QFR No - 8000827592
Defect Details
| NC No. | 8000827592 |
| NC Date | 26/04/2023 |
| 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 | LENGTH UNDERSIZE-TOTAL LENGHT LESS |
1. Problem Description
| Defect Description | Seat pipe total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | myxhb1uoyxroq2e4tssk4rhv.jpg |
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 |
4000
|
0
|
0
|
2000
|
0
|
6000
|
| Check Qty |
4000
|
0
|
0
|
4
|
0
|
4004
|
| NG Qty |
2
|
0
|
0
|
4
|
0
|
6
|
| Scrap | 6 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all parts at ETL, at Warehouse & at NPC Nabha. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Raw Material 2.Cutting & Chamfering 3. Multistation Draw 4.Head Formation 5.Rough Grinding 6.Punching 7.CNC Head Turning 8.CNC Boring & Facing 9.Tapping 10. Chamfering 1&2 11.Finish Grinding 12.Final Inspection 13.Cleaning 14.Oiling 15.Packing & Dispatch |
4. Process Details
| Process / Operation | CNC Boring |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC-04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Material hardness less/more | After verification we found material Hardness as per spec. | O |
| Method | Other model mixed during processing | after verification We found material was ok. | O |
| Machine | Cnc Program was tampered | After verification we found CNC program was ok as per drawing. | O |
| Method | vernier not calibrated | after Verification vernier was Calibrated | O |
| Method | Material clamping method inadequate | After verification we found material clamping method inadequate. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | as per CP |
7. Root Cause Analysis (Occurance)
| Why 1 | seatpipe total length Less |
| Why 2 | seat pipe did not proper fit in collet. |
| Why 3 | Part did not clamp as per requirement. |
| Why 4 | Chips stucked with stopper pin |
| Why 5 | no proper cleaning during operation |
| Root Cause (Occurance) | no proper cleaning during operation |
Root Cause Analysis (Outflow)
| Why 1 | seatpipe total length Less |
| Why 2 | Could not be detected at final inspection |
| Why 3 | Skipped in Sampling at Final Inspection |
| Why 4 | Sampling quantity was less |
| Why 5 | |
| Root Cause (Outflow) | Sampling quantity was less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% inspection during final inspection | Mr. Ankush | 29/04/2023 | 28/04/2023 | Completed |
| Occurance | freezed cleaning frequency by Air gun during operation. | Mr. Gurpreet Singh | 29/04/2023 | 28/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection During final inspection. |
| Inspection Method | Other |
| Other Inspection Method | Use Flat plate |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Chips stucked with stopper 433_Occurance_Before.jpeg |
| Occurance (After) |
freezed cleaning frequency by Air gun during operation. 433_Occurance_After.jpeg |
| Outflow (Before) |
We checked with sampling inspection By Digital vernier 433_Outflow_Before.jpeg |
| Outflow (After) |
Increase sampling quantity at work station & use of surface flat for length checking at final inspection 433_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | CNC Machine |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | Reviewed 2000 no`s found ok |