CUSTOMER QUALITY COMPLAIN LIST 2015

Date of Dispatch Defect Countermeasure

Customer occurrence Part Name & No. Quantity Quantity Defect Name Root Cause Improvement measures Processing details Submitted -Yes / No Remarks

Instruction to cutting operator to check part visualy before hand over to

Double cuttmark upon next stage also started mark in near tube for insuirty quality alert displayed
Siel Noida 05-01-2015 Pipe Cluster 1200 1 tube Due to coil get entanglement during cutting Yes NC Closed
on M/C

Cluster pipe broken from

Siel Noida 09-01-2015 Pipe Cluster 300 1 welding line DC model Raw material problem The same informed to customer and ask countermeasure Yes NC Closed

Siel Noida 18-02-2015 Pipe Cluster 1 Weld Line Crack manufacturer end defect The same informed to customer and ask countermeasure Yes NC Closed

It is the constraint of cutting Machine which don't allow to open the bobin
of coil for leak test,however we have called our tooling person to make
inside round rib so that,after leak test coil don't entangle in each other
Siel Noida 06-04-2015 Pipe Suction 400 1 Tube leakage Leakage in coil as it is manufacturer defect while feeding to roller Used Yes NC Closed
Informed to customer to release inside end approx half meter for easy end
finding.

Bending process reviewed & Changed. Earlier bending was started from
Siel Noida 06-04-2015 Pipe Cluster (Two 200 U Bend profile less than No control mechanism in bending non-flaring side, now bending is started from expanding side. Used Yes NC Closed
door) spec jig for 55mm dim. Instruction & training to bending operators for follow the revise process
strictly and Strict Periodic Check of this dimension at every 2 hrs.

Jig to be modify in such a way that 4.75mm side not to insert in groove
Siel Noida 06-04-2015 Pipe Immerging 400 1 Pipe Immerging reverse Operator negligence before start bending Used Yes NC Closed
bending 100% gauging to be done at Expanding Side

Strictly adherance to tool life/cycle

Single expanding 1000 nos daily
Cluster Pipe Flaring OD Flaring punch wornout final expanding 2000 nos.
Siel Noida 06-04-2015 Pipe Cluster 1800 Less Improper management of tools Used Yes NC Closed
Training to expanding operator/QC Inspector for proper checking of
expanding OD throughout the expanding length

Arrange to start visual inspection of capillary before issue on line for

Improper cut mark on capillary tubes soldering, and marking on capillary bellow cut mark for ensuring Cut Mark
Siel Noida 06-04-2015 Pipe Suction 400 Capillary cut mark missing Manufacturer end problem Availability. Used Yes NC Closed
Supplier has been informed and countermeasure asked.
 Immediately arrange to re-check allchecked up our inventories and found
that we neither have Finished goods stock nor semi-finished stock of
problemetic pcs.
Earlier we were expanding pipe cluster in two times first punch by 3.65 and
second 4.4, but now onwords we are planning to change the flaring method
Siel Noida 25-06-2015 Cluster pipe Cluster Pipe Flaring Newly join person was deputed on machine at from two times to single time to avoid problem testing is under process Used Yes NC Closed
Missing and Flaring Crack that time Mean time Instructed to line leader don't allow to work on Machine of
newly join person
100% Gauging to be ensured immediate after expanding by
expanding operator & visual inspection for flaring crackness then marking
near flaring

Tube Leakage found at

Siel Noida 01-09-2015 Pipe Cluster 1 Siel line due to tube Supplier Raw material problem Countermeasure asked to supplier and arrange to fixed meeting with Siel Reject Customer submitted NC Closed
crackness

Bending process reviewed & earlier there was no support on bending jig for
Dim NG No control mechanism in bending jig for 528mm controlling of dim-528, now we have fixed support on bending jig for
Siel Noida 03-09-2015 Hot Pipe 490 6 Req Dim-528 dim. controlling dim variation during bending Used Yes NC Closed
Obs-521mm Instruction & training to bending operators for follow the revise process
strictly

Bending process reviewed & found less dia roller was used by operator for
Used bending roller as per drawing requirement bending, also earlier there was no support on bending jig for controlling
R-25 tube pinching problem during bending , now we have changed bending
Siel Noida 11-09-2015 Suction Assy 840 1 Tube Piching Issue roller dia from R-25 TO R-30 for controlling pinching problem during Reject Yes NC Closed
Operator carelessness bending
Instruction & training to bending operators for follow the revise process
strictly

Tube Leakage found at

Siel Noida 15-09-2015 Pipe Cluster 1 Siel line due to tube Supplier Raw material problem Countermeasure asked to supplier and arrange to fixed meeting with Siel Reject Customer submitted NC Closed
crackness
1-Improper gauging by operator Now we have improved our bending jig and also fixed a stopper with
Siel Noida 17-09-2015 Pipe Immerging 4 Expanding ID NG 2-Operator negligence groove for 100% checking during hisi tube assy Reject Yes NC Closed

Immediately arrange to re-checked up our inventories and found that we

neither have Finished goods stock nor semi-finished stock of problematic
pcs.
Improper setting of soldering machine
Siel Noida 12-10-2015 Suction Assy Soldering bellow foam pe 1-Instruction & training has been provided to our soldering Machine Used Yes NC Closed
Operator negligence operators for follow the revise process strictly
2-Now we have generated Quality alert for the same and display on
soldering and final stage also
3-Visual inspection has been started

Immediately arrange to check all stock qty at our end as well as Siel line also
Cutter edge was get blunt but cutter was not and no such type of defect found nor our end neither Siel line also.
changed by operator as per define frequency
Siel Noida 14-10-2015 Pipe Immerging Burr found Strictly instructed to cutting operators to changed cutter on time as per tool Used Yes NC Closed
Operator negligence change frequency and arrange to change cutter immediately w/out any
delay.
Also implemented hourly cutter check sheet for cutter checking and
instructed to operator to follow the same strictly.

Immediately arrange to check all FG stock at our end as well as customer

1-Forcely hang finished good part on old type of end also and arrange to replaced defective pcs with OK one
trolley, cause dim get stretch.
Dim NG-Req Dim-1385, Process reviewed and observed
Siel Noida 20-10-2015 Hot Pipe Obs-1391mm 2-No control mechanism in bending jig for dim- Old type trolley arms, it was not modified also bending process reviewed Reject Yes NC Closed
1385±3mm and found there was no support on bending jig for controlling of dim-
1385,hence we have modified all trolley arms and also fixed support on
bending jig for controlling dim variation during bending

Tube Leakage found at

Siel Noida 27-10-2015 Pipe Suction 1 Siel line due to rackness Supplier Raw material problem Countermeasure asked to supplie Reject NO Open
of tube
 Doc No-QMS-F-11

ISPM CUSTOMER DEFECT RATE 2015(SIEL REF) Rev No/Date

03/01-08-11

200.00

180.00

160.00

140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
1 2 3 4 5 6 7 8 9 10 11 12

Goal 100 100 100 100 100 100 100 100 100 100 100 100
PPM 5.19 2.55 0.00 13.79 3.56 2.97 15.34 5.70 49.01 38.50 0.00 0.00
Percentage 0.05% 0.03% 0.00% 0.14% 0.04% 0.03% 0.15% 0.06% 0.49% 0.38% 0.00% 0.00%
NG Qty 2 1 0 7 1 1 2 1 14 15 0 0.0
Dispatch Qty 384993 391663 345086 507448 280974 337169 130409 175343 285674 389650 93314 66036.0
Month Jan Feb March Apr May Jun Jul Aug Sep Oct Nov Dec

PREPARED BY VERIFIED BY APPROVED BY

 CUSTOMER QUALITY COMPLAIN LIST 2015

Date of Dispatch Defect Countermeasure

Customer occurrence Part Name & No. Quantity Quantity Defect Name Root Cause Improvement measures Processing details Submitted -Yes / No Remarks

Maretial-4.76*0.5mm 38000
Videocon 11-02-2015 MS-HDG LWC Mtrs All Pillot Damage
 CUSTOMER QUALITY COMPLAIN LIST 2015

Date of Dispatch Defect Countermeasure

Customer occurrence Part Name & No. Quantity Quantity Defect Name Root Cause Improvement measures Processing details Submitted -Yes / No Remarks

Education to Leak Test Operators / Brazers towards Standard

Procedure on monthly basis with master / defective pieces samples.
Certification program to Leak Test Operators / Brazers after duly
monitoring of brazed parts via Cut off analysis and Re-verification of
Leak Tested parts.
Low education level of Brazers / Leakage
Proper lighting arrangement at Leak Test Stations/ Water Change
Operators; Low light intensity level at All defective pcs rework
Midea Jan-2015 WRAC & ODU 33 Connector Leak
leakage stations; Buzzer settings were not
frequency defined at every day/ Lock & Key arrangement for buzzer
on line at customer end
Yes Done
control unit/ Cycle Time Increase from 20 Sec to 40 Sec.
secure; After Correction no re-test process.
Coupler Management (Repair/Replace) to be improved / Penalty &
Award System for Leak Operators to be initiated for encouraging
detection of Leak.
Leak Test Pressure to be increased from 22~25 Kgf/Sq cm (Existing)
to 42~45 Kfg/Sq cm to detect every minute leak.

1-All defective pcs

A. Bidding processing tool (For bidding) was
A. After brazing W/o bidding / Less bidding connector is difficult to return back
not available at that time.
Evap. Connecting verify. 2-All defective parts
B. From reducing to bidding information was
Process tube without B. Bidding information (ECN drawing) were not communicated to process tubes de-
Midea Jan-2015 Tube Assy 200 91 bidding
not circulated to Shop Floor after sample
Prod/QC brazed and new Yes Done
1025656 submission.
C. ECN was considered as new development part and keep it under connectors / process
C. ECN was considered as new development
approval. tube with bidding to be
part and keep it under approval.
brazed.

1-All defective pcs

A. Bidding processing tool (For bidding) was A. After brazing W/o bidding / Less bidding connector is difficult to
return back
not available at that time. verify.
2-All defective parts
B. From reducing to bidding information was B. Bidding information (ECN drawing) were not communicated to
Header Assy Process tube without process tubes de-
Midea Jan-2015 50 50 not circulated to Shop Floor after sample Prod/QC Yes Done
1026217 bidding brazed and new
submission. C. ECN was considered as new development part and keep it under
connectors / process
C. ECN was considered as new development approval.
tube with bidding to be
part and keep it under approval
brazed.

Midea 25-05-2015 Installation kit 10 Singe (Burnt) Its very dificult to find out problem but its Informed to supplier and ask CAPA Feedback Awaited No Pending
1026280 seems to supplier raw material problem
 CUSTOMER QUALITY COMPLAIN LIST 2015

Date of Dispatch Defect Processing Countermeasure

Cusromer occurrence Part Name & No. Quantity Quantity Defect Name Root Cause Improvement measures details Submitted -Yes / No Remarks

The same thickness of tube process which

we have dispatch from last two years and
still we have not received any single Now we have changed process tube thickness from 0.039" to
0.025" as per customer requirement. And the same informed to
Carrier 31-01-2015 Header Liquid 2GX5-32-456 10 Process Tube Thickness complaint regarding thickness issue,in our production deptt with chenged BOM. Rework Yes NC Closed
Gurgaon 0.025" Check 0.040" drawing htere which clearly mention tube Pin gauge has been provided on final fitment line for 100%
process thickness 0.039" the same we have
shown to Mr.Shashi Pandya on dated 16-02- checking
2015 during visiit at our end.

Now we have changed process tube thickness from 0.039" to

At the time of part development it was 0.025" as per customer requirement. And the same informed to
Thickness Observed prepared at 0.7mm thickness instead of our production deptt with chenged BOM.
Carrier Strict Instructions to final fitment operator have been given to
03-02-2015 Tube Liquid 2AGZO-00-041 73 0.028" instead of 0.8mm and the same submitted sample to Rework Yes NC Closed
Gurgaon 0.032"mm carrier after that we have started supply and check every pieces properly and mark on the particular tube each
consided thickness 0.8 to 0.7mm. piece.
Arrange to make pin gauge for gauging tube process id to avoid
thickness NG problem

Carrier 1-Improper fitment Education and Training to fitment Operators

Gurgaon 15-02-2015 Tube Suction 2AGZ0-00-051 50 Dim.NG 2-Operatot negligence Periodic Training to implemented & executed accordingly Rework Yes NC Closed

Water Inside part and
Carrier connector thickness NG
Gurgaon March-2015 Tube Liquid 2AGZO-00-041 247 Required 0.032’’
observed 0.028’’
1-Instruction has been given to line leader, not allow to work Re N² flush,
1-1st- Improper N² flushing into part directly on line before prior on spot training/Education to newly re-fitment
2nd-Low N² pressure on line joined person check, pack
2-Since the development 0.028’’ thickness Periodic check on line by QC for ensuring N² flushing and Yes NC Closed
connector was in used 2-BOM /Control plan has been revised & now tube0.032’’ thickness dispatched
is being cut & used.

Strict Instructions to Leakage operators have been given that take Re-Leak Test,
Leakage would be very minor, which could extra precaution while testing and focus the brazing joints re-fitment
Carrier Distributor Assy consistently and reject the piece if any single bubble over brazing
Gurgaon March-2015 3AGKO-00-335 132 Leakage not be detected by the operator and this joint is seen. check and Yes NC Closed
pieces got skipped. On-Spot training & Brain storming session to be arranged for dispatched
leakage testing & Brazing operators.

Carrier March-2015 Suction Tube 30 Dim NG Part make as per old drawing BOM /Control plan has been revised as per received drawing Rework Yes NC Closed
Gurgaon 2GZO-20-051 Updated Drawing not available at that time

As 0.025’’ was running connector successfully hence QC person did

not object
Carrier Header Assy Liquid Required 0.025’’ Since the development 0.037’’ thickness Still we have not received updated drawing from customer side,
March-2015 20 hence informed to our marketing deptt. To arrange updated Rework Yes NC Closed
Gurgaon 2GX5-32-456 observed 0.037’’ connector was in used drawing immediately
BOM /Control plan to be revised

Carrier Header Assy Gas 1-Part make as per old drawing 1-Part prepared as per existing drawing
Gurgaon March-2015 2GYO-30-454 24 Angle NG 2-Updated Drawing not available at that time 2-As per existing drawing part founded OK at the tome of OQC Rework Yes NC Closed
Part check 100% by newly modified jig.

Since the development 0.039’’ thickness

Carrier Header Assy Liquid Required 0.025’’ connector was in used Still we have not received updated drawing from customer side,
March-2015 50 hence informed to our marketing deptt. To arrange updated Rework Yes NC Closed
Gurgaon 2GYO-30-456 observed 0.039’’ As 0.025’’ was running connector
successfully hence QC person did not object drawing immediately
 Jig is also calibrate by Carrier But as per IQC advice we have to
arrange stopper on Jig
The Existing Jig's is OK, but After managing Strict Instructions to final fitment operator have been given to
Carrier Connector Angle fitment slightly angle got distrubed because check every piece properly and mark the fitment code on each
Gurgaon 09-04-2015 Header Gas 2GYO-30-454 400 Problem there is no stopper support for controling of piece. Rework Yes NC Closed
angle Stopper has to fix
We have to implement stopper for all similer jig to avoid such type
of problems in future.

1-Low N² Pressure at the time of flushing N² Arrange to fixed pressure gauge on line to maintain pressure at
Carrier 09-04-2015 Header Liquid 2GKO-10-456 200 Water Inside Tube into part as there was no Pressure Gauge on 5.5±0.5kgf/cm² and also education and Training to Operators Rework Yes NC Closed
Gurgaon
to the line Periodic check sheet for N² pressure has been implemented

Carrier 09-04-2015 Tube Suction 2GYO-70-51 103 Dim.NG 1-Improper fitment Education and Training to fitment Operators Rework Yes NC Closed
Gurgaon 2-Operatot negligence Periodic Training to implemented & executed accordingly

Carrier June-2015 Tube Liquid A 2GZ0-10-045 10 Flare nut crack Manufacturer end problem The same informed to supplier and ask CAPA Reject Yes NC Closed
Gurgaon
Dimension NG: Manual Part Profile adjustment as per
Carrier June-2015 Tube Liquid -2GZO-11-041 46 Dim 66.3 drawing; No Jig Available for proper and Fitment Jig Implemented to ensure Accurate Dimension Reject Yes NC Closed
Gurgaon
checks 59~76 mm accurate fitment

I.D NG 1.4M Basis Root Cause - Method

I.D 12.8+0.1
Carrier July-2015 Header Assy Gas 2GK0-10-454 5 ANGLE 10DEG CKS I.D 2. ID gauge Wear Out During usage; during New ID gauge implemented to ensure correct ID as per Rework Yes NC Closed
Gurgaon 12.9~13.04; ANGLE investigation the gauge was observed in plus Specification
ID specification
5DEG~8DEG

Deputed Permanent Dispatch Person in both the shifts to control

1.4M Basis Root Cause - Method Damage issues during transportation.
Carrier SUCTION HEADER ASSY-3AGZO- 2. Handling of Parts during Dispatch -
Gurgaon July-2015 00-334 1 Tube Pinch Loading and unloading of Bins & Parts during Replaced Yes NC Closed
Transportation Quality Person to be Deputed during Dispatch to ensure proper
handling
 CUSTOMER QUALITY COMPLAIN LIST 2015

Counterme
Date of Dispatch Defect Processing asure
Cusromer occurrence Part Name & No. Quantity Quantity Defect Name Root Cause Improvement measures details Submitted Remarks
-Yes / No

1. One day safely stock to be

1. Deburr process was not maintain strictly
performed adequately as material Arrange to
Tube Tapper cutting & 2. Strict instruction / Education to
Daikin 03-01-2015
4PA17865-5 J
60 60
Outer burr
was urgent to dispatch. segregation and
deburring and gauging operators for repalce with ok
Yes NC Closed
2. OD gauging was done on not to break the system even incase
randomly basis to urgent. of urgency.

1-Water change frequency at 1-Water frequency set as daily &

PLATE FINNED COIL RUST OBSERVED leakage not followed as RO system the same has been implemented All defective pcs
got breakdown. has been
Daikin 07-01-2015 INLET PIPE ASSY 100 100 (OUTSIDE AND 2-During OQC rust was not strictly. replaced with OK Yes NC Closed
3P313489-1 INSIDE). detected as rust could not be 2-Check pointat c/p to be added for one.
checking the rust during OQC.
detected immediate.

1. Education/Training to all
1. Tool marks occurred due to ID inspection operators about gauging
gauge, because during length methode.
PLATE FINNED COIL checking operator rotate the ID 2. ID gauge repaired by rounded
TOOL MARK
Daikin 08-01-2015 OUTLET PIPE 750 750
(SCRATCH).
gauge inside the flare ID. the sharp edge. Used Yes NC Closed
3P365145-1 2. ID gauge was sharped edge. 3. Instruction to OQC inspectors
3. Problem was not detected at about visual inspection to inspect
the time of OQC. the parts more carefully from both
sides outside & inside.

1-Training and Instruction provided Arrange to

Auxiliary Inlet Pipe 1-Manufacturing defect to cutting operators,to check Visual replace all
BLACKNESS FOUND 2-Visual operator could not be inside surface also defective pcs
Daikin 09-01-2015 Assy 600 8 INSIDE PIPE able to detect blackness as he was 2-Control plan has been revised for with OK pcs & Yes NC Closed
3P362222-1 B not aware. verification inside blackness in tube defective pcs to
as final checking stage also. be scrapped.

1. Cut mark developed during

cutting, as collet was opened
AUXILIARY OUTLET CUT MARK IN ONE during cutting. 1. Training/Instruction to cutting Treatment can
Daikin 12-01-2015 PIPE ASSY 310 1 PCS. FOUND AFTER 2. Problem was not detected at operators and visual checking not possible. NG Yes NC Closed
3P362253-1 A 100 % SEGREGATION. our end , because piece skipped operators part to be scrap.
by visual inspector due to
negligence.
 LEAKAGE:Leakge B-we have done leak test at
from brazing joint A-During dated 23-01-2015 to 12- 25~25kgf/cm² in two way
DISTRIBUTOR ASSY. 1. Brazing joint 02-2015 one additional brazer was (i) Half portion dipping into water
23.01.2015~1 3P387228- leakage deputed to do brazing under (Distributor side)
Daikin
4.02.2015 1,3P386710-
58 4 2. Leakage due to pin brazing supervisor.It was (ii) Half portion with soap solution Rework at line Yes NC Closed
1,3P387173-1 hole cosidering to increase certified (Connector side)
3.Leakage due to brazers from 02 nos to 04 being just half leak pressure vs
Distribution pipe nos,future dispatch qty. required pressure leak was not
crack detected at our end.

1. Brazing Jig re-modify and a plate

VISUAL having marks with color code
NG:Distribution pipe sequence to remind all the time
Sequence while placing capillaries into
interchange 1.KE~KF , 1.There were no such system in
Brazing jig to remind the brazer distributor. Also horizontal Defective parts
DISTRIBUTOR ASSY KF~KG , KG~KH next color code sequence. deployment to be done for other to be taken back
Daikin 18.02.2015 3P387076-1 12 3 similar parts also. and to be again Yes NC Closed
2. 2. 100% Inspection was skipped. 2. Education & Instructions to QC dispatched after
KE~KF ,3.KD~KE (Plz refer next sheet "Counter Inspectors for not to show any lack reworking.
Measure". in inspection in case of urgent
dispatch also.
(Plz refer next sheet "Counter
Measure"

1. Minimum inventory level at

stores to be maintained.
2. Education & Training to packing,
dispatch & QC Inspector has been
1. Packing standards w.r.t. Box provided. Defective parts
DISTRIBUTOR VISUAL NG: Size & No. of Parts per Box were 3. No. of parts per box again to be to be taken back
Daikin 28.02.2015
ASSY.3P386710-1
17 4 Distribution pipe
not followed due to non-
reviewed with DAIPL and to be Yes NC Closed
crack / Pinch QC/Procurement Team, if required dispatched after
availability of boxes. existing standard of rework.
10 pcs / Box to be reduced to 05
pcs / Box and to be implemented
after approval of DAIPL
QC/Procurement.

1-Two identical parts were packed

at same table 1-Two identical parts will not be
2-OQC was done on sampling packed at same table, the same
DIMENTIONAL NG: basis, total 60 pcs were packed & education/training to packing Arrange to
Daikin 01.03.2015 DISTRIBUTION PIPE 20 20 Req Dim (ID) - 5pcs were verified found operators has been given. replaced with OK Yes NC Closed
SET 3P161929-12 C 2.5±0.3mm, Obs Dim ok.Bundle was 2-OQC inspector has been has been one
(ID)- 2.775mm
20 pcs x 3=60pcs we have verified educated/training, to collect sample
balance stock at our end & found foe each bundle.
OK
 ON SPINNING SIDE,
SPINNING AND 1.Defective pcs kept to redbin,the 1.Strict instruction & education has
PLATE FINNED COIL FLARING BOTH same system was not being been given to packing and fitment Treatment not
OPETATION DONE
Daikin 19.03.2015 OUTLET PIPE 100 1 BUT ON FLARING followed by packing operator. operators. possible.Part will Yes NC Closed
3P357272-1 SIDE FLARING 2.During sampling this defect was 2.OQC person will check 100% parts be scraped.
not seen. for visual inspection till nest 5 lots.
OPERATION NOT
DONE.

Pinch occurred due to miss

DISTRIBUTION PIPE handling. Strict Instructions to vehicle drivers Treatment not
Distribution pipe
Daikin 3.04.2015 SET 20 1 pinch Mishandling reason could not to take precaution while jurk during possible.Part will Yes NC Closed
3P184286-15 C find out, however highly the way. be scraped.
possibilities during in transit.

1-Drill process skipped. 1-Education and Instruction to Treatment

VISUAL NG : Hole 2-Operator caught the problem drilling operator/Final fitment cannot possible
during fitment, but did not keep in at DAIPL end. NG
DISCHARGE PIPE miss Req Hole : Red bin with NG sticker and part operator to keep defective part in parts to be
Daikin 08.04.2015 3P372408-1 A 20 1 6.5mm ±0.1 red bin immediately once any Yes NC Closed
Obs hole : hole mixed with ok one at packing, defect observed return back &
miss operatornegligency. drill process to
3-Part is not detected during PDI, 2-100% Sampling in OQC for next be done &
as sampling this part not detected. three lot. resend

Defective pc received & re-leak

test, but could not find at High pressure leak test set up under
25kgf/cm² for 30 sec.Only one process, Pipe line/Booster system Treatment can't
CAPILLARY TUBE LEAKAGE FROM tube come out at re-test for 60 has been installed/ 1st installment possible ,
Daikin 09.04.2015 ASSY 300 1
BRAZING JOINT. sec.
defective pc to
of coupler has been received target be returned back Yes NC Closed
3P386224-1 Such type of leak could not detect date for start up is 1st Week of
at routine process of 30 sec at 25 May-2015. & analysis.
kgf/cm²

CAPILLARY TUBE LEAKAGE FROM Leakage not detctable @25 Leakage test pressure to be
Daikin 14.04.2015 ASSY 25 1 BRAZING JOINT. Kgf/sq.cm pressure. increased up to 45 Kgf/sq.cm Rework On Line Yes NC Closed
3P393448-1
CAPILLARY TUBE
LEAKAGE FROM Leakage not detctable @25 Leakage test pressure to be
Daikin 04.05.2015 ASSY 750 1 BRAZING JOINT. Kgf/sq.cm pressure. increased up to 45 Kgf/sq.cm Rework On Line Yes NC Closed
3P386224-1

1-Problematic stock to be replaced

to supplier
2-Instruction has been given to
packing operator,line leader don't After rework has
Suction Pipe Assy 1-Supplier end problem
Daikin 07.05.2015 3P382071-1A 300 300 Putty not stick 2-Putty was not open at our end use putty Whose release paper been ok at Dikin Yes NC Closed
yellow. end
Also heat putyy by Heat Gun in
proper way to eliminate such type
of problem.
 Instruction/education to all brazers
has been given to concentrate
during part brazing to avoid overlap
Auxillary Inlet Pipe Over brazing on 1-1st Brazing operator negligency brazing on union joint and also Defective pcs to
Daikin 07.05.2015 Assy 300 2
union joint and 2nd packing operator also instructed to packing operator to
be replaced with Yes NC Closed
3P364512-1 inspect visual and marking on union OK
joint for ensuring 100% visual
inspection.

CAPILLARY TUBE
LEAKAGE FROM Leakage not detctable @25 Leakage test pressure to be
Daikin 09.05.2015 ASSY 250 1 BRAZING JOINT. Kgf/sq.cm pressure. increased up to 45 Kgf/sq.cm Rework On Line Yes NC Closed
3P386509-1 A

Treatment can't
DISTRIBUTION PIPE Leakage observed Leakage not detctable @25 High pressure leak test set up under possible ,
Daikin 11.05.2015 4P201195-1 55 1 from brass joint Kgf/sq.cm pressure. process, Leakage test pressure to be defective pc to Yes NC Closed
increased up to 45 Kgf/sq.cm be returned back
& analysis.

Strict instruction/training to leakage

testing operators to check part
CAPILLARY TUBE Leakage test was performed at more carefully. Defective pc to
Daikin 15.05.2015 ASSY 350 2 Found Leak 350psi on which leakage was not
We are going to upgrade our
be returned back Yes NC Closed
3P386509-1 A detected at our end. leakage testing facility upto 45 kgf, & analysis.
it is under process

We have displayed part Treatment can't

identification standard on line in Now we have changed sequence of possible at daikin
Capillary Tube Req. Dim.- 315±2 mm which similar parts are sequences similar part code in identification end hence
Daikin 28.05.2015
4PA51412-12 F
37 37
Obs. Dim.- 280 mm hence operator mis-reading the standard for avoid mis-reading arrange to Yes NC Closed
standard and put wrong part code replace with OK
sticker in hurry. pcs

Arrange to prepared new OD gauge

Dim-NG and provided on line, also Arrange to
Joint Tube Req Dim (OD) instructed to operators to perform
Daikin 17.06.2015 4P362972-1 A 118 39 -22.20mm±0.09mm Final gauge was wear out gauging adequetly each part replace defective Yes NC Closed
pcs with ok pcs
Obs Dim- 22.48mm properly and the same monitoring
by line leader

Defective pc received & re-leak High pressure leak test set up under
FOUND LEAKAGE test, but could not find at process, Pipe line/Booster system Treatment can't
Capillary Tube Assy FROM BRAZING 25kgf/cm² for 30 sec.Only one has been installed/ 1st installment possible ,
Daikin 17.06.2015 3P386921-1 A 40 1
JOINT DUE TO PIN
tube come out at re-test for 60
of coupler has been received target
defective pc to Yes NC Closed
HOLE. sec.Such type of leak could not date for start up is 1st Week of be returned back
detect at routine process of 30 sec May-2015. & analysis.
at 25 kgf/cm²
 We are maintaining flatness under
tolereance at manual bending 1-Instruction has been given to all
FLATNESS NG stage, but after brazing part get leakage and packing operators to
REQUIRED some more flexible, and during
Motor Operated FLATENESS 8% leakage testing part profile get take precaution while leakage and Arrange to
Daikin 18.06.2015 Valve 70 70 OBSERVED FLATNESS some disturb after charging fitment rework at Daikin Yes NC Closed
3P385436-1 2-Coupler design has been changed end
12 % AND SCRATCH pressure therefore at final fitment from TCL to Sleek to avoid slightly
FOUND ON PART. stage operator press part slightly
and put into jig for fitment hence open condition during leakage.
flatness gets increase

Defective pc received & re-leak High pressure leak test set up under
test, but could not find at Treatment can't
Capillary Tube Assy FOUND LEAKAGE 25kgf/cm² for 30 sec.Only one process, Pipe line/Booster system possible ,
17.06.2015,1 FROM BRAZING has been installed/ 1st installment
Daikin 9.06.2015 3P386932-1 A 1350 2 JOINT DUE TO PIN tube come out at re-test for 60 of coupler has been received target defective pc to Yes NC Closed
HOLE. sec.Such type of leak could not date for start up is 1st Week of be returned back
detect at routine process of 30 sec May-2015. & analysis.
at 25 kgf/cm²

Defective pc received & re-leak

test, but could not find at High pressure leak test set up under Treatment can't
FOUND LEAKAGE process, Pipe line/Booster system
Capillary Tube Assy FROM BRAZING 25kgf/cm² for 30 sec.Only one has been installed/ 1st installment possible ,
Daikin 19.06.2015 3P386223-1 300 4 JOINT DUE TO PIN tube come out at re-test for 60 of coupler has been received target defective pc to Yes NC Closed
sec.Such type of leak could not be returned back
HOLE. detect at routine process of 30 sec date for start up is 1st Week of & analysis.
at 25 kgf/cm² May-2015.

1) High Pressure line set-up &

01 PCS FOUND samples submitted to DAIPL for
Capillary Tube Assy LEAKAGE FROM approval.
Daikin 04.07.2015 3P386570-1 B 350 1 REDUCER AND Less Brazing leading to leakage. 2) Leak Check monitoring on hourly Rework On Line Yes NC Closed
CAPILLARY BRAZING basis implemented on .
JOINT.
line
 1) Classification of brazers model-
wise.
2) Brazers strictly instructed to bend
the brazing rod n then use in order
to ensure proper material flow
Leakage due improper material inside the base metal.
AUXILIARY INLET LEAKAGE OBSERVED flow inside tha base 3) Frazers given a training settion on
material.Request to DAIPL to flame setting & proper heating of
Daikin 13.07.2015 PIPE ASSY 1000 1 FROM BRAZING return the NG part for cut-off metal. Rework On Line Yes NC Closed
3P364512-1 JOINT. analysis & find root cause of the 4) Cut-off analysis for less brazing.
problem. Frequency: 5 pcs/1000 pcs. For
Detection: 1) High Pressure line
set-up & samples submitted to
DAIPL for approval. 2) Leak Check
monitoring on hourly basis
implemented on line.

LEAKAGE: Leakage The same informed to Raw Material

Distribution pipe due to crack observe Raw Material manufacturer end Supplier and ask CAPA and the
Daikin 20.07.2015
3P161930-11 C
1000 1
in tube ( Crack length problem same countermeasure to be
Reject Yes NC Closed
upto 15mm) submitted to you

1-Now quality alert generated for

1-Copper collected during making the same problem and display on
CUT MARK part on machine due to some line and also 100% visual inspection
AUXILIARY OUTLET OBSERVED .( 1 PCS chips stick on to die and make a has been started before brazing
Daikin 20.07.2015 PIPE ASSY 700 1
AFTER 100% deep line on branch pipe
2-Strict instruction has been Reject Yes NC Closed
3P362253-1 A provided to tube header making
SEGREGATION ) 2-Defective pcs get mixed with ok
pcs during part production operator to don't keep such type of
pc on table immediate put it in red
bin to avoid mixing problem
 Doc No-QMS-F-11

ISPM CUSTOMER DEFECT RATE 2015(SIEL REF) Rev No/Date

03/01-08-11

200.00

180.00

160.00

140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
1 2 3 4 5 6 7 8 9 10 11 12

Goal 100 100 100 100 100 100 100 100 100 100 100 100
PPM 6.62 0.00 2.68 0.00 0.00 2.75 8.72 0.00 3.21 0.00 0.00 0.00
Percentage 0.07% 0.00% 0.03% 0.00% 0.00% 0.03% 0.09% 0.00% 0.03% 0.00% 0.00% 0.00%
NG Qty 2 0 1 0 0 1 2 0 1 0 0
Dispatch Qty 302316 406412 373175 413198 387057 363188 229420 292513 311212 212490 65931
Month Jan Feb March Apr May Jun Jul Aug Sep Oct Nov Dec

PREPARED BY VERIFIED BY APPROVED BY

 Doc No-QMS-F-11

ISPM CUSTOMER DEFECT RATE 2015(SIEL REF) Rev No/Date

03/01-08-11

200.00

180.00

160.00

140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
1 2 3 4 5 6 7 8 9 10 11 12

Goal 100 100 100 100 100 100 100 100 100 100 100 100
PPM 0.00 0.00 0.00 0.00 5.21 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Percentage 0.00% 0.00% 0.00% 0.00% 0.05% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
NG Qty 2
Dispatch Qty 384234
Month Jan Feb March Apr May Jun Jul Aug Sep Oct Nov Dec

PREPARED BY VERIFIED BY APPROVED BY