QFR No - 8000886620
Defect Details
| NC No. | 8000886620 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2LG05302B |
| Part Name | SEAT PIPE - ABWB ENDURO |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-OD OVER SIZE |
1. Problem Description
| Defect Description | NOT AS PER SPECIFICATION-OD OVER SIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 20 |
| 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
|
3500
|
0
|
0
|
0
|
4460
|
| Check Qty |
960
|
3500
|
0
|
0
|
0
|
4460
|
| NG Qty |
20
|
50
|
0
|
0
|
0
|
70
|
| Scrap | 0 |
| Rework | 70 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection of Seat Pipes with fitment part |
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 | Finish Grinding |
| Outsource | No |
| Machine / Cell | Centerless Grinding Machine |
| Machine / Cell No. | Grinding Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Grinding wheel wearout | During defect simulation part made with wearout grinding wheel stem OD found oversize. | X |
| Material | Material Hardness more | Material hardness found to be within limits | O |
| Man | In Process Operator Negligent | In process operator was not found to be negligent . | O |
| Tool | Wrong measuring instrument used | As per Control Plan instrument is used for inspection. | O |
| Method | Low lux level | Lux level is within specified limit,920Lux. | O |
| Method | Inspection method inadequate | During Gemba visit we found Inspection method inadequate | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As per std |
7. Root Cause Analysis (Occurance)
| Why 1 | Stem OD Oversize |
| Why 2 | Taper in OD |
| Why 3 | Grinding Wheel wear out |
| Why 4 | Grinding Wheel Dressing frequency inadequate |
| Why 5 | |
| Root Cause (Occurance) | Grinding Wheel Dressing frequency inadequate |
Root Cause Analysis (Outflow)
| Why 1 | Stem OD Oversize |
| Why 2 | Defected part was Skipped at final inspection |
| Why 3 | Could not be detected at final inspection |
| Why 4 | Sampling qty was less |
| Why 5 | |
| Root Cause (Outflow) | Sampling qty was less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Training to be given to operators for prevent from this type of defect. | Mr. Gurpreet Singh | 15/08/2024 | 14/08/2024 | Completed |
| Outflow | Q-alert to be displayed at Final Q-gate. | Mr. Princ | 13/08/2024 | 12/08/2024 | Completed |
| Occurance | Q-alert to be displayed at final Grinding station. | Mr. Princ | 13/08/2024 | 12/08/2024 | Completed |
| Outflow | 100% Inspection of stem OD to be done with Plain Ring Gauge . | Mr. Vinay Tiwari | 20/08/2024 | 19/08/2024 | Completed |
| Occurance | Dressing frequency of Grinding Wheel to be revised after proper validation (Before -125 pc to After validation-100pc) and to be followed strictly. | Mr. Ankush | 20/08/2024 | 16/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection of stem OD to be started with Plain Ring 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) |
Before Grinding dressing frequency was 125 pc 1011_Occurance_Before.jpg |
| Occurance (After) |
After Grinding dressing frequency is 100 pcs 1011_Occurance_After.jpg |
| Outflow (Before) |
Sampling Inspection of stem OD was done with micrometer. 1011_Outflow_Before.png |
| Outflow (After) |
100% Inspection of stem OD to be started with Plain Ring Gauge . 1011_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Similar model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |