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.