ROHTAS FASTE
SUPPLIER / IN-PLANT QUALITY PROBLEM ANAL
VENDOR / DEPTT : Inhouse
PROBLEM Forging In-complete Part - Forming NOK
ACTUAL CONTENTS
PLACE OF RANK
MODEL:
OCCURRENCE
SAFETY /
REJ. QTY.:
50 Nos 5/8" National PERFORMANCE/
Fit/Function
OTHERS:
DETAIL OF PROBLEM (DATA/SKETCH)
NG / Bad
parts
OK
ROOT CAUSE :
(SKETCH/DATA/DETAIL)
After going through tracability record and defect analysis it has been
found that 1st & 2nd station setting parts was stay in small bin / catch
pan which resulting in got mixup with ok running parts.
Occurrence
Socket across flat under
PROBLEM
size
setting parts i.e.1st & 2nd
station parts got mix-up
I
with Ok parts.
Because setting parts was
already available in small
II
catch pan.
WHY-WHY ANALYSIS :
Because small tray / catch
pan was not clear before
pan which resulting in got mixup with ok running parts.
III
running the machine for
mass production.
Because improper
IV
handling of setting parts
OHTAS FASTENERS PVT. LTD.
UALITY PROBLEM ANALYSIS AND COUNTERMEASURE SHEET (5-RULE)
PART NAME : Ball Pin PROBLEM NO.
Forming NOK PART NO. : 1762
ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERI
MACHINE
-MEN
Allocation of
Transfer finger operator & un-skilled
inspectors sorting
not working
operator
properly
Neglegence of
Loose fastning machine
of die block operator
Improper handling of
setting part NG /
unidentified RM
Setting part
material used
Pictroial Work got mixed up
instruction not with ok parts Forging
In-
available
complet
e Part -
Forming
NOK
: METHOD MATERIAL
COUNTERMEASURE DETAIL RESP.
CORRECTIVE ACTION :
1.material sortout and defect pcs scrapped
2.Setting part handling work instruction made in local language and
displayed in all relevent areas to follow the proper handling of setting
P.SHARMA/
parts to avoid mixing with ok parts. VIKAS KUMAR
3. Instruction
given to all machine operators and supervioser small
bin must be clear before running the machine for mass production.
PREVENTIVE ACTION :
1. Setting part handling work instruction made in local language and
displayed in all relevent areas to follow the proper handling of setting
parts to avoid mixing with ok parts.
P.SHARMA/
2. Quality alert displayed at all relevant areas. VIKAS KUMAR
1. Setting part handling work instruction made in local language and
displayed in all relevent areas to follow the proper handling of setting
parts to avoid mixing with ok parts.
P.SHARMA/
2. Quality alert displayed at all relevant areas. VIKAS KUMAR
3. Training provided to all operators & final inspector about defect
awarness.
MONITORING SHEET (REOCCURANCE OF DEFECT ) (QTY./GRAPH)
V I MONTH II MONTH III MONTH IV MONTH V MONTH
pictorial work instruction
Because there is no
available on machine.
FMT NO.: F/QA/08-A
REV.NO.: 01
E) EFF.DT.: 20/04/18
APPROVED
PREPARED BY CHECKED BY DATE:
BY
Vikas Kumar P. Sharma Vijay Kumar 4/28/2018
ACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)
PROCESS FLOW RESULT ANALYSIS
OK
RM Incoming
OK
RM Inspection
Not OK
Forging
After going through tracability record and defect
OK analysis it has been found that 1st & 2nd station
Thread Rolling
setting parts was stay in small bin / catch pan
OK which resulting in got mixup with ok running
Heat Treatment
parts.
OK
F. Inspection
OK
Packing &
Despatch
IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)
4/30/2018
Next coming Lot
Next coming Lot
FEED BACK TO OTHER (HORIZONTALLY
DEFECT ) (QTY./GRAPH) DEPLOYMENT)
VI MONTH REMARKS PROCESS ( IF SAME TYPE
PROBLEM)
INSTRUCTIONS
TO AVOID MATERIAL MIXING
DURING SETUP CHANGE
COLD FORGING
1) maSaIna kI T/aMsafr
ifMgar maoM ipClaI
saOiTMga ka kao[ BaI
paT- nahI haonaa
caaihyao.
2) knvaoyar T/o maoM
ipClaI saOiTMga ka
kao[ BaI paT- nahI
haonaa caaihyao.
3) paT- kUilaMga T/o
maoM ipClaI saOiTMga
ka kao[ BaI paT- nahI
haonaa caaihyao.
4) Dayala sTOMD pr
ipClaI saOiTMga ka
kao[ BaI paT- nahI
haonaa caaihyao.
5)maSaIna knvaoyar
maoM ipClaI saOiTMga
ka kao[ BaI paT- nahI
haonaa caaihyao.
6) @vaailaTI
[MspO@Sana Tovala pr
6) @vaailaTI
[MspO@Sana Tovala pr
ipClaI saOiTMga ka
kao[ BaI paT- nahI
haonaa caaihyao.
Prepared By Approved By:
TIONS
RIAL MIXING
P CHANGE
pproved By:
Objective Evidenc
Before Afte
COMMENTS"- COMMENTS"-
One complete revolution of conveyor could not ensured which is required for One shell of conveyor marked with colour s
complete disposition of previous setting parts. ensured and complete disposition of previo
Evidence
After
nveyor marked with colour so that complete revolution can be
mplete disposition of previous setting parts.
