RUN OUT MORE-RUNOUT OVERSIZE. 0.5 AGAINST 0.1 MAX |
1. Problem Description
| Defect Description | M8 threading runout wrt to outer dia. observed up to 0.55, 0.5 mm against drg. requirement of 0.1 mm. This concern leads to assembly movement NG as well as noise concern. |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 1700 |
| 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 |
1700
|
1500
|
0
|
0
|
0
|
3200
|
| Check Qty |
15
|
0
|
0
|
0
|
0
|
15
|
| NG Qty |
15
|
0
|
0
|
0
|
0
|
15
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 15 |
| Containment Action |
|---|
| Segregated all parts at ETL, at Warehouse & at NPC Nabha. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Raw Material 2.Cutting & Chemfering 3.Multistation Draw 4.Head Formation 5.Rough Grinding 6.Punching 7.CNC Head Turning 8.CNC Boring & Facing 9.Tapping 10.Chemfering 1&2 11.Finish Grinding 12.Final Inspection 13.Cleaning 14.Oiling 15.Packing &Dispatch |
4. Process Details
| Process / Operation | CNC Boring & Facing |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | NPC/CNC/011 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | skipped at final inspection | it was observed that parts skipped during sampling at final inspection. | X |
| Man | In process operator negligent | operator was aware about the defect he found to be non negligent | O |
| Machine | Grinding wheel center out | Grinding wheel was not center out | O |
| Material | collet sleeve damage | Collet sleeve wearout | X |
| Machine | grinding wheel will good condition. | grinding wheel was not dress | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | ssp (0.65) |
7. Root Cause Analysis (Occurance)
| Why 1 | collet sleeve was damage. |
| Why 2 | Collet sleeve wearout during CNC boring operation |
| Why 3 | collet sleeve was not change. |
| Why 4 | collet sleeve was wear out before expiry |
| Why 5 | |
| Root Cause (Occurance) | collet was wear out before expiry |
Root Cause Analysis (Outflow)
| Why 1 | run out oversize. |
| Why 2 | Could not be detected at final inspection. |
| Why 3 | skipped at final inspection. |
| Why 4 | Skipped in Sampling inspection. |
| Why 5 | |
| Root Cause (Outflow) | Skipped in Sampling inspection.k |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Sampling plan doubled. | Mr. Gurpreet | 21/06/2022 | 20/06/2022 | Completed |
| Occurance | Reduce life cycle time of collet sleeve after validation. | Gursewak singh | 24/06/2022 | 22/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | sampling plan double. |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | double |
10. Evidance of Countermeasure
| Occurance (Before) |
collet sleeve was wear out before expiry 159_Occurance_Before.jpg |
| Occurance (After) |
Collet sleeve is change after life time reduce (according to new validation) 159_Occurance_After.jpg |
| Outflow (Before) |
Skipped in Sampling inspection. 159_Outflow_Before.jpg |
| Outflow (After) |
Sampling inspection doubled 159_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC Machine |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, WISOP, JHCheckSheet, ProcessFlowChart, InspCheckSheet |
| Specify Other Document | validation report |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | No any improvement observed in received lots. |