QFR No - 8000862167
Defect Details
| NC No. | 8000862167 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | F2LG05902B |
| Part Name | SEAT PIPE (K17B/D) |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-OD OVERSIZE |
1. Problem Description
| Defect Description | OD oversize |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 10 |
| 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 |
1500
|
6000
|
4500
|
0
|
0
|
12000
|
| Check Qty |
1500
|
6000
|
4500
|
0
|
0
|
12000
|
| NG Qty |
10
|
30
|
0
|
0
|
0
|
40
|
| Scrap | 0 |
| Rework | 40 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all material at customer and NPC end. |
3. Process Flow
| Process Flow Description |
|---|
| PFD |
4. Process Details
| Process / Operation | Finish Grinding |
| Outsource | No |
| Machine / Cell | Centerless grinding |
| Machine / Cell No. | CG-04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | NG parts skipped at Final Inspection | Verified found not OK | X |
| Machine | Control wheel Size NG | Verified and found OK. No linkage with defect | O |
| Method | Wrong parameter use | All parameter was followed as per std. | O |
| Tool | Wrong Instrument used for measurement | Verified found OK | O |
| Machine | Non uniform removal of material after Grinding | During defect verification and simulation it was observed that there is less material removal from t | 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 | as per std |
7. Root Cause Analysis (Occurance)
| Why 1 | Non uniform removal of material after Grinding |
| Why 2 | Non uniform removal of material after Grinding |
| Why 3 | Taper in control wheel |
| Why 4 | Control Wheel Dressing not done after model change |
| Why 5 | |
| Root Cause (Occurance) | Control Wheel Dressing not done after model change |
Root Cause Analysis (Outflow)
| Why 1 | NG parts skipped at Final Inspection |
| Why 2 | NG parts skipped at Final Inspection |
| Why 3 | Could not be detected at Final Inspection |
| Why 4 | Skipped in Sampling at Final Inspection |
| Why 5 | Sampling plan inadequate |
| Root Cause (Outflow) | Sampling plan inadequate |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Dressing made mandatory for both wheels (Control wheel & Grinding wheel) after model change at Centre less Grinding machine). | Mr. Gurpreet Singh | 10/02/2024 | 08/02/2024 | Completed |
| Outflow | Single Sampling plan to be replaced with double sampling plan . | Mr. Ankush | 08/02/2024 | 08/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Single Sampling plan to be replaced with double sampling plan . |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | as per std |
10. Evidance of Countermeasure
| Occurance (Before) |
Control and grinding wheel dressing done as per freezed qty 665_Occurance_Before.png |
| Occurance (After) |
Dressing made mandatory for both wheels (Control wheel & Grinding wheel) after model change at Centre less Grinding machine). 665_Occurance_After.png |
| Outflow (Before) |
Single Sampling plan used 665_Outflow_Before.jpg |
| Outflow (After) |
Single Sampling plan to be replaced with double sampling plan 665_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar models |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 517 |
| Reason for submission | Found ok |