QFR No - 7000822416
Defect Details
| NC No. | 7000822416 |
| NC Date | 03/03/2022 |
| NC Submission Date | |
| Part No. | S2PL01307B |
| Part Name | WASHER |
| Supplier Name & Code | 100299-CITIZEN EXPORTS |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DIMETER UNDERSIZE-Diameter Undersize. |
1. Problem Description
| Defect Description | I/D undersize in Washer P/C B104E (S2PL01307B) - I/D Specification : 28.10 + 0.20 mm & I/D Observation : 27.88 mm. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 2000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualitypantnagar@citizencomponents.com |
| Plant Head/CEO Email ID | citizenexports@citizencomponents.com |
| MD Email ID | ceo@citizencomponents.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7850
|
0
|
0
|
6500
|
0
|
14350
|
| Check Qty |
7850
|
0
|
0
|
6500
|
0
|
14350
|
| NG Qty |
2000
|
0
|
0
|
120
|
0
|
2120
|
| Scrap | 0 |
| Rework | 2120 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Part Checked at Customer end & our FG & WI Stage and after inspection put a dot marking on part with white paint marker . |
3. Process Flow
| Process Flow Description |
|---|
| Hole ID Punching (Blanking & Punching ) |
4. Process Details
| Process / Operation | Blank & Punching |
| Outsource | No |
| Machine / Cell | Power Press Machine |
| Machine / Cell No. | 75Ton -02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | trained Operator | Operator aware about the ID specification for washer | O |
| Tool | Tool Punch ok as per required | Tool Punch observed in lower side as per required | X |
| Method | After Powder coating part ID inspection | After Powder coating part ID inspection on sampling base (5 no`s/Lot) | O |
| Material | Material Grade or Thickness as per drawing | Material Grade or Thickness is ok as per drawing | O |
| Machine | Machine capacity | 75 Ton machine to maintain part thickness & OD of the part | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 Nos /L |
7. Root Cause Analysis (Occurance)
| Why 1 | Washer ID Observed under size -27.88 mm against 28.10+0.2mm. |
| Why 2 | Tool Punch diameter observed 28 mm, lower than the specification of part ID |
| Why 3 | Tool wear out before the set life of 50K no`s |
| Why 4 | No daily verification of tool condition & part ID during process set up |
| Why 5 | |
| Root Cause (Occurance) | No daily verification of tool condition & part ID during process set up |
Root Cause Analysis (Outflow)
| Why 1 | Washer ID not as per specification after powder coating |
| Why 2 | Defective parts not arrested during inspection |
| Why 3 | Checking only 5 No`s during final stage |
| Why 4 | Final process not designed to arrest defective parts |
| Why 5 | |
| Root Cause (Outflow) | NG Part not found during sampling inspection due to less sample size (5 no`s/ Lot) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool Punch Outer Diameter 28.30 ~28.40mm will checked during process setup in FPPI | Mr. Jaswant Singh & Mr. Vineet Kumar | 07/03/2022 | 20/04/2022 | Completed |
| Occurance | New Tool Punch designed consider powder coating process 28.40mm | Mr. Amrish Sharma | 07/03/2022 | 20/04/2022 | Completed |
| Outflow | 100% Part Will checked after powder coating with ID plug gauge before dispatch at quality gate | Mr. Yogesh Kumar | 07/03/2022 | 20/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection done after Powder coating before Dispatch for 1Month at Quality Gate |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | per Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
1-NO daily verification of tool condition during setup approval
2- Punch ID under Size as per Required 0.35mm. 3_Occurance_Before.pptx |
| Occurance (After) |
1- Daily verification started of tool condition during setup approval
2- New ID punch provided 28.45mm and part ID observation 28.18~28.25mm after P/C. 3_Occurance_After.pptx |
| Outflow (Before) |
Sampling Inspection done by instruments (DVC) 3_Outflow_Before.pptx |
| Outflow (After) |
1- 100% Inspection done with ID checking gauge and after Inspection dot marking done on part with white paint marker 3_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | 533PL00207 Washer / ETL Suspension |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | Not changed |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Ok |