QFR No - 8000784732
Defect Details
| NC No. | 8000784732 |
| NC Date | 21/04/2022 |
| 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 | Rusty pieces mix up |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 148 |
| 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 |
1440
|
0
|
0
|
1100
|
0
|
2540
|
| Check Qty |
1440
|
0
|
0
|
1100
|
0
|
2540
|
| NG Qty |
148
|
0
|
0
|
0
|
0
|
148
|
| Scrap | 0 |
| Rework | 148 |
| 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 |
| Man | Trained Opreator | Operator aware about the Material Specification | O |
| Machine | Machine Capacity | Machine Capacity is ok | 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 |
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% P/L |
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 | Clutch Plate Blank Grinding process after 100% Clutch Plate clean with Anti Rust chemical for avoiding rust issue at customer end | Mr. Yogesh Kumar & Mr. Vineet Kumar | 21/04/2022 | 29/04/2022 | Completed |
| Outflow | 100% checked after cleaning | Mr. Yogesh Kumar & Mr. Vineet Kumar | 21/04/2022 | 29/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | After cleaning 100% part check by visual method |
| Inspection Method | Other |
| Other Inspection Method | Visaul |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Per Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Rusted Part cleaning have not done with anti rust chemical 61_Occurance_Before.pdf |
| Occurance (After) |
Rusted part Cleaning have started with Anti rust chemical and after cleaning rust prevent oil used on part avoiding rust issue 61_Occurance_After.pdf |
| Outflow (Before) |
Part checked only final stage 61_Outflow_Before.pdf |
| Outflow (After) |
After Cleaning part have checked 100% before Planishing process and 2nd visual inspection have done at Final Stage 61_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 | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |