QFR No - 7000834887
Defect Details
| NC No. | 7000834887 |
| NC Date | 06/05/2022 |
| NC Submission Date | |
| Part No. | 520JT00102 |
| Part Name | PLATE CLUTCH K-70 |
| Supplier Name & Code | 100299-CITIZEN EXPORTS |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | OXDISED- |
1. Problem Description
| Defect Description | visual defects- rust on plate |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 512 |
| Is Defect Repeatative? | Yes |
| 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 |
1440
|
0
|
0
|
1259
|
594
|
3293
|
| Check Qty |
1440
|
0
|
0
|
1259
|
594
|
3293
|
| NG Qty |
39
|
0
|
0
|
9
|
0
|
48
|
| Scrap | 0 |
| Rework | 48 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Part checked at customer end & Citizen end FG with WIP Stage and after inspection defective part resting in Red Bin |
3. Process Flow
| Process Flow Description |
|---|
| RM & Blanking |
4. Process Details
| Process / Operation | Blanking |
| Outsource | No |
| Machine / Cell | Power Press Machine |
| Machine / Cell No. | Power Press Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tooling ok as per required | Tooling is ok as per required | O |
| Method | After Planishingdept material has been clean | After Planishing dept material has been clean done at Citizen End | O |
| Material | Material Grade or Thickness and visual as per required ok | Material Grade or Thickness as per required ok but RM observation rusted type | X |
| Man | Trained Opreator | Operator aware about the Material Specification | O |
| Machine | Machine Capacity | Machine Capacity is ok | 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 | Per/Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Clutch Plate Rusted Observation at ETL end |
| Why 2 | RM rusted observation at Storage area |
| Why 3 | Due to RM inventory carry out 3 to 4 Month at Citizen End |
| Why 4 | Due to RM MOQ define approx 20Ton with RM Supplier . |
| Why 5 | |
| Root Cause (Occurance) | Due to RM MOQ define approx 20Ton with RM Supplier . |
Root Cause Analysis (Outflow)
| Why 1 | Defective Part Not arrested during inspection |
| Why 2 | Rusted Part After cleaning not checked |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | NG part not found during final quality gate. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1- Clutch Plate Blank Grinding process after 100% Clutch Plate clean with Anti Rust chemical for avoiding rust issue at customer end 2- Clutch Plate Thickness Minimum 1.58 deviation received from ETL Side avoid to defined Supplier MOQ and other issue | Mr. Yogesh Kumar & Mr. Vineet Kumar | 02/06/2022 | 02/06/2022 | Completed |
| Outflow | 1- 100% Part will cheeked after blanking and also 100% part checked at Quality Gate before dispatch | Mr. Yogesh Kumar & Mr. Vineet Kumar | 02/06/2022 | 02/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Part will checked after blanking and also 100% part checked by Visual Method at quality gate before dispatch . |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | P/L |
10. Evidance of Countermeasure
| Occurance (Before) |
Rusted Part cleaning have not done with anti rust chemical 91_Occurance_Before.pdf |
| Occurance (After) |
1- Rusted part Cleaning have started with Anti rust chemical and after cleaning rust prevent oil used on part avoiding rust issue.
2- Clutch Plate thickness 1.58mm deviation received against to minimum 1.60mm from ETL Side for avoiding to rust and other issues due to supplier defined MOQ 20T 91_Occurance_After.pdf |
| Outflow (Before) |
Part checked only final stage 91_Outflow_Before.pdf |
| Outflow (After) |
After Cleaning part have checked 100% before Planishing process and 2nd visual inspection have done at Final Stage 91_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Power Machine |
12. Document Review
| Documents | ProcessFlowChart, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |