Doc No. MTP/QAD/FM/38 CC /IC No. - Part No.

CC /IC No. - Part No. & Name CAAAA00000003643/644 & Front Map Pocket LH/RH Prepared By Reviewed By Approved By
Detailed Root Cause Analysis Report (8D Report) Rev NO 3 Phenomenon Model & Customer S201 & MATE

Phenomenon Occur 1st time √ Phenomenon Occur 2nd time Phenomenon Repeat (Yes/No) No Rev Date 26.12.2019 Batch Code CFT Member List:-

Step 1 (Problem Description ) Step 2 (Process Flow Diagram) Step 3 Immediate Action (Within 24 hrs of defect noticed)

Occurence Parts Checked at Date Checked OK NG Batch Code Id mark on OK Remarks

location Qty.

INJECTION PREDRYING
RM STORAGE & RAW MATERIAL Customer End (MATE) 07.07.2022 2500 2493 7 09.06.2022 OK
Please add Ok part MOULDING MATERIAL FEEDING
INSPECTION
Please add Defeictive
part picture with clear picture with same Marking provide on short
IN-HOUS (NPP) 08.07.2022 415 415 0 09.06.2022 OK
identification of defect angel as in defective mold area.
part

FPA Inprocess FINAL PACKING &

Inspection INSPECTION LABELLING

NOT OK OK Non Detection FG STORAGE

Details :
Customer Voice:- Short Mold Observed.
MATE Definition:- Explain the problem in 5W,1H
'What' is the problem (Defect)- Short Mold PRE DELIVERY
'Where' the problem detected-At MATE DISPATCH INSPECTION
'When' the problem detected-During Incoming Inspection
'Who' detect the problem- IQA Inspector
'Why' issue is highlighted (Purpose)- Short mold observed at fittment area.
'How' Much (Quantity)- 07

Step 4 CAUSE ANALYSIS (INSPECTION OVER LOOK /DEFECT OUTFLOW) Step 5 (Cause validation of outflow ) Why - Why Analysis
(Timeline for root cause analysis within 5 Days of concern raised and for Rare Claim within 3 Days of concern raised)

Cause Specification Observation Status (Yes/No) Why Why Why Why Why
MEASUREMENT
MACHINE
MAN
Man Operator Negligency Operator should be aware about this defect. Operator has known about this defects yet not arrest at moulding stage. Yes
Operator negligency.

Operator as well as inspector should be aware about Short mould parts observed at Parts skipped by Operator as Only sample basis insp.was done
Man Short mould part skipped by Operator as wel as inspector. this defect. Operator has known very well about this defect bt due to negligency parts skipped by Operator. Yes customer end. well as by final inspector. by Final inspector.

Short mold part

skipped by Process monitoring should be done on defined
Operator as well Method Process parameter not cross verified after restart the machine periodic basis. Process monitoring observed ok. Yes
as inspector

Short mold

Process parameters not

cross verified after
restart the machine.

ENVIRONMENT METHOD MATERIAL

Step 6 CAUSE ANALYSIS (Occurrence) Step 7 ( Cause Validation Of occurrence) Why - Why Analysis
(Timeline for root cause analysis within 5 Days of concern raised and for Rare Claim within 3 Days of concern raised )

MAN Cause Specification Observation Status (Yes/No) Why Why Why Why Why
MEASUREMENT MACHINE

Barrel Machine Barrel Temp.low Barrel temp.should be as per SPPS Barrel temperature observed ok. Yes
temprature Low
Machine Machine parameters are not set as per SPPS Machine parameters should be set as per SPPS Machine parameters observed ok as per SPPS Yes
Machine parameters
are not set as per
SPPS Method Parts not verify after power restart up. Part should be verify after power restart. As it is parts kept in ok box, not verify as like fpa. Yes

Method Restatr up parts kept on table. Restart up initial parts should be kept at Red bin After restart up parts observed on table & that parts mixed in ok parts. Yes No checkpoint was added in QA
area. checksheet.
Short mould

Part not verify after

machine re-start.
Re-startup part kept on
working table.

ENVIRONMENT METHOD MATERIAL

Step 8 Countermeasure taken (Against Outflow ) Step 9 Counter measure taken (Against Occurrence)
(Timeline for temporary action within 2 Days of concern raised) (Timeline for temporary action within 2 Days of concern raised) Step 10 Standardisation Step 11 Horizontal Deployment (After 3 months of effectiveness monitoring)

Status Status Sr. Status Status

Applicable
Sr. No Temporary action Responsibility Target Date (Open Sr. No Temporary action Responsibility Target Date (Open No. Document Timeline (Yes/No) Responsibility Target Date (Open Part Name Part Number Machine/Area Responsibility Target Date (Open /Closed)
/Closed) /Closed) /Closed)

1 OPL/Q-Alert display at work station. Sumed 09.07.2022 Closed 1 Restart up parts start to keeping seperatly. Sumed/Nilesh 09.07.2022 Closed 1 Process Flow Diagram After Root Cause Analysis No

2 Training provided to Operaotr as well QA Sumed 08.07.2022 Closed 2 PFMEA After Root Cause Analysis No
2 Restart up parts checkpoint added in FPA reports. Sumed/Nilesh 09.07.2022 Closed
inspector.

3 Control plan After Root Cause Analysis No

Timeline for Permanent action within < 30 business days of concern raised and Timeline for Permanent action within < 30 business days of concern raised 4 Q Alert Within 4 hrs YES Mr. Sumed Tayade 09.07.2022 Closed
for Rare Claim within < 20 business days for Rare Claim within < 20 business days

Status Status
Sr. No Permanent action Responsibility Target Date (Open Sr. No Permanent action Responsibility Target Date (Open 5 SOP After Root Cause Analysis No
/Closed) /Closed)

Same day(Warranty,customer),
6 Progress control sheet 2nd Week of every No
After every power failure start to revised FPA sample & reject first 3 month(Inhouse)
1 100% inspection started with marking Sumed 09.07.2022 Closed 1 Sumed / Nilesh 09.07.2022 Closed
shots monitoring started.
Same day(Warranty,customer),
Past Trouble data
7 Updation 2nd Week of every No STEP 12 Check Effectiveness
month(Inhouse)
8 FPA As & when required YES Mr. Sumed Tayade 09.07.2022 Closed Month 1 Month 2 Month 3 Month 4 Month 5 Month 6

9 AIS After Root Cause Analysis No

10 Setup check sheet After Root Cause Analysis No

PM Machine check
11 After Root Cause Analysis No
sheet
12 Inspection report After Root Cause Analysis YES Mr. Sumed Tayade 09.07.2022 Closed

Process parameter
13
sheet
After Root Cause Analysis No STEP-13 Please Circle Appropriate Root Cause allocation

14 RIS After Root Cause Analysis No

Technical know how

15 document After Root Cause Analysis No
MAN MATERIAL MACHINE METHOD MEASUREMENT ENVIRONMENT
16 Lesson learnt After Root Cause Analysis YES Mr. Sumed Tayade 09.07.2022 Closed

17 Drawings AS & when required

 QUALITY ALERT
COMPLAINT DATE 07.07.2022 PART NO CAAAA00000003643/644
CUSTOMER MATE Nashik PART NAME Front Map Pocket
MODEL - DEFECTIVE QTY 7
INHOUSE - CUSTOMER END √
Complaint Detail : Short mould observed in part.
NOT OK PART OK PART

PREPARED BY: Mr. Sumed Tayade APPROVED BY: Mrs. Suprabha Jadhav

NPP/F/QA/04 REV NO:00 REV DATE:21.12.2015

 ONE POINT LESSON
Short mold issue reported at MATE (Nashik) in Front Map PART NO/NAME: Front Map Pocket LH/RH.
THEME
Pocket LH/RH. DATE: 07.07.2022
BASIC KNOWLEDGE PREPARED BY: Mr. Sumed Tayade
CLASSIFICATION IMPROVEMENT CLASS APPROVED BY: Mrs. Suprabha Jadhav
TROUBLE CLASS THEACHER: Mr. Sumed Tayade

NOT OK OK

KNOW WHY:
NAME
SIGN
NAME
RECORD OF LESSON
SIGN
NAME
NPP/F/QA/03 REV NO:00 REV DATE:21.12.2015
 RECORD OF LESSON

SIGN

NPP/F/QA/03 REV NO:00 REV DATE:21.12.2015

 Doc no - MTP/Qalert/FM/001
QUALITY ALERT & EFFECTIVENESS MONITORING Rev no. - 2
Original date - 20.02.2018

(Customer complaint /Warranty /In-house)

Product Name: Kite Resonator Duct Assembly New/Repeat : New Customer: TML, Sanand Process Name : Blow molding & Assembly

Complaint received date: 25.06.2018 Date of root cause analysis: 26.06.2018 Date of CAPA implementation: 27.06.2018 Quantity: 2

Problem description: Loose fitment observed in Kite Resonator duct assembly at TML

Root cause analysis: No special requirement from customer for loose fitment issue & Part thickness variation observed 1.64 to 3.37mm against specification 2.5 ± 1 mm

Countermeasure taken: 1) Awareness training regarding loose fitment of Kite duct issue given to all the assembly operators
2) Limit sample displayed at assembly station
3) Q-Alert displayed at assembly and inspection stations
4) Awareness training regarding loose fitment of Kite duct issue given to all the inspectors

OK NOT OK
Effectiveness Monitoring

EM Start Date 25.06.2018 EM End Date

Effectiveness monitoring - Quantity : ………………2529 / 3 Months :
Customer Rejection

Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Prdn Qty (M1)

Rej.Qty

Prdn Qty (M2)

Rej.Qty

Prdn Qty (M3)

Rej.Qty

Prdn Qty (M4)

Rej.Qty

In-house Rejection

Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Prdn Qty (M1)

Rej.Qty

Prdn Qty (M2)

Rej.Qty

Prdn Qty (M3)

Rej.Qty

Prdn Qty (M4)

Rej.Qty

Supplier Rejection

Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Prdn Qty (M1)

Rej.Qty

Prdn Qty (M2)

Rej.Qty

Prdn Qty (M3)

Rej.Qty

Prdn Qty (M4)

Rej.Qty

Name Sign Name Sign Name Sign 4M Allocation

1 5 9
1. MAN 3. METHOD
 5. MEASUREMENT

2 6 10

3 7 11 2. MACHINE 4. MATERIAL 6. ENVIRONMENT

4 8 12

Rev No. Rev Date Reason for Rev Rev No. Rev Date Reason for Rev

0 01.01.2013 New release

1 21.10.2015 Effectiveness monitoring cells arranged , added date & qty

2 20.02.18 Effectiveness monitoring added for In-house Rejection & Supplier Rejection