8D Problem Analysis Report

[ROTOR ID OVER SIZE] Updated

Customer: TPIL Date Issue Occurred: 18-May-20

Program: RTFTH-55 REGN 4D Due Date: 18-May-20
Product: ROTOR 8D Due Date: In Process
Issue #: ROTOR SMALL ID OVER SIZE Date Issue Closed: 27-May-20
Champion Name Champion Title Champion Phone Number Champion E-mail Address
Kuldeep Singh QUALITY ENGINEER 8126866800 quality@poojametalprocessors.com
Additional Team Member Name(s) Title(s) Phone Number(s) E-mail Address(es)
Dharamveer Singh PLANT HEAD 9582220163 production@poojametalprocessors.c
1. Team Members
Dinesh QUALITY ENGINEER 9050905122
Dharmendra PRODUCTION 8010404101

2. Problem Description
3. Interim Containment
4. Root Cause
Description (Describe issue in terms of what, where, when and how many)
Rotor Small id over size found of 19 I.D , At Tecumseh,18.05.2020, 02 Pcs
Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..)
Production Losses/Line interruptions
Facilities Involved (Customer, Tecumseh Products and any Suppliers)
Pooja metal and Tecumseh Products
What actions were taken to immediately protect the customer and contain any suspect inventory?
All Existing Material at pooja metal is checked 100% by plug gauge and sampling done by marpose after every 5 pieces.
Other Product/Platform at Risk ? Identification of certified material ?
Check all existing Identified
Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)
Pooja metal does not have any old existing Material, All material is punched new.
Sorted Defect # Interim Containment Start Date
All Material 0 5/20/2020
ROOT CAUSE
Why Made & How Verified
1. Rotor id over size made at the burnishing stage as the Inspection is done by marpose . The rotor found over size is oval at one point not the complete rotor
is not oval.
Why Shipped & How Verified
id checked both side by plug gauge in the final stage and that couldnot detect the id over size in microns in rotor.
Permanent corrective action
Corrective Action for Why Made

As the material will be burnished the size will be checked with marpose and then will be moved to next process to avoid the variation in ovality.
5. Permanent Corrective
Action Corrective Action for Why Shipped

Id of the rotor will be checked by marpose and no rotor of id over size will be sent to customer that will be NG at our stage only.

Verification of Corrective Action: Has the issue been turned on and off? How? Verification through statical evidence / hypothesis testing. Verification of
corrective action for each why made and why shipped is required.

We start the production first of we FPA then continue the production. Cross verification by Line Engineer for inspected Parts in every hour per shift (5 Nos).

6. Verification of Corrrective Action Owner Name C.A. Owner Phone Number C.A. Owner E-mail Address Target Completion Date
Corrective Actions
Dharmendra 8010404101 5/22/2020

Build Date for Certified Material How Will New Parts Be Identified?
5/23/2020 for the new parts Prior Information will be Given.
How will this issue be avoided in the future?
Cross verification by Line Engineer for inspected Parts in every hour per shift (5 Nos).
Other Facilities or Platforms At Risk
Name Part Number C.A. Owner for Follow Up Due Date
Due Date
Affected Document Owner for Update Date
7. Prevention DFMEA
PFMEA
Has the necessary documentation been Control Plan
updated? Process Flow
Operation Instructions
Drawing
Design Standards
Closure Statement
8. Closure & Team Celebration
Identify the Root Causes (What caused the defect to produced (occurren

Why was this defect made (occurrence)? Why -1

ID over size

Why was this defect shipped (escape)? Why -1

Rotor id check
by plug guage at
final stage

Why was this not recognized (System)? Why -1

system by pass
by checking
Inspector
sed the defect to produced (occurrence), shipped (escape) and to bypass System)

Why -2 Why -3 Why -4

as in the burnishing size on the

at the burnishing stage
stage the the size vary heigher side

Why -2 Why -3 Why -4

Plug Gauge does sampling done by mix up of NG

not detect vaiation in marpose after every 5 Rotor in OK
microns pieces Rotor

Why -2 Why -3 Why -4

material is checked
by marpose
pass System)

Why -5

Why -5

Why -5