QFR No - 8000859513
Defect Details
| NC No. | 8000859513 |
| NC Date | 19/01/2024 |
| 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 | MIX UP OTHER MODEL-NOT USING K0PG MODEL MIX UP AT NP SUP |
1. Problem Description
| Defect Description | K86 seat pipe wrong part supplied to ETL not using KOPG FF model MIX up at supplier end . |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 250 |
| 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 |
4400
|
0
|
0
|
400
|
0
|
4800
|
| Check Qty |
4400
|
0
|
0
|
400
|
0
|
4800
|
| NG Qty |
250
|
0
|
0
|
0
|
0
|
250
|
| Scrap | 0 |
| Rework | 250 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segregated all material at both end |
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 | Packing station |
| Outsource | No |
| Machine / Cell | STATION-2 |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Quality Inspector Negligence | Verified and found OK. No linkage with defect | O |
| Tool | Wrong gauge and instrument use | Measuring instrument is found calibrated & ok condition. | O |
| Method | material stock place not define | Material stock place was identified | O |
| Method | Packing Method Inadequate | Inside material polybag was not identified | X |
| Method | Holding the part not as per define method | Verified and found OK. No linkage with defect | O |
| Method | Wrong identification tag | After verification we found wrong identification tag found | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Other model box replace with K-86 box |
| Why 2 | mixing was occur in Packing station |
| Why 3 | Other model parts box put together with the box of k-86 model |
| Why 4 | Identification mark was not available before final packing |
| Why 5 | |
| Root Cause (Occurance) | Identification mark was not available before final packing |
Root Cause Analysis (Outflow)
| Why 1 | Other model box replace with K-86 box |
| Why 2 | Material was mixed after final inspection |
| Why 3 | wrong sticker pasted as per identification mark at dispatch station. |
| Why 4 | Verification point was not available at dispatch station |
| Why 5 | |
| Root Cause (Outflow) | Verification point was not available at dispatch station |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Model details should be written at the starting of packing | Mr. Ankush | 22/01/2024 | 22/01/2024 | Completed |
| Occurance | Q-alert to be displayed at final and packing station | Mr. Princ | 20/01/2024 | 20/01/2024 | Completed |
| Outflow | Sample inspection started of packed lots after packing. | . Mr. Ankush | 22/01/2024 | 22/01/2024 | Completed |
| Outflow | Q-alert to be displayed at Dispatch station | Mr. Princ | 20/01/2024 | 20/01/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling method to be used for reverification. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 box/lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Model details was written at the end of packing. 645_Occurance_Before.jpg |
| Occurance (After) |
Model details should be written at the starting of packing. 645_Occurance_After.jpg |
| Outflow (Before) |
No verification done 645_Outflow_Before.jpg |
| Outflow (After) |
Sample inspection started of packed lots after packing. 645_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar models . |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | Reviewed next 3 lots no mixes up found ok |