QFR No - 8000877797
Defect Details
| NC No. | 8000877797 |
| NC Date | 11/06/2024 |
| NC Submission Date | |
| Part No. | F2LG05402B |
| Part Name | SEAT PIPE - J1A & J1D |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID STEP |
1. Problem Description
| Defect Description | ID STEP |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 3 |
| 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 |
2080
|
46000
|
0
|
0
|
0
|
48080
|
| Check Qty |
2080
|
46000
|
0
|
0
|
0
|
48080
|
| NG Qty |
3
|
23
|
0
|
0
|
0
|
26
|
| Scrap | 26 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregate all material at both 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 | Forging |
| Outsource | No |
| Machine / Cell | Header |
| Machine / Cell No. | MDM-8 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator negligence | Operator found to be non negligent | O |
| Machine | Non detection of material unclear in ID at final Inspection | Material unclear in ID could not be detected at final inspection | X |
| Tool | Damage of Pin at Forging | Pin was found to be damaged which lead to accumulation of material in ID | X |
| Machine | Variation in Forging machine | No variation in Forging machine found | O |
| Material | Material composition not OK | Material composition found to be OK | 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 | Step in ID |
| Why 2 | accumulation of material in ID |
| Why 3 | Forging Pin got damaged |
| Why 4 | Miss alignment of PC clamping finger on the forging machine. |
| Why 5 | The spring`s clamping finger was loose. |
| Root Cause (Occurance) | The spring`s clamping finger was loose. |
Root Cause Analysis (Outflow)
| Why 1 | Step in ID |
| Why 2 | Could not be detected at final inspection |
| Why 3 | ID step checkpoint not available at final inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | ID step checkpoint not available at final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Sampling Inspection to started with the plug gauge at the final inspection. | Mr. Ankush | 15/06/2024 | 12/06/2024 | Completed |
| Occurance | clamping finger Inspection checkpoint to be added in Daily machine checksheet. | Mr. Princ | 15/06/2024 | 14/06/2024 | Completed |
| Occurance | Quality Alert to be displayed in Forging Shop | Mr. Prince | 12/06/2024 | 11/06/2024 | Completed |
| Outflow | Quality Alert to be displayed at Final Inspection. | Mr. Princ | 12/06/2024 | 11/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | The part should be inspected using a plug gauge and undergo 100% visual inspection. |
| 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) |
clamping finger Inspection was not done at daily basis. 841_Occurance_Before.jpg |
| Occurance (After) |
clamping finger Inspection checkpoint to be added in Daily machine check sheet. 841_Occurance_After.jpg |
| Outflow (Before) |
Only Visual Inspection but Step id checkpoint not available. 841_Outflow_Before.png |
| Outflow (After) |
Sampling Inspection to started with the plug gauge at the final inspection. 841_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Header |
12. Document Review
| Documents | ControlPlan, PFMEA, JHCheckSheet, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |