Doc No.

8D Report Rev. No.

Name of the Customer : New Lord Nigeria. Commissioning Date :

Product Model : Falcon 8500 Date of Issue Occurred:

Rating : 100kva Date of Issue Closed:

Product Sr. No : P1201943126333 Initiated By :

CRM No. : Department:

Cross function team members

Team Members

Name Department Email Contact No.

Mr.Mukund Hajare Quality
Mr.Amol Gaikwad Testing
1 Mr.Suraj Pratap Singh Quality

Mr.Mukund Gavate Testing

Mr.Nitin Kumawat Production

Description (Describe issue in terms of what, where, when and how many)
Problem Description

2
 What : Wrong setting-During parameter change value put 100 instead of 1000 in nominal setting. Due to this system rating changed fr

Problem Description
Rated current value & KW value is properly set.

Where : Newlord Nigeria

2 When: During Installation

Who: Service Engg.

How Many: 1

What actions were taken to immediately protect the customer.

Responsible /Target
Interim Containment

Mr.Swapnil G
On Site Service engg changed count as per System rating.

3
Actions taken on suspected inventory.Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)

We cheked all unit on shop floor & dispatched system (advance setting file) after complaint received. Found 1 defect as per recvived

Sorted Qty : Defect Qty :

40 1 -
 ROOT CAUSE

Why Made Why missed

Why 1: Wrong setting-During parameter change value put 100 instead of 1000 in nominal Why 1: Wrong setting-During parameter c
setting. Due to this system rating changed from 100KVA to 10KVA instead of 1000 in nominal setting. Due to
from 100KVA to 10KVA
Why 2: System divert from 120KVA to 100KVA.
Why 2: After conversion advance setting
Why 3: During system conversion Nominal setting count placed 100 instaed of 1000. system.

Why 4: Typing error by engineer. Why 3: Advance setting file not compare

Why 5: Why 4:

Root Cause Obtained from Why Why Analysis: Why 5:

After conversion from 120KVA to 100KVA system Setting file not checked.
Root Cause Obtained from Why Why Ana

4 After conversion from 120KVA to 100K

Root Cause

setting file not compared with Master f

Fish Bone
Man Method Material Measurement
 Root Cause Obtained from Fish Bone:

ROOT CAUSE :
Permanent Corrective
Corrective Action
Corrective Action Responsible /Target
Action

5 1) After rating changed get advance setting of particular system & compare with Master
file(changes done through DC source as discussed with Desgin Team).
2) OQA engg verified the Master file PDF comparison file.
1) Amol G. 23-06-20
2) Suraj S. 23-06-20
3) Test report - Output current need to mention for both rating i.e. 100/120, 250/300kVA, 3)Mukund Gavate/Amol G.
60/80kVA(7K) no tick mark. 4)Mukund Gavate/Amol G.
4) Manual - No tick mark on rating for MSL system

Verification of Corrective Action

Verification

6 Above corrective action stated filled and verified. For current systems only Specification and Engrave name plate stickers will be chang

Preventive action :
Preventive Action Responsible /Target
n
 1) All Stickers i.e. Engrave name plate/QR code/Specification Sticker - Remove kVA rating.
1)Atul Gawande - 01-08-20
2)Warranty certificate is now generated from SAP, Remove from Manual & Test report(We
2)Sagar Bari - 01-08-20
provide test reports on demand.)
3)Amol Kulkarni
Prevention

3)Setting guidelines need to add in commissioning procedure

7
Affected Document Owner for Update Completion status
Workmanship Std. Mr.Atul Gawande Open
Work Instructions / SOP Mr.Amol Kulkarni Open
Has the necessary documentation QAP / ML
been updated?
Process Flow
Drawing Mr.Sagar Bari Open
Aspect Impact / HIRA
Risk Assessment Register Mr. Atul Gawande Open
Closure Statement (Validation)
Closure

8 Containtment actions are already taken at site and system made operational and same is working in normal condition , corrective actio
closed as per Target date mentioned above.
 QA.FQ.FO03
0

6/11/2020

6/11/2020

6/16/2020

Mr.Amol Kulkarni
Service

Contact No.
em rating changed from 100KVA to 10KVA.

Status

Closed.

ect as per recvived complain.

 -During parameter change value put 100
minal setting. Due to this system rating changed
VA

ion advance setting file not taken of this

ng file not compare with Master file.

d from Why Why Analysis:

m 120KVA to 100KVA system advance
pared with Master file.

Environment
 Status

1) Closed
2) Closed
3)Immediate for MSL
4)Immediate for MSL

stickers will be changed as per SO.

Status
 1 & 2) Open
3) 20-07-20

Date
1-Aug-20
1-Aug-20

1-Aug-20

22-Jul-20

tion , corrective actions will be taken and