QFR No - 8000889511
Defect Details
| NC No. | 8000889511 |
| NC Date | 02/09/2024 |
| NC Submission Date | |
| Part No. | F2LG05402B |
| Part Name | SEAT PIPE - J1A & J1D |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID UNDERSIZE |
1. Problem Description
| Defect Description | ID UNDERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 5 |
| 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 |
2000
|
50000
|
10000
|
1000
|
0
|
63000
|
| Check Qty |
2000
|
50000
|
10000
|
1000
|
0
|
63000
|
| NG Qty |
5
|
2
|
0
|
0
|
0
|
7
|
| Scrap | 7 |
| 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 | Final Inspection |
| Outsource | No |
| Machine / Cell | Manual |
| Machine / Cell No. | Q-gate no-3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Low Lux Level | After verification we observed Lux level as per standard. | O |
| Method | 5S not Maintain | 5`S should be maintained in shop. | O |
| Material | Wrong part mixed | After verification we found there are high chance of mixing | X |
| Man | Inspector negligency during in process | After verification inspector observed to be negligent. | X |
| Material | Identification missing on packing box / trolley / Bin | After verification we found Identification available | 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 | The Shank ID part under-sized |
| Why 2 | wrong model part remain in the process after the model change |
| Why 3 | Previous model parts were not removed during the model change |
| Why 4 | Model change inspection process not followed correctly |
| Why 5 | model change procedure poorly enforced |
| Root Cause (Occurance) | model change procedure poorly enforced |
Root Cause Analysis (Outflow)
| Why 1 | Shank ID under-size part found. |
| Why 2 | Wrong model mix during inspection. |
| Why 3 | Other model part did not get removed after the model change. |
| Why 4 | Few pieces were not detected during the model change inspection because they were hidden in the station corner. |
| Why 5 | Some space was available between the bin and gauge/equipment on Q-gate working floor/surface. |
| Root Cause (Outflow) | Some space was available between the bin and gauge/equipment on Q-gate working floor/surface. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | all bins to be fitted tightly and properly positioned to prevent parts from being misplaced. | Mr. Ankush | 12/09/2024 | 06/09/2024 | Completed |
| Occurance | Training to be given to inspectors at the workstation to reinforce proper inspection instruction. | Mr. Vinay Tiwari | 07/09/2024 | 06/09/2024 | Completed |
| Occurance | Design and install a custom tray for inspection parts at the Q-gate. Ensure bins are placed outside the tray. | Mr. Ankush | 12/09/2024 | 06/09/2024 | Completed |
| Outflow | Display a Quality Alert at the Q-gate station | Mr. Princ | 02/09/2024 | 06/09/2024 | Completed |
| Outflow | Establish a real-time supervision person to oversee model change processes and ensure that procedures are followed correctly. | Mr. Vinay Tiwari | 04/09/2024 | 04/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Design and install a custom tray for inspection parts at the Q-gate. Ensure bins are placed outside the tray. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Some space was available between the bin and gauge/equipment on Q-gate working floor/surface. 1066_Occurance_Before.jpg |
| Occurance (After) |
Design and install a custom tray for inspection parts at the Q-gate. Ensure bins are placed outside the tray. 1066_Occurance_After.jpg |
| Outflow (Before) |
real-time supervision person was not available to oversee model change processes 1066_Outflow_Before.png |
| Outflow (After) |
Display a Quality Alert at the Q-gate station & Establish a real-time supervision person to oversee model change processes 1066_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Model |
12. Document Review
| Documents | WISOP, JHCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |