QFR No - 8000851574
Defect Details
| NC No. | 8000851574 |
| NC Date | 10/11/2023 |
| NC Submission Date | |
| Part No. | F2LG05402B |
| Part Name | SEAT PIPE - J1A & J1D |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID STEP, OD GRROVE STEP |
1. Problem Description
| Defect Description | Step observed in head groove |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 82 |
| Is Defect Repeatative? | No |
| 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 |
58240
|
60000
|
18000
|
0
|
0
|
136240
|
| Check Qty |
58158
|
59990
|
18000
|
0
|
0
|
136148
|
| NG Qty |
82
|
10
|
0
|
0
|
0
|
92
|
| Scrap | 92 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segregate all material |
3. Process Flow
| Process Flow Description |
|---|
| Cutting - Draw - Forging - Rough Grinding - Punching - CNC Head Turning - CNC Tail Facing - Tapping & Chamfering - Final Grinding - Final Inspection - Cleaning - RPO Oiling - Packing & Dispatch. |
4. Process Details
| Process / Operation | CNC Head Turning |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC - 07 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Variation during part loading | After verification we found No variation observed during part loading | O |
| Tool | Worn out Head Forging Punch Pin | After verification we observed usage of worn out Punch Pin results in step mark | X |
| Machine | CNC program tempered | After verification we found CNC program was not tampered | O |
| Tool | CNC insert fitment NG | After verification we found CNC insert was Dislocate | X |
| Man | Operator unskilled | After verification we found Operator observed to be skilled | O |
| Material | Other grade material use | After verification we found Material was used as per define std. | O |
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 std |
7. Root Cause Analysis (Occurance)
| Why 1 | Step in Hex ID and step in Groove OD surface. |
| Why 2 | Worn out Punch not changed at forging & Variation in size during CNC Turning . |
| Why 3 | Punch change frequency followed at forging & Dislocation of the Turning tool bit at CNC. |
| Why 4 | Punch change frequency not adequate at forging & Turning tool bit loose. |
| Why 5 | |
| Root Cause (Occurance) | 1. Punch change frequency not adequate at forging 2. Turning tool bit loose. |
Root Cause Analysis (Outflow)
| Why 1 | Step in Hex ID and step in Groove OD surface. |
| Why 2 | Could not be detected at Final inspection |
| Why 3 | Skipped in Sampling at Final Inspection |
| Why 4 | Sampling Quantity was inadequate |
| Why 5 | |
| Root Cause (Outflow) | Sampling Quantity was inadequate |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Q- alert to be displayed in Final inspection . | Mr. Princ | 11/11/2023 | 11/11/2023 | Completed |
| Outflow | New snap gauge to be modified for detection of the groove width. | Mr. Ravinder | 15/11/2023 | 12/11/2023 | Completed |
| Occurance | Q- alert to be displayed in Forging & CNC shop. | Mr. Princ | 11/11/2023 | 11/11/2023 | Completed |
| Outflow | 100 % Inspection to be start with Visual & Snap Gauge at final inspection. | Mr. Ankush | 14/11/2023 | 11/11/2023 | Completed |
| Occurance | Punch change frequency to be revalidated and freezed | Mr. Narinder | 15/11/2023 | 15/11/2023 | Completed |
| Occurance | Insert tightening bolt inspection to be added in daily Startup checksheet | Mr. Princ | 15/11/2023 | 12/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection start |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
No any checkpoint available in daily Startup checksheet 593_Occurance_Before.jpeg |
| Occurance (After) |
Insert tightening bolt inspection to be added in daily Startup checksheet 593_Occurance_After.png |
| Outflow (Before) |
Sampling plan follow at final inspection 593_Outflow_Before.jpg |
| Outflow (After) |
New snap gauge to be modified for detection of the groove width. 593_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC Machine |
12. Document Review
| Documents | ControlPlan, WISOP, JHCheckSheet, InspCheckSheet |
| Specify Other Document | Not Required |
13. Effectiveness Of Action
| Reviewed Quantity | 280 |
| Reason for submission | All parts found ok during verificaction |