QFR No - 8000807218
Defect Details
| NC No. | 8000807218 |
| NC Date | 08/10/2022 |
| 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 | THREADING NOT OK-THREAD GO GAUGE NOT ENTERED. |
1. Problem Description
| Defect Description | Threading M8 observed not Ok (Go gauge not entered.) Concern repetitively communicated from last six months, but yet no any improvement observed in received lots. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 3000 |
| 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 |
5600
|
1000
|
0
|
0
|
0
|
6600
|
| Check Qty |
5600
|
1000
|
0
|
0
|
0
|
6600
|
| NG Qty |
3000
|
200
|
0
|
0
|
0
|
3200
|
| Scrap | 0 |
| Rework | 3200 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all parts at ETL, at Warehouse & at NPC Nabha. |
3. Process Flow
| Process Flow Description |
|---|
| 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 | Tapping |
| Outsource | Yes |
| Machine / Cell | tapping machine |
| 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 | Operator negligence at in process | operator was aware about the defect he found to be non negligent | O |
| Method | Chips in thread | After validation no chips found in thread | O |
| Method | Minor Dia u/s | after verification we found ok | O |
| Material | Material Hardness less / more | after verification we found ok | O |
| Method | Tap Wear Out | after verification we found tap was wear out | 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 | M8 GO TPG not answering |
| Why 2 | Wear out tapping tool used in process. |
| Why 3 | Operator was less awareness about the tapping tool |
| Why 4 | New operator appointed and training gap observed |
| Why 5 | |
| Root Cause (Occurance) | New operator appointed and training gap observed |
Root Cause Analysis (Outflow)
| Why 1 | M8 GO TPG not answering |
| Why 2 | Could not be detected at Final Inspection |
| Why 3 | Skipped in Sampling at Final Inspection |
| Why 4 | Less quantity in our Sampling at Final Inspection |
| Why 5 | |
| Root Cause (Outflow) | Less quantity in our Sampling at Final Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | TPG Inspection to be done after every 60pcs(or 10minutes) by operator. | Mr. Rajinder | 08/11/2022 | 02/11/2022 | Completed |
| Outflow | Increase sampling size at Final inspection. | Mr. Yadvinder | 16/10/2022 | 13/10/2022 | Completed |
| Occurance | Training to be provided to new operator about the process any new station. | Mr. Gurpreet Singh | 08/11/2022 | 02/11/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Increase sampling size at Final inspection. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | asper plan |
10. Evidance of Countermeasure
| Occurance (Before) |
New operator appointed and training gap observed 277_Occurance_Before.jpg |
| Occurance (After) |
Training to be provided to new operator about the process any new station. 277_Occurance_After.jpg |
| Outflow (Before) |
Less quantity in our Sampling at Final Inspection 277_Outflow_Before.jpg |
| Outflow (After) |
Increase sampling size at Final inspection. 277_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | DRILLING MACHINE |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PokayokeCheckSheet, WISOP, JHCheckSheet, AuditCheckSheet, InspCheckSheet |
| Specify Other Document | TRAINING SHEET |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Completed. |