1 4 DEFECT CONTROL REPORT 12 Date :17.01.

2019
Defect : FITMENT PROBLEM ANALYSIS RESULT : Where Vendor Sub-Vendor Vendor Name : AFFY INDIA PVT LTD
Reported By : MR. PURSHOTTAM Nos Reported : DGM (SQIG)
Repeat (In 1yr) 1'st Time Sub-Vendor :
Date of Occurance : 13.01.2019 Model :
Part Name : BLUE NUT Part No : 83119M75JOO Root Cause FITMENT PROBLEM Prepared By Verified By Approved By
Batch Code :
(4M) SHSHANK ABHISHEK AKSHAY
PROD MGR ASST. MGR QA MGR

2 IMMEDIATE ACTION 6

Id Mark on
As per Investigation, we found that due to tool life PROCESS FLOW : NG Process Sketch / Photo
Parts Checked at Date OK NG Batch Code Remarks compeletion, part got struck in mould and double shot
ok part Reciept of raw material Final Inspection
occurred. Due to which slider pin broked.One NG part got
On Line skipped & mixed with OK parts during retroactive
inspection.
Trim India Store Storage Packing

Godown (Vendor) 17-01-2019 44000 nil

Factory (Vendor) 14-01-2019 8000 nil Issuance of Rm Storage

Parts in SPD

Vehicles Checked QUALITY ALERT Injection Moulding Dispatch

Chassis No.
at

VI Final
Deflashing/
Inspection
Cutting

FVPA

7 Suspected Quantity (Indicate OK for 3 days before and after the Defective Batch Code)
Actual Defect Sketch/Photo
3 Sl No Part No / Date Remarks

Batch code
Qty Produced

Dispatch/Receipt from
Sub-vendor

In-house processing/
Final inspection qty.
13 VERIFICATION / CHECK POINTS (Implementation of Countermeasures in Process & Documentation
8 STUDY OF CAUSE & SIMULATION TEST 10 COUNTERMEASURES
with Date)
Sl No Process Test Result DECESION Sl No Countermeasure Date Sl No Checkpoints / Standardization at Vendor End Date Remarks

Inspection was done & RM is enter in incoming

1 Incoming Inspection of Rm OK 1 TOOL IS REPAIRED 20.11.2018
inspection check sheet (NYLON 6)

Machine parameter is verified from the 1st part TRAINING PROVIDED TO OPERATOR AND
2 Machine Parameter OK 2 14.01.2019
approval sheet & found ok as per control plan INSSPECTOR FOR RETROACTIVE INSPECTIO

1st part approval was made but dispose of QUALITY ALERT PROVIDED TO VISUAL
3 1st Part & Last Part approval OK 3 14.01.2019
rejected qty ( Power failure & other Interval ) INSPECTION AND ON MACHINE

Petrol inspection was done at

10:00am. On his next visit at 12:00 pm, he DEFECT ADDED IN DEFECT CHART FOR
4 Patrol inspection OK 4 20.01.2019
found that Sslider pinwas broken during AWARENESS OF OPERATOR & VISUAL INSPECTOR
production due to double shot.
As per 4M Change management, setup approval
was done and material between the interval sent
for retroactive inspection, During retroactive IN PROCESS OF GETTING APPROVAL FOR NEW
5 CONTROL 4M CHANGE MANAGEMENT NG 5 ASAP
inspection, material was checked and 11 NG TOOL FROM CUSTOMER.
parts found. One NG parts gets mixed with OK
parts during retroactive inspection

11 Horizontal Deployment

1 ALL MACHINE & ALL PARTS

9 5 WHY ANALYSIS 14
Step 1 2 3 4 5 Sl No CHECK POINTS & STANDARDIZATION Date Remarks
Tool life over due to which
Mould running in auto
part got strucked in mould
Slider pin broken during condition, shot got struck in
Occurrence Fitment problem at customer end. Fitment hole is blocked and double shot occurred
production. mould and double shot
leading to breakage of
occurred.
slider pin.
PDI QC PERSON VERIFIED
MATERIAL CHECKED DURING RETROACTIVE THE LOT AS PER SAMPLING
NG PARTS GOT SKIPPED & MIXED WITH OK PARTS
Flow INSPECTION UNDER 4M CHANGE. 11 NG PARTS
DURING RETROACTIVE INSPECTION
BASIS LEADING TO THE
FOUND AS PER RECORD. PROBLEM THAT PART GOT
SKIPPED FROM PDI STAGE