QFR No - 8000879500
Defect Details
| NC No. | 8000879500 |
| NC Date | 22/06/2024 |
| NC Submission Date | |
| Part No. | 550LG06202 |
| Part Name | SEAT PIPE -K23A/PRFH-006 |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIMN.O/SIZE.-TOTAL LENGTH MORE |
1. Problem Description
| Defect Description | KONF FF seat pipe total length more issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| 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 |
5000
|
0
|
0
|
6000
|
2000
|
13000
|
| Check Qty |
5000
|
0
|
0
|
6000
|
2000
|
13000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| 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 | Cleaning operation |
| Outsource | No |
| Machine / Cell | Brush Cleaning Machine |
| Machine / Cell No. | BC-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wrong identification tag | After verification we found correct identification tag found | O |
| Method | Packing Method Inadequate | After verification we found packing method was inadequate for prevent the mixup. | X |
| Method | No checkpoint available | After verification we found no checkpoint available at packing | X |
| 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 |
| Man | Quality Inspector Negligence | Verified and found OK. No linkage with defect | 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 | Total length variation found in seatpipe . |
| Why 2 | Other model mix-up found with PRFH 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 | Q-alert to be displayed at packing station. | Mr. Princ | 23/06/2024 | 24/06/2024 | Completed |
| Occurance | Parts should be picked for packing directly from the Oiling holding tray. | Mr. Ankush | 29/06/2024 | 25/06/2024 | Completed |
| Outflow | Inspection of 5 pieces for model mix-up starts every hour at the packing stage. | Mr. Ankush | 25/06/2024 | 22/06/2024 | Completed |
| Outflow | The Packing Work Instruction (WI) should be updated, implemented, and followed. | Mr. Vinay | 27/06/2024 | 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. 880_Occurance_Before.jpeg |
| Occurance (After) |
Parts should be picked for packing directly from the Oiling holding tray. 880_Occurance_After.jpeg |
| Outflow (Before) |
No checkpoint is available at packing station. 880_Outflow_Before.jpg |
| Outflow (After) |
The Packing Work Instruction (WI) should be updated, implemented, and followed and inspection checkpoint no. 5 updated. 880_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 | 5000 |
| Reason for submission | Reviewed next two lots found ok |