QFR No - 8000873487
Defect Details
| NC No. | 8000873487 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2LG05302B |
| Part Name | SEAT PIPE - ABWB ENDURO |
| 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 | 5 |
| 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 |
640
|
2200
|
0
|
0
|
0
|
2840
|
| Check Qty |
640
|
2200
|
0
|
0
|
0
|
2840
|
| NG Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Scrap | 0 |
| Rework | 5 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segregation done at ETL and NP End |
3. Process Flow
| Process Flow Description |
|---|
| Process Flow Description 1.0 Raw Material 2.0 Cutting 3.0 Drawing 4.0 Head Formation 5.0 Rough Grinding 6.0 Punching 7.0 CNC Head Turning 8.0 CNC Boring & Facing 9.0 Tapping 10.0 Chamfering 11.0 ID Deburring 12.0 Finish Grinding 13.0 Final Inspection 14.0 Cleaning 15.0 Oiling 16.0 Packing &Dispatch. |
4. Process Details
| Process / Operation | Final Grinding |
| Outsource | Yes |
| Machine / Cell | Centerless grinding |
| Machine / Cell No. | CG-05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | skipped during inspection | After verification we observed part was skipped | X |
| Man | Inprocess quality inspector negligent | After verification found OK | O |
| Material | Dressing not done as per define freq. | After verification we found dressing done as per define feq. | O |
| Man | Inprocess operator negligent | after verification found ok | O |
| Method | Setting Part Mixed | After verification found no chance of mixing of setting part | O |
| Method | Operation skipped | After verification we found operation was skipped | 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 | The outer diameter is larger than the specified tolerance. |
| Why 2 | Grinding operation is uneven |
| Why 3 | Part could not be fully ground |
| Why 4 | Operator skipped Grinding from Tail side |
| Why 5 | Due to length being more operator performed 2operations simultaneously on one part (One from head side and then from tail side) |
| Root Cause (Occurance) | Due to length being more operator performed 2operations simultaneously on one part (One from head side and then from tail side) |
Root Cause Analysis (Outflow)
| Why 1 | Outer Diameter over size |
| Why 2 | Part could not detected at final inspection |
| Why 3 | skipped in Sampling at Final Inspection |
| Why 4 | Sampling qty was less |
| Why 5 | |
| Root Cause (Outflow) | Sampling qty was less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Sampling qty doubled during final inspection. | Mr. Vinay | 08/05/2024 | 07/05/2024 | Completed |
| Occurance | Final grinding work instruction to be updated | Mr. Princ | 09/05/2024 | 09/05/2024 | Completed |
| Occurance | only one side operation is performed at a time, and the next operation begins once the first operation is completed during final grinding | Mr. Ankush | 09/05/2024 | 09/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling qty doubled |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | updated |
10. Evidance of Countermeasure
| Occurance (Before) |
Grind Both (tail & Head) Sides of a part simultaneously 780_Occurance_Before.jpg |
| Occurance (After) |
only one side operation (Head side) is performed at a time, and the next operation (tail side) begins once the first operation is completed during final grinding. 780_Occurance_After.jpg |
| Outflow (Before) |
Follow the sampling inspection method as per plan so sampling quantity was less 780_Outflow_Before.png |
| Outflow (After) |
Sampling Qty to be doubled. 780_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, JHCheckSheet, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |