QFR No - 8000879489
Defect Details
| NC No. | 8000879489 |
| 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 | HIGHT O/SIZE.-TOTAL LENGTH MORE |
1. Problem Description
| Defect Description | K86 SEAT PIPE TOTAL LENGTH MORE ISSUE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| 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 |
3000
|
9600
|
0
|
1500
|
0
|
14100
|
| Check Qty |
3000
|
9600
|
0
|
0
|
0
|
12600
|
| NG Qty |
200
|
0
|
0
|
0
|
0
|
200
|
| Scrap | 0 |
| Rework | 200 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% visual inspection for model mix |
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)Cleaning 13)Oiling 14)Packing & Dispatch |
4. Process Details
| Process / Operation | Packing |
| Outsource | No |
| Machine / Cell | Packing |
| Machine / Cell No. | Packing Deptt |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wrong identification tag | After verification we found correct identification tag found | O |
| Man | Quality Inspector Negligence | Verified and found OK. No linkage with defect | O |
| Method | Material mix-up during transit form one station to another station. | After verification we found material was not mixed during transit | O |
| Man | Packing persons were untrained | After verification we found packing persons were trained | O |
| Method | Packing Method Inadequate | After verification we found packing method was inadequate for prevent the mixup. | X |
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 | Total length variation found in seatpipe . |
| Why 2 | Other model mix-up found with K86 seat pipe. |
| Why 3 | Other model was mixed during the packing stage. |
| Why 4 | Other model pieces were remaining in the oil tray during packing. |
| Why 5 | All pieces from the oiled holding tray bin were directly emptied onto the tray at one time. |
| Root Cause (Occurance) | All pieces from the oiled holding tray bin were directly emptied onto the tray at one time. |
Root Cause Analysis (Outflow)
| Why 1 | Total length variation found in seatpipe . |
| Why 2 | Other model mix-up could not be detected . |
| Why 3 | Other model mixed at packing station after final inspection . |
| Why 4 | No checkpoint is available at packing station. |
| Why 5 | |
| Root Cause (Outflow) | No checkpoint is available at packing station. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Parts should be picked for packing directly from the Oiling holding tray. | Mr. Ankush | 29/06/2024 | 24/06/2024 | Completed |
| Outflow | The Packing Work Instruction (WI) should be updated, implemented, and followed. | Mr. Vinay | 27/06/2024 | 25/06/2024 | Completed |
| Occurance | Q-alert to be displayed at packing station. | Mr. Princ | 23/07/2024 | 22/06/2024 | Completed |
| Outflow | Inspection of 5 pieces for model mix-up starts every hour at the packing stage. | Mr. Ankush | 25/07/2024 | 24/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | New inspection check point added at packing stage |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 pcs/ Hr |
10. Evidance of Countermeasure
| Occurance (Before) |
All pieces from the oiled holding tray bin were directly emptied onto the tray at one time. 877_Occurance_Before.jpeg |
| Occurance (After) |
Parts should be picked for packing directly from the Oiling holding tray. 877_Occurance_After.jpeg |
| Outflow (Before) |
No checkpoint is available at packing station. 877_Outflow_Before.jpg |
| Outflow (After) |
The Packing Work Instruction (WI) should be updated, implemented, and followed and inspection checkpoint no. 5 updated. 877_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | all similar model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 20000 |
| Reason for submission | Reviewed next three lots found ok |