QFR No - 8000874507
Defect Details
| NC No. | 8000874507 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | F2LG07102B |
| Part Name | SEAT PIPE - J1D |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CRACK - MATERIAL DEFECT |
1. Problem Description
| Defect Description | CRACK - MATERIAL DEFECT |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 1 |
| 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 |
960
|
20000
|
0
|
0
|
0
|
20960
|
| Check Qty |
960
|
20000
|
0
|
0
|
0
|
20960
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all material at the customer end 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 | Raw material |
| Outsource | Yes |
| Machine / Cell | -- |
| Machine / Cell No. | -- |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | setting part mixed with ok material | During verification we found possibility of setting part mixing | X |
| Method | part was skipped at final Q gate (NPC) | Part was skipped during visual inspection | X |
| Material | Designated Grade not use | Material Observed as per specification | O |
| Method | Process Parameters NG | After verification we found OK | O |
| Method | Preventive Maintenance | Preventive maintenance carried out at defined interval | O |
| Man | Un skilled Operator | Checked & Observed that skilled operator was running the line. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | one pc head crack found at customer end |
| Why 2 | NG crack setting parts got mixed with ok material |
| Why 3 | NG part kept in open bin |
| Why 4 | Locked bin not available at Draw |
| Why 5 | |
| Root Cause (Occurance) | Locked bin not available at Draw |
Root Cause Analysis (Outflow)
| Why 1 | Part was skipped at final inspection. |
| Why 2 | Crack was not visible during inspection. |
| Why 3 | Crack might be microscopic and not detectable by naked eye. |
| Why 4 | Inspector may have lacked sufficient training to detect micro-cracks. |
| Why 5 | |
| Root Cause (Outflow) | The inspector may have lacked sufficient training to detect micro-cracks. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Q -Alert to be displayed at the final Q-gate | Mr. Princ | 17/05/2024 | 16/05/2024 | Completed |
| Outflow | Micro crack detection regarding training to be given to NPC final inspection inspectors. | Mr. Gurpreet singh | 20/05/2024 | 17/05/2024 | Completed |
| Occurance | Open red bin to be replaced with locked red bin in forging area | Mr. Narinder | 20/05/2024 | 18/05/2024 | Completed |
| Occurance | Training to be given to all setters and operators for setting process regarding. | Mr. Kulwant | 21/05/2024 | 18/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual & testing met |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Open Red bin used 810_Occurance_Before.jpeg |
| Occurance (After) |
Open red bin to be replaced with locked red bin in forging area 810_Occurance_After.jpeg |
| Outflow (Before) |
N/A 810_Outflow_Before.png |
| Outflow (After) |
Micro crack detection regarding training to be given to NPC final inspection inspectors. & Q -Alert to be displayed at the final Q-gate 810_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar model |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |