QFR No - 8000873488
Defect Details
| NC No. | 8000873488 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2LG07702B |
| Part Name | SEAT PIPE - J1C2 FF |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-TOTAL LENGTH UNDERSIZE |
1. Problem Description
| Defect Description | TOTAL LENGTH UNDERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| 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 |
960
|
7120
|
1245
|
0
|
0
|
9325
|
| Check Qty |
960
|
0
|
1245
|
0
|
0
|
2205
|
| NG Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Scrap | 5 |
| Rework | 0 |
| 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 | CNC Boring |
| Outsource | No |
| Machine / Cell | CNC Boring & Chamfering |
| Machine / Cell No. | CNC SP1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Stopper design not adequate | Stopper design observed to be adequate | O |
| Method | Head Stopper loose | Head Stopper found to be tight | O |
| Man | Negligence of quality inspector at in process | Quality inspector found to be non negligent . | O |
| Man | Operator unaware | Operator found to be aware about the process | O |
| Method | Operator located part incorrectly during Facing operation | It was verified and observed that Operator is locating part incorrectly. This is resulting in extra | X |
| Method | NG part skipped at Final inspection | It was verified and observed that parts skipped during sampling at final inspection | X |
| Method | Burr on Stopper pin | No burr observed on Stopper pin | O |
| Material | Material Hardness more | Receiving inspection report verified . Material hardness found to be within limits. 35 – 55 HRB | O |
| Machine | Wrong Program run | After verification we found correct Program run as per std. | O |
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 | Total length undersize |
| Why 2 | Facing operation done incorrectly |
| Why 3 | Extra Facing done |
| Why 4 | Operator located part incorrectly |
| Why 5 | |
| Root Cause (Occurance) | Operator located part incorrectly |
Root Cause Analysis (Outflow)
| Why 1 | Total length undersize |
| Why 2 | Could not be detected at Final Inspection |
| Why 3 | Skipped in Sampling inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Skipped in Sampling inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Quality alert to be displayed at CNC station | Mr. Prince | 07/05/2024 | 06/05/2024 | Completed |
| Occurance | Training to be provided to all CNC operators | Mr. MohinderPal | 10/05/2024 | 08/05/2024 | Completed |
| Occurance | Min level 3 operator will be allowed to operate CNC Facing Machine | Mr. Harwinder | 08/05/2024 | 07/05/2024 | Completed |
| Outflow | 100% inspection with Length Snap Gauge to be done before dispatch | Mr. Vinay | 07/05/2024 | 06/05/2024 | Completed |
| Outflow | Length Snap Gauge to be provided at Godown for Sampling Inspection | Mr. Mohinder Pal | 11/05/2024 | 09/05/2024 | Completed |
| Occurance | Home position of insert to be changed from 22mm to 2.5mm | Mr. Harwinder | 11/05/2024 | 10/05/2024 | Completed |
| Outflow | Quality alert to be displayed at final inspection station | Mr. Princ | 07/05/2024 | 06/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection to be start for total length |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Home position of insert was 22mm 781_Occurance_Before.png |
| Occurance (After) |
Home position of insert to be changed from 22mm to 2.5mm
Training to be provided to all CNC operators 781_Occurance_After.png |
| Outflow (Before) |
Sampling inspection was being conducted for length 781_Outflow_Before.png |
| Outflow (After) |
100 % Inspection to be start with length gauge. 781_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | similar model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, AuditCheckSheet, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 180 |
| Reason for submission | OK |