QFR No - 8000890615
Defect Details
| NC No. | 8000890615 |
| NC Date | 10/09/2024 |
| 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 | MIX UP OTHER MODEL-NOT USING KON MODEL |
1. Problem Description
| Defect Description | Wrong seat pipe received not using kONF front fork model |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 100 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | mmuyicwg5a5ntybia1zkifgc.jpg |
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 |
10000
|
0
|
4500
|
5000
|
5000
|
24500
|
| Check Qty |
10000
|
0
|
4500
|
5000
|
5000
|
24500
|
| NG Qty |
100
|
0
|
0
|
0
|
0
|
100
|
| Scrap | 0 |
| Rework | 100 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% visual inspection of available material |
3. Process Flow
| Process Flow Description |
|---|
| 1.RM Receipt 2. Cutting 3.Multistation Draw 4. Head Formation 5. Punching 6. Rough Grinding 7. CNC Head Turning & Chamfering 8. CNC Boring & Facing 9. Thread M8x1.25 Tapping 10. Chamfering-1 11. Chamfering-2 12. ID Deburring 13. Finish Grinding 14. Final Inspection 15. ID Cleaning 16. Oiling 17. Packing & Dispatch |
4. Process Details
| Process / Operation | Packing & Dispatch |
| Outsource | No |
| Machine / Cell | Packing & Dispatch Section |
| Machine / Cell No. | Dispatch |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Mix up at final Inspection | No mix up at final observed | O |
| Method | No checkpoint for checking Barcode Stickers | It was observed no checkpoint available for checking Barcode stickersde Stickers | X |
| Method | Mix up by transport | Mix up by transport observed | X |
| Man | In process operator negligent . | In process operator was not found to be negligent . | O |
| Man | Quality Inspector negligent | Quality Inspector was not found to be negligent. | O |
| Method | Mix up during Packing | After verification it was observed that parts were not mixed during Packing | O |
| Method | Material identification missing | Material identification observed to be present | 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 | Mix up other model |
| Why 2 | Other model box dispatched to Narsapura |
| Why 3 | Wrong sticker got pasted on Packing Bag |
| Why 4 | Sticker gets detached from Bag |
| Why 5 | Sticker pasted on Bag instead of Tag |
| Root Cause (Occurance) | Sticker pasted on Bag instead of paper Tag |
Root Cause Analysis (Outflow)
| Why 1 | Mix up other model |
| Why 2 | Wrong sticker got pasted on Packing Bag |
| Why 3 | Could not be detected before dispatch |
| Why 4 | No checkpoint for checking Barcode Stickers by Transport before dispatch |
| Why 5 | |
| Root Cause (Outflow) | No checkpoint for checking Barcode Stickers by Transport before dispatch |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | WI to be displayed in Dispatch Area | Mr Ankush | 17/09/2024 | 16/09/2024 | Completed |
| Outflow | 100% inspection of Barcode Stickers before dispatch to be done | Mr Ankush | 13/09/2024 | 13/09/2024 | Completed |
| Outflow | Quality Alert to be displayed in Dispatch Area | Mr Princ | 18/09/2024 | 14/09/2024 | Completed |
| Occurance | Barcode Stickers to be pasted on Tags instead of Bags | Mr Ankush | 16/09/2024 | 14/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checkpoint of checking Barcode Stickers 100% implemented |
| 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) |
Sticker pasted on Bag instead of paper Tag 1087_Occurance_Before.jpeg |
| Occurance (After) |
Barcode Stickers to be pasted on Tags instead of Bags 1087_Occurance_After.jpeg |
| Outflow (Before) |
No checkpoint for checking Barcode Stickers by Transport before dispatch. 1087_Outflow_Before.png |
| Outflow (After) |
Quality Alert to be displayed in Dispatch Area & 100% inspection of Barcode Stickers before dispatch to be done 1087_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Models |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, WISOP, PackingStd, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 40000 |
| Reason for submission | reviewed next 3 Lots no mix up issue found ok |