QFR No - 8000851178
Defect Details
| NC No. | 8000851178 |
| NC Date | 06/11/2023 |
| NC Submission Date | |
| Part No. | 550LG06702 |
| Part Name | SEAT PIPE-(HMS-30 & HMP-30) |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | NOT AS PER SPECIFICATION-HALF THREAD |
1. Problem Description
| Defect Description | Seat Pipe M8 X 1.25 -6G half thread and Thread Length Short |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | f3flbtnxltmnvijxhuriho0h.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 |
3800
|
8200
|
0
|
0
|
0
|
12000
|
| Check Qty |
3800
|
8200
|
0
|
0
|
0
|
12000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Thread length checking with thread plug gauge. |
3. Process Flow
| Process Flow Description |
|---|
| Raw material Inspection - Cutting - Draw - Forging - Rough Grinding - Punching - CNC Head turning - CNC Tail facing - Tapping & Chamfering - Final Inspection - Cleaning - Oiling - Packing & Dispatch |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping machine |
| Machine / Cell No. | TM-03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Incorrect location of part during Tapping | After verification we found part was located at Incorrect location. | X |
| Man | Operator negligence | After verification we found operator was aware about process | O |
| Material | Material Hard | After verification we found material was used as per std. | O |
| Tool | Wrong tapping tool use | After verification we found tapping tool was used as per std. | O |
| Machine | Tap tightening not ok | After verification we found tap tightening was ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As per std |
7. Root Cause Analysis (Occurance)
| Why 1 | Half thread seatpipe found |
| Why 2 | part was located at Incorrect location. |
| Why 3 | The part was setted below the specified location |
| Why 4 | No reference available on Fixture |
| Why 5 | there was not available any stopper. |
| Root Cause (Occurance) | there is not available any stopper. |
Root Cause Analysis (Outflow)
| Why 1 | Half thread seatpipe found |
| 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 |
|---|---|---|---|---|---|
| Occurance | New clamp fixture to be modified with stopper. | Mr Ravinder Singh | 10/11/2023 | 09/11/2023 | Completed |
| Outflow | Sampling quantity to be increased. | Mr. Ankush | 08/11/2023 | 07/11/2023 | Completed |
| Occurance | Quality Alert to be displayed at working station | Mr. Princ | 07/11/2023 | 06/11/2023 | Completed |
| Outflow | Quality alert to be displayed at final Q- inspection station | Mr. Princ | 07/11/2023 | 06/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | sampling quantity to be doubled at final inspection station. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | double |
10. Evidance of Countermeasure
| Occurance (Before) |
No stopper was available in clamp fixture 588_Occurance_Before.png |
| Occurance (After) |
New clamp fixture to be modified with stopper. 588_Occurance_After.png |
| Outflow (Before) |
Quality alert not available at final inspection.
Sampling qty was less. 588_Outflow_Before.jpg |
| Outflow (After) |
Display quality alert at work station & final Q-gate.
Samling qty to be double. 588_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Tapping machine |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | Not required |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |