QFR No - 8000879488
Defect Details
| NC No. | 8000879488 |
| NC Date | 22/06/2024 |
| NC Submission Date | |
| Part No. | F1LG00902B |
| Part Name | SEAT PIPE -K86A |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | HOLE BLOCK-TENSION HOLE BLOCK |
1. Problem Description
| Defect Description | K86 seat pipe tension hole block issue |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 3 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | i2z4kjrrzalkbmbwopa4sgmv.gif |
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 |
9000
|
15600
|
0
|
1500
|
2500
|
28600
|
| Check Qty |
9000
|
15600
|
0
|
0
|
0
|
24600
|
| NG Qty |
25
|
36
|
0
|
0
|
0
|
61
|
| Scrap | 0 |
| Rework | 61 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Checking parts 100% visually for hole block |
3. Process Flow
| Process Flow Description |
|---|
| 1)Cutting 2)Draw 3)Head Formation 4)Punching 5)Rough Grinding 6)CNC Head Turning 7)CNC Boring & Facing 8)Tapping 9)Chamfering 10)Final Grinding 11)Final Inspection 12)Oiling 13)Packing & Dispatch |
4. Process Details
| Process / Operation | Punching |
| Outsource | No |
| Machine / Cell | Power Press |
| Machine / Cell No. | Punching Deptt |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Skip during inspection | After verification it was observed that parts was skipped during inspection . | X |
| Material | Wrong grade material used | After verification we found material grade as per std. | O |
| Method | Operation Miss part mixed | After verification we found there was no chance of mixing | O |
| Tool | Punch damage | After verification we found punch was damage during running operation. | X |
| Machine | DF punch stroke length less | It was observed that this is no linkage with the defect | 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 | 2X Smp std |
7. Root Cause Analysis (Occurance)
| Why 1 | Tension hole block found . |
| Why 2 | punch burr/chips was generated in the tension hole |
| Why 3 | tension punch was damaged during in process. |
| Why 4 | Punch setting was loosed |
| Why 5 | |
| Root Cause (Occurance) | Punch setting was loosed |
Root Cause Analysis (Outflow)
| Why 1 | Tension hole block found . |
| 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 | Training will be provided to Satter to check the settings after installing the punch and die on the machine. | Mr. Paramjit | 25/06/2024 | 25/06/2024 | Completed |
| Occurance | The condition of the punch and die should be checked by the setter every hour. | Mr. Rajinder | 26/06/2024 | 25/06/2024 | Completed |
| Occurance | Q-alert to be displayed at the Punching station. | Mr. Princ | 24/06/2024 | 22/06/2024 | Completed |
| Outflow | 100% inspection to be start at final inspection by pin plug gauge. | Mr. Ankush | 25/06/2024 | 24/06/2024 | Completed |
| Outflow | Q-alert to be displayed at the Final station. | Mr. Princ | 24/06/2024 | 22/06/2024 | Completed |
| Occurance | Punching WI to be updated | Mr. Princ | 26/06/2024 | 25/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection start with pin plug gauge |
| 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) |
Die frequently monitoring checkpoint was not available in the WI. 876_Occurance_Before.jpg |
| Occurance (After) |
The condition of the punch and die should be checked by the setter every hour. this point to be added in WI. 876_Occurance_After.jpg |
| Outflow (Before) |
Sampling plan followed 876_Outflow_Before.jpg |
| Outflow (After) |
Q-alert to be displayed and 100 % inspection to be started at final Q-gate. 876_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | K-86 |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 20000 |
| Reason for submission | Reviewed next 3 lots found ok |