QFR No - 8000877824
Defect Details
| NC No. | 8000877824 |
| NC Date | 11/06/2024 |
| 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-GROOVE DIA. OVERSIZE |
1. Problem Description
| Defect Description | GROOVE DIA. OVERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 13 |
| 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
|
14000
|
0
|
0
|
0
|
14960
|
| Check Qty |
960
|
14000
|
0
|
0
|
0
|
14960
|
| NG Qty |
13
|
0
|
0
|
0
|
0
|
13
|
| Scrap | 0 |
| Rework | 13 |
| 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 | CNC Head Turning |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | BC-CNC-21 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator unaware | Operator found to be aware about the process | O |
| Man | Negligence of quality inspector at in process | Quality inspector found to be non negligent . | O |
| Tool | Damage of Grooving Insert | It was verified and observed that Grooving Insert got damaged which resulted in width becoming under | X |
| Tool | Forging dia over | Forging dia observed to be correct. No linkage with defect observed | O |
| Machine | Wrong program selection | It was verified that correct program was selected for machining. | O |
| Method | NG part skipped at Final inspection | It was verified and observed that parts skipped during sampling at final inspection | X |
| Method | Improper clamping of insert | It was observed that clamping of insert is proper | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | as per std |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove width undersize |
| Why 2 | Step observed |
| Why 3 | Grooving Insert got damaged |
| Why 4 | Part could not be clamped properly |
| Why 5 | Rough Grinding dia down due to Rough Grinding Setting parts mixed |
| Root Cause (Occurance) | Rough Grinding dia down due to Rough Grinding Setting parts mixed |
Root Cause Analysis (Outflow)
| Why 1 | Groove width 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. Princ | 12/06/2024 | 11/06/2024 | Completed |
| Outflow | Quality alert to be displayed at final inspection station | Mr. Princ | 12/06/2024 | 11/06/2024 | Completed |
| Outflow | Min level 3 operator will be allowed to operate CNC Head Turning Machine | Mr. Harwinder | 14/06/2024 | 13/06/2024 | Completed |
| Outflow | 100% inspection with Slip Gauge to be done before dispatch | Mr. Ankush | 13/06/2024 | 12/06/2024 | Completed |
| Occurance | Rough Grinding setting parts to be quarantined in Lock & Key Bin by Quality Inspector himself | Mr. Ankush | 13/06/2024 | 12/06/2024 | Completed |
| Outflow | Training to be provided to all CNC operators for abnormal sound and checking insert manually | Mr. Harwinder | 14/06/2024 | 13/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection with Slip Gauge to be done before dispatch |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Open redbin used for rejection pcs at rough grinder 845_Occurance_Before.jpeg |
| Occurance (After) |
Locked Redbin implemented at rough grinder 845_Occurance_After.jpeg |
| Outflow (Before) |
use sampling method for inspection at final Q gate 845_Outflow_Before.png |
| Outflow (After) |
100 % inspection to be started with slip gauge and Q alert to be displayed at final Q gate. 845_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Similar model |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |