ROHTAS FASTENER PVT.

LTD

CUSTOMER/SUPPLIER / IN PLANT QUALITY PROBLEM ANALYSIS AND CO

CUSTOMER/VENDOR / DEPTT : Rockman Industries PART NAME : Cam rear B

PROBLEM Without punch Part Mix PART NO. :

ACTUAL CONTENTS ACTUAL INVESTIGATIO

MODEL: PLACE OF OCCURRENCE RANK
Man Machine
SAFETY / New
REJ.QTY- 3 Nos.
PERFORMANCE/
Rockman Industries FIT FUNCTION
Operator
OTHERS: Un Trained

DETAIL OF PROBLEM (DATA/SKETCH) Process Serration Teeth

Damage
Awareness Oversize Serration
Major Dia
Without punch Part Mix Product
K O Pin length
short

Work Instruction
not displayed
Grade Not ok

Raw Material Setting pcs. not disposed

Heat Mixed

Material Method

ROOT CAUSE COUNTERMEASURE DETAIL

(SKETCH/DATA/DETAIL) CORRECTIVE ACTION:

After analysis it is analysed that during Running Punch not lpierced just 1. Material Sorted
entered in cavity area so impression not formed.
2. Quality Alert displayed at concernd Process.
After analysis it is analysed that during Running Punch not lpierced just
entered in cavity area so impression not formed.

Open to see the PREVENTIVE ACTION:

simulation 1. Tool verified by taking moulds

analysis 2. Limit sample provide for judgement to the operator

3. On Job Training provide to operators for the concerned defect.

4.

WHY-WHY ANALYSIS : MONITORING SHE

PROBLEM I II III IV V Sep. Oct

O
C
C
U
Punch pin Mark not Material not fill at first less angle on KO Pin
R More cavity on face
A appeared on Part station Face
N
C
E

Punch Miss

O
U
T
Part not catch
F during FI
L
O
W
BLEM ANALYSIS AND COUNTERMEASURE SHEET ( 5 - RULE )
PREPARED
Cam rear Brake PROBLEM NO. PRODN.MGR. QA MGR.
BY
DATE:

P. Sharma Vijay Kumar Vikas Kumar 5/29/2018

ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)

PROCESS FLOW RESULT ANALYSIS
Temprature
Machine
OK
Broken Punch pin RM rec. & Inspection
Forging Not OK

Punch Pin(Serrationl Knotching OK

Worn Out Heat Treatment OK

K O Pin length
short
CNC After analysis it is analysed that
Punch Miss OK
during Running Punch not
Process Surface Finish lpierced just entered in cavity
OK area so impression not formed.
.S.O.P
F. Inspection
Not OK
Packing &n Despatch
OK
Checking Frequency not followed

RESP. IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)

Kapil WIE

d at concernd Process. Vikas 5/29/2018

moulds
Manjeet 5/29/2018
or judgement to the operator
Ajeet 5/30/2018
de to operators for the concerned defect.
Parveen 5/29/2018

MONITORING SHEET (REOCCURANCE OF DEFECT ) (QTY./GRAPH) FEED BACK TO OTHER

Nov Dec Jan Feb REMARKS PROCESS ( IF SAME TYPE
PROBLEM)

Limit sample provide which is

applicable for all CAMS Brake
 Improvement - 1

Less Angle

Due to Less angle material not fill at tail side face which contribute in more cavity formation up
Angle increase to fill more material to tail side face.
to 4th stn.
mprovement - 1

Angle increase to fill more material to tail side face.

 Limit Sample
(CAM Family)

s.no. Defect Category Sample Description Sample Part Judgement Remarks

Crieteria

1
OK
P
2
OK
P
3
CAM REAR
BRAKE
& CAVITY on Tail
OK
face
CAM FRONT
BRAKE P
4
NG
O
5
NG
O
PREPARED BY:- Yuvraj APPROVED BY:- Ajeet