QFR No - 8000886627
Defect Details
| NC No. | 8000886627 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2LG05402B |
| Part Name | SEAT PIPE - J1A & J1D |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-MIX-UP |
1. Problem Description
| Defect Description | Mix-up Issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 37 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
3000
|
0
|
5000
|
5000
|
15000
|
| Check Qty |
2000
|
3000
|
0
|
5000
|
5000
|
15000
|
| NG Qty |
37
|
0
|
0
|
0
|
0
|
37
|
| Scrap | 0 |
| Rework | 37 |
| Under Deviation | 0 |
| Containment Action |
|---|
| STOCK CHECK 100% AT OUR END |
3. Process Flow
| Process Flow Description |
|---|
| 1-RM 2- FORGING 3-PUNCHING -IST 4-ROUGH CLG 5-CNC-IST 6-CNC-II 7-PUNCHING -II 8-I.D CHIP REMOVE 9-REAMING IST 10-REAMING-IIND 11- TAPPING 12-FINAL GRINDING 13-ALKLINE WASHING 14- FINAL INSPECTION 15 - PACKING |
4. Process Details
| Process / Operation | Packing |
| Outsource | No |
| Machine / Cell | no |
| Machine / Cell No. | no |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | material mix-up machine stage | validation and found ok | O |
| Man | UNAWARENESS OF OPERATOR | VALIDATION AND FOUND MACHINE OPERATOR AWARENESS FOR J1A & J1D MATERIAL HANDLING | O |
| Method | PACKING STANDARDS NOT EFFECTIVE | VALIDATION FOUND MATERIAL MIX-UP FOR PACKING STAGE | X |
| Material | RM GRADE AND SIZE NOT OK | VALIDATED AND FOUND OK O | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | PACKING OTHERS STAGE |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-MIX-UP |
| Why 2 | The problem occurred at packing stage |
| Why 3 | Material handling not properly rust preventive oil stage |
| Why 4 | Rust preventive oil stage as per part wise specification bin not use so parts mix-up at this stage |
| Why 5 | No any quality gate available after rust preventive oil material handling |
| Root Cause (Occurance) | No any quality gate available after rust preventive oil stage W I not update as per part wise specification bin |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-MIX-UP |
| Why 2 | 100% inspection is not done at packing stage |
| Why 3 | Inspection is also as per sampling plan |
| Why 4 | So final inspection person not caught this defect |
| Why 5 | So NG parts dispatched to customer end |
| Root Cause (Outflow) | Seat pipe J1D material identification groove require as per process drg. same implement but at packing stage this point not highlight in packing std. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | prepared quality gate and W I update point after rust preventive oil stage same specification bin use for input /output material | Anil | 14/08/2024 | 14/08/2024 | Completed |
| Outflow | packing std. change and highlight groove identification mark and all packging opr. training provide | Ganesh mourya | 14/08/2024 | 14/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | AFTER MATERIAL INSPECTION SOME TABLE PACKING DONE |
| 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) |
No any quality gate available after rust preventive oil stage W I not update as per part wise specification bin 1019_Occurance_Before.pdf |
| Occurance (After) |
quality gate available after rust preventive oil stage W I update as per part wise specification bin 1019_Occurance_After.pdf |
| Outflow (Before) |
PACKING STANDARDS NOT UPDATE AS PER PART WISE IDENTIFICATION MARK 1019_Outflow_Before.pdf |
| Outflow (After) |
PACKING STANDARDS UPDATE AS PER PART WISE IDENDITFICATION MARK 1019_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | J1A ~ J1D MODLE |
12. Document Review
| Documents | ControlPlan, PFMEA, PackingStd |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | Occurrence side action plan? |