KOINS MECHATRONICS

Report No
Report Date

ELECTRIC WATER HEATER PLANT, KALA AMB

8D Inlet block complaint Pebble

Revision
3D
Date of notification :

Header data
Title : Customer complaint from field
Customer : V-Guard Industries Ltd.
Address
: Kala Amb

Contact
Address

QA , V-Guard Kala Amb

V-Guard industries ltd.
EWH division
Kala Amb , Himachal Pradesh
D1 . Investigation of the problem done by & team
members

Title : Customer complaint from field

Description of complaint
D3
Containment actions
D4.1
Root causes
1
Dummy cap dimension
2
Inlet & outlet pipe dimension
4
Re use of dummy caps
5
Polythene thickness variation
6
Without dummy cap production
7
Wrong dummy cap design
8
Chemical filled at any other area
D4.2 Main cause
D4.3 How could the failure happen?
D4.4 Why could the failure reach the customer?

Application
Part No
Manufacturing date : 0
Tracking No
Name
Email

Inlet pipe blocked by PUF filled in

-----------------------------------------------

Listed below
Checked 8 different parties dumm
penetraion
found
Checked
8 different
tanks Inlet an
dimensions
Operators are accepted the re use
store,Checked
but novaried
chemical
pe
Polythene thickness
in som
Checked but no chemical penetra
Not done
For easy usage, there is no thread
caps/check
nuts required.
Chemical penetrate
inside the pip
or near bypenetrate
PUF mixing
area)
Chemical
inside
the pip
For
easy
usage,
there
is
no
or near by PUF mixing area)thread
nuts
required.
bag or
any other reason the chem
threaded caps there is no chance
Safety test fault detecting error a
Attached Process flow chart

D5
Definition of corrective actions
Sl.No
Planned Corrective actions
1
Before /After MS tank storage area marked and there will not have any ta
the chemical mixing area /PUF dies
Dummy cap will design with thraeded end which prevent thepenetration o
2
inside the pipe

Dummy cap will design with thraeded end which prevent thepenetration o
inside the pipe

Safety test process modified and trained operated (New SOP implemente

Planned to modify the cycle time after study (Safety test will do at 2 stage

Trained payroll operator only do safety tests and should decord the same

D6
Implantation of corrective actions
D6.1
Implemented corrective actions
1
D5.1
2
D5.2
3
D5.3
4
D5.4
5
D5.5
D6.2
Stop of containment action N/A
D7
Preventive Actions
D7.1
Implantation of QM systems (Qua
Sl.No
Implantation of QM systems (Quality plan work instructions etc.)
1 All the documents to be implemented as per D6.1
D8
Final Discussion
Report approved by

Report No
eport Date

KM/TANK/QA/8D-01
12/21/2014

evision
D
Date of notification :

8D

pplication
:
art No
:
Manufacturing date : 05-2014
racking No
:
Name
bkuma584@gmail.com
mail
Ph: 9541956280

locked by PUF filled in it.

------------------------------------------------

w
different parties dummy cap and found all are same. Checked but no chemical
found
different
tanks Inlet and outlet pipe thread dimensions and found no variations on
are accepted the re use of dummy caps when the material is not available at
ked
but novaried
chemical
penetraion
hickness
in some
lots andfound
which causes the tight fitment of dummy caps.
ut no chemical penetraion found

age, there is no thread on dummy. For block the chemical flow threaded dummy
nuts required.
enetrate
inside the pipe before /after PUF moulding (Tanks stored beneat the PUF dies
PUF
mixing
area)
enetrate
inside
the pipe before /after PUF moulding (Tanks stored beneath the PUF dies
age,
there
is
no
PUF mixing area)thread on dummy. For block the chemical flow threaded dummy check
ed.
other reason the chemical penetrate inside the cap and inlet pipe. If we are using
aps there is no chance of chemical flow inside the pipe.
fault detecting error and wrong process of safety testing.
rocess flow chart

re will not have any tanks near by

event thepenetration on chemincal

Pro.date

Effected
1.12.2014

3.12.2014

7.12.2013

8.12.2013

7.12.2013

8.12.2013

(New SOP implemented )

1.12.2014

1.12.2014

y test will do at 2 stages)

5.12.2014

5.12.2014

5.12.2014

5.12.2014

hould decord the same

Responsibility
Mr. Kunal Gupta (QC)
Mr. Idinesh (QA)
Mr. Hemath Sharma
Mr. Idinesh (QA)
Mr. Hemath Sharma

Pdn Date Effected

1.12.2014
8.12.2014
1.12.2014
5.12.2014
5.12.20141

n of QM systems (Quality plan work instructions etc.)

tc.)
Responsible
Mr. Idinesh K V

Long term
yes

Actual date
1.12.2014

Attachments