Escorts Kubota Limited
NCR/QPRS CAPA PPT
Confidential_ EKI Supplier Upgradation Project®
UPLOAD THE SAME PPT (IN PDF FORMAT) ON PORTAL WHILE CLOSING NCR/QPRS AFTER REVIEW.
ISSUES DESCRIPTION :-
Supplier Problem Solving Team (List of C.F.T Members)
S.No. Name Department Location Phone No. Email
1 Mr. Ajay Raj Sales HB Industries Unit-II +91-9780700048 [email protected]
2 Mr. Deepak Quality HB Industries Unit-II +91-XXXXXXXXXX XXXXXX
3 Mr. Laskar Singh QMS HB Industries Unit-II +91-XXXXXXXXXX [email protected]
5 Mr. Dharamvir Production HB Industries Unit-II +91-XXXXXXXXXX XXXXXX
QPRS/NCR ISSUE DETAILS
Issue Issue Stage Batch code
Supplier
QPRS/NCR No. Date of Issue Part No. Part Name Model Part Category Repeated (RI/LINE/ Quality Issue NG Qty. identification /
Name
(YES/NO) PDI/FIELD) Traceability (if any)
QPRS/DEC/ 07.12.24 D10595170AC Carrier HB Industries Normal NO R.I Reqd. IDØ32.895-Ø32.920 Obs. 11 XXXXXX
2024/24449 Planetary Gear Unit-II Ø32.88
DRAWING VIEW BY HIGHLIGHTING NG DIMENSIONS BY RED ACTUAL ISSUE IMAGE (Received from Customer end-If available)
CONTAINMENT ACTION DETAILS AT EKL AS WELL AS AT SUPPLIER END :-
CONTAINMENT MARKING ON OK SEGREGATED PARTS
IDENTIFICATION
STOCK TOTAL OK N.G CONTAINMENT IDENTIFICATION REMARKS (IF
S. NO. & ACTION ON
DETAILS AT QTY QTY QTY METHOD ON SEGREGATED ANY)
N.G PARTS
OK PARTS
1 EKL end 130 119 11 ID inspection OK with Tick mark RTV to Supplier 11pc RTV
2 In transit 0 0 0
Supplier's
3 Warehouse (if 0 0 0 SCRAP NOTE OF N.G PARTS/MOM
any)
Supplier end's By ID inspection
4 50 48 2 Reworked
FG Bore gauge
Supplier end's
5 50 50 0
WIP
PROCESS FLOW OF PART BY HIGHLIGHTING NCR DEFECT RELATED PROCESS :-
ISSUE REPETITION DETAILS :- (History details of similar type issue in same or different parts)
QPRS Repetition for Same issue
Repetition of QPRS in Last 1 years -2023~24
Repetition of NCRs in CHANGE GRAPH
Month 1.2 2024
Last 1 years) HERE
1
APR 0 1
MAY 0
JUN 0 0.8
JUL 0
AUG 0 0.6
SEP 0
OCT 0 0.4
NOV 0
DEC 0 0.2
JAN 0
FEB 0 0 0 0 0 0 0 0 0 0 0 0
0
MAR 0 APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR
PREVIOUS ACTIONS (IN CASE OF ISSUE REPETITION ONLY)
Actions (1st Time) Actions (2nd Time) Actions (3nd Time) Actions (4th Time)
ti m e at
Occurrence No past history
rre d first
s s u e occu
le if i en d
p lica b m e r
N ot Ap custo
Outflow
Ishikawa Diagram/ Fishbone Diagram :-
MANPOWER MATERIAL MEASUREMENT
Instrument not properly
used
High hardness , poor
Lack of Skill machinability
ID shrink as it
was made near
lower limit after
shrinking size
became
Clamping issue
undersize 15-20
micron
Size made between mean
and lower limit Cold weather ID shrinked
METHOD MOTHER OF
MACHINE
ENVIRONMENT
WHY-WHY ANALYSIS :-
WHY-WHY ANALYSIS (Up to System level gap is mandatory)
ACTUAL ISSUE :- ID shrink due to cold weather
Occurrence Outflow
Why-01 ID Ø32.895-32.920 was made near mean and lower limit. Why-01 100% inspection was not done in final stage
Why-02 as due to cold weather shrinking in dia. Occurred Why-02 inspection frequency was 50% of lot in final inspection
Why-03 due to shrinking the bore size decreased upto 15-20 micron Why-03 skipped in inspection.
Why-04 due to shrinking id was observed upto Ø32.88 Why-04
Why-05 Due to the unawareness of contraction due to cold environment Why-05
Actual Root Cause of Quality Issue
Occurrence Outflow
Final RCA- Final RCA- As no past issue was there so as usual 50% inspection was
Due to unawareness of extent of ID shrinking due to weather change
Occurrence Outflow done in PDI for Bore
ACTION PLAN DETAILS & CUT-OFF DATE :-
CURRENT RCA & ACTION PLAN
Root Cause Root Cause Occurrence level
Concern Area Outflow level Actions
Occurrence Out Flow Actions
At Supplier End / ID will be made on higher side of
At Sub Supplier Due to unawareness of extent of ID Part skipped in inspection as in
regular practice bore inspection
tolerance i.e above mean so that 100% part inspection to be done
End (IF shrinking due to weather change
was 50% in final inspection
even incase of shrink issue size is by in Final inspection
Applicable) within tolerance range.
CUT-OFF DATE FOR NEXT OK SUPPLY CONSIDERING ALL NECESSARY ACTIONS AT OCCURRENCE & OUTFLOW LEVEL
Supplies as per schedule after 15/12/24
EVIDENCE FOR CORRECTIVE/PERMANENT ACTION :- (Occurrence level)
PROBLEM Before After IMPROVED
× ID size observed undersize upto Ø32.88
× ID was made targeting mean.
• ID will be made near upper limit while
manufacturing on VMC.
• ID will be made near upper limit and up to mean.
• OPL displayed and Training provided to operator.
S. No. Actions (OCCURRENCE LEVEL) Implementation Date Status
Action-1 ID will be made on higher side of tolerance i.e above mean so that even incase of shrink issue size is within 15.12.24 ok
tolerance range.
IMPROVED
Action-2 XXXXX XXXXX XXXXX
Action-3 XXXXX XXXXX 9XXXXX
EVIDENCE FOR CORRECTIVE/PERMANENT ACTION :- (Outflow level)
PROBLEM
Before After IMPROVED
100% inspection to be done for bore Ø32.895-32.920
ID inspection was 50% for bore in Final inspection
OPL displayed and training provided
S. No. Actions (OCCURRENCE LEVEL) Implementation Date Status
Action-1 100% part inspection to be done in Final inspection 15.12.24 DONE
IMPROVED
Action-2 XXXXX XXXXX XXXXX
Action-3 XXXXX XXXXX XXXXX
10
STANDARDIZATION :- (Attached updated documents here)
System Standardization
Document Change
S. No. Document Changed or Not Updated Documents
(Applicable or N/A)
1 PFD N/A
2 PFMEA N/A
3 Control Plan N/A PLEASE
UPLOAD ALL
MODIFIED
4 WI/SOP/OPS/OPL Applicable YES
DOCUMENTS
IN SINGLE
5 Process Check sheet N/A
EXCEL SHEET
Tool/Fixture/Jig History
ALONGWITH
6 N/A
Card or Drawing CAPA SHEET
ON PORTAL
7 Training/Awareness Applicable YES FOR REVIEW
Preventive Maintenance
8 N/A
Plan / Check sheet
Any Other (Inspection
9 N/A
reports/CMM report etc..)
Horizontal Deployment :- (If applicable)
Horizontal Deployment
Horizontal Deployment Target
S. No. Part Code Part Name Similar types of process Resp. date
1 D10647950 Carrier Planetary Gear Bores QUALITY ASSURANCE 15.12.24
5
Thanks
