QFR No - 8000892985
Defect Details
| NC No. | 8000892985 |
| NC Date | 25/09/2024 |
| NC Submission Date | |
| Part No. | F1LG00902B |
| Part Name | SEAT PIPE -K86A |
| Supplier Name & Code | 100538-NARINDER PARKASH AND CO |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | BROKEN-HEAD SIDE SEAT PIPE BROKEN |
1. Problem Description
| Defect Description | Crack from head side |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| 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 |
10000
|
15000
|
20000
|
15000
|
10000
|
70000
|
| Check Qty |
10000
|
15000
|
20000
|
15000
|
10000
|
70000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection of available material. |
3. Process Flow
| Process Flow Description |
|---|
| 1) Cutting 2) Draw 3) Head Formation 4) Punching 5) Rough Grinding 6) CNC Head Turning 7) CNC Boring & Facing 8) Tapping 9) Chamfering 10) Final Grinding 11) Final Inspection 12) Cleaning 13) Oiling 14) Packing & Dispatch |
4. Process Details
| Process / Operation | CNC Head Turning |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Head formation pin depth more | It was observed that Head Formation Pin Depth is OK | O |
| Method | Part with less wall thickness near groove skipped Final `Q` Gate during inspection | It was observed that part having less wall thickness near groove skipped Final `Q` Gate | X |
| Machine | Stroke variation | No Stroke variation observed | O |
| Material | Hardness more | Material Hardness observed 45HRB which is observed to be within range | O |
| Method | Setting part got mixed | It was observed that setting part got mixed | X |
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 | Head Broken part |
| Why 2 | Crack on part |
| Why 3 | Wall thickness got less |
| Why 4 | Extra machining done |
| Why 5 | Setting part |
| Root Cause (Occurance) | Setting part |
Root Cause Analysis (Outflow)
| Why 1 | Head Broken part |
| Why 2 | Could not be detected at final inspection |
| Why 3 | Skipped at Final `Q` Gate |
| Why 4 | Skipped in Groove dia sampling inspection |
| Why 5 | Groove dia sampling qty less |
| Root Cause (Outflow) | Groove dia Sampling Qty less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% inspection of Groove dia to be done | Mr Toti | 02/10/2024 | 02/10/2024 | Completed |
| Occurance | Proper disposal of setting parts to be ensured before starting new shift | Mr Harwinder | 30/09/2024 | 30/09/2024 | Completed |
| Occurance | Open Red Bin to be replaced with lock & key Red Bin | Mr Harwinder | 30/09/2024 | 30/09/2024 | Completed |
| Occurance | WI to be displayed at Work Station | Mr Princ | 01/10/2024 | 01/10/2024 | Completed |
| Outflow | Quality Alert to be displayed at "Q" Gate | Mr Princ | 25/09/2024 | 25/09/2024 | Completed |
| Occurance | Quality Alert to be displayed at CNC Section | Mr Princ | 25/09/2024 | 25/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection of Groove Dia |
| 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) |
Open red bin was used. 1113_Occurance_Before.jpg |
| Occurance (After) |
Open Red Bin to be replaced with lock & key Red Bin. 1113_Occurance_After.jpg |
| Outflow (Before) |
Sampling inspection was followed for Groove dia. 1113_Outflow_Before.png |
| Outflow (After) |
100% inspection of Groove dia is started at final inspection. 1113_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All CNC Machine / Similar Model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | HEAD SIDE SEAT PIPE BROKEN |