QFR No - 8000795498
Defect Details
| NC No. | 8000795498 |
| NC Date | 18/07/2022 |
| 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 | MIX UP OTHER MODEL-LENGTH LESS MIX UP NOT USING KON MODEL |
1. Problem Description
| Defect Description | KON front fork seat pipe total length less mix up repeated issue compression one through hole available |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 50 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | hy34ct1limjq3bxzxoomdguv.xlsx |
Supplier Communication Details
| Quality Head Email ID | qaharshad@gmail.com |
| Plant Head/CEO Email ID | qaharshad@gmail.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 |
4000
|
0
|
0
|
2150
|
5550
|
11700
|
| Check Qty |
4000
|
0
|
0
|
0
|
0
|
4000
|
| NG Qty |
20
|
0
|
0
|
0
|
0
|
20
|
| Scrap | 20 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done for ETL End, HEC WIP & FG material |
3. Process Flow
| Process Flow Description |
|---|
| Cutting-Draw-Forging(Head Formation)-Rough Grinding-CNC (Head, Boring & Tapping)-Punching-Finish Grinding-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | Inspection & packing |
| Outsource | No |
| Machine / Cell | Packing & Inspection |
| Machine / Cell No. | 120-A & B |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Mix-up while packing & Inspection | Mix-up while polybag filling& Packing | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
7. Root Cause Analysis (Occurance)
| Why 1 | Mix-up with other model |
| Why 2 | Mix-up while packing |
| Why 3 | No separate color identification to polybag |
| Why 4 | use standard polybag for packing |
| Why 5 | |
| Root Cause (Occurance) | No separate color identification to polybag |
Root Cause Analysis (Outflow)
| Why 1 | Mix-up with other model |
| Why 2 | While polybag sealing manual parts counting done |
| Why 3 | weight polybag & Box not done/Measured |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | weight polybag & Box not done/Measured |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Yellow color polybag used for PRFH | VAibhav | 29/07/2022 | 27/07/2022 | Completed |
| Outflow | Polybag & box weight done | Vaibhav | 29/07/2022 | 27/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Box wt. done after packing on weighing scale & modelwise wt. chart displayed |
| Inspection Method | Other |
| Other Inspection Method | Manual Polybag fill |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
standard color polybag used for all seat pipes 202_Occurance_Before.jpg |
| Occurance (After) |
Yellow color polybag used for PRFH seat pipe 202_Occurance_After.jpg |
| Outflow (Before) |
Box & polybag wt. not done 202_Outflow_Before.jpg |
| Outflow (After) |
Box & polybag wt. done as per modelwise wt. chart 202_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Packing & Dispatch section |
12. Document Review
| Documents | WISOP, ProcessFlowChart, PackingStd |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 3000 |
| Reason for submission | reviewed 3000 number found ok |