Format No.

KCEI / CAR / 01
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE October 27, 2017

CELL 7411203744
Referance
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad,Arun,Dinesh,Ravi Kumar

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # YN03P02712P1 Part Desc. Bracket Assy. QTY. 20Nos

Supplier ACE

1)Flatness out by 3mm

2)Mounting Block taper

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
1) Segragated at Customer end,parts are having problem QA
2) Replacement Done Qty.20Nos 16-Nov-17

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause

1)Part made Manually Without Fixture

Root
Cause

100% Inspection Not done to check the flatness

Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.
 1 Fixture made to control block taper welding QA 17-Nov-17

D6 Implement & Validate Best Permanent Corrective Action Plan

Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.
Parts made with fixture Qty 5nos and inspected found Ok.Same lot Qty 20 nos Supplied to
Kobelco dated 21/11/17 and accepted. QA 17-Nov-17

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow Waseem 17-Nov-17

PFMEA Waseem 17-Nov-17

Control Plan Waseem 17-Nov-17

Poka-Yoke

Drawing

PPAP

Horizontal Deployment

Work instruction

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Shakti Prasad Waseem Pasha Ajay mourya

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI
 Format No. KCEI / CAR / 02
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE October 27, 2017

CELL 7411203744
Referance
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad,Arun,Dinesh,Ravi Kumar

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # LC21C04562P1 Part Desc. Cover QTY. 10Nos

Supplier ACE

1)Wrong Color top coat , Observed Blue Green, Required One coat enamel black

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
1) Segreated at KECI Qty 10 nos found Not Ok.Checked at ACE no stock Available. Mahesh
27-Oct-17

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause

Work Insrtuction not Available

Root
Cause

Inspection not done.

Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.

Parts Colour shade displayed @ workstation with colour print outs .Same Point added in
2 Mahesh 28-Oct-17
PDI
D6 Implement & Validate Best Permanent Corrective Action Plan
Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.

Painted 10 samples after training & found OK. Mahesh 28-Oct-17

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow
PFMEA

Control Plan

Poka-Yoke

Drawing

PPAP

Horizontal Deployment
Work instruction Mahesh 28-Oct-17

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Prasad Waseem Ajay Mourya

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI
 Format No. KCEI / CAR / 03
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE October 12, 2017

CELL
Referance
KCEI-2016-1704
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad,Arun,Dinesh,Ravi Kumar

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # YN17M01709P1 Part Desc. Cover QTY. 25Nos

Supplier ACE

1)Wrong Bending Of Plate.

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
1) Segreated at KECI Qty 25 nos found Not Ok.Checked at ACE no stock Available. Waseem
Replaced Defective Qty 25 nos dated 13/10/17 12-Oct-17

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause
1)Drawing Confusuion, Top view and Right View Mismatch, & Bending Line not provided in drawing.

Root
Cause

These 25 samples made Ok by KCEI SQA Person Mr.Gajendra

Escape
Point
 Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.

1 Requested to update drawing Views KCEI

Made 25 samples as instructed by mr.Ajay Mourya and supplied its is accepted.According

2
to this we have made master sample to bend for next batch.

D6 Implement & Validate Best Permanent Corrective Action Plan

Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow

PFMEA
Control Plan

Poka-Yoke

Drawing

PPAP

Horizontal Deployment

Work instruction

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Prasad Waseem Pasha Ajay Mourya

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI
 Format No. KCEI / CAR / 04
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE October 24, 2017

CELL
Referance
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad,Arun,Dinesh,Ravi Kumar

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # YN25M01168P1 Part Desc. Seat,Stand QTY. 2Nos

Supplier ACE

1)Nut taper welded

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
1) Segreated at KECI Qty 2 nos found Not Ok. QA
24-Oct-17

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause
Nut welding done by plane/round Sockets.

Root
Cause

100% Inspection not done.

Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.
 1 Nut Socket with Threaded Head Implemented Qa 26-Oct-17

D6 Implement & Validate Best Permanent Corrective Action Plan

Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.

1 Given instruction to the operators to use threaded Sockets for All types of Nuts QA 26-Oct-17

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow

PFMEA

Control Plan

Poka-Yoke

Drawing

PPAP

Horizontal Deployment

Work instruction Waseem 26-Oct-17

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Prasad Waseem Pasha Ajay Mourya

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI
 Format No. KCEI / CAR / 05
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE 15-11-2017

CELL 7411203744
Referance
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # Part Desc. All parts QTY. NA

Supplier ACE

1)) All Painting Parts: Tapping Issue

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
Segregated & All Painting Rettaped at KCEI Mahesh
16-Nov-17

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause
Nut is not covered with any Rubber plugs during painting

Root
Cause

inspection not done

Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.
 Implemented Rubber Plugs to nuts during painting proces & Implemented 100% tapping
Mahesh 16-Nov-17
for All Painted Parts

D6 Implement & Validate Best Permanent Corrective Action Plan

Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.

1 Work instruction provided to the operators to use the Plugs to cover the Nuts Mahesh 16-Nov-17

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow

PFMEA

Control Plan
Poka-Yoke

Drawing

PPAP

Horizontal Deployment

Work instruction Mahesh 16-Nov-17

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI

 Format No. KCEI / CAR / 06
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE November 16, 2017

CELL 7411203744
Referance
KCEI-2017-1904
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad,Arun,Dinesh,Ravi Kumar

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # YN22E01388P2 Part Desc. Plate QTY. 200Nos

Supplier ACE

Bending position wrong

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
1) Segreated at KECI Qty 200 nos found Not Ok.& Checked @ ACE ZERO Stock. QA
2) Replacement Done Qty.200Nos 17-Nov-17

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause

Operator Error.(Part loaded in Reverse direction)

Root
Cause

Samling Inspection Not done

Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.
 To Avoid the reverse orientation Implemented Engraving Mark on the part to identifiy
1 bending orientation. QA 18-Nov-17
Setup approval Updated.

D6 Implement & Validate Best Permanent Corrective Action Plan

Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.
Parts made with Engraving Mark Qty 100 nos and inspected found Ok.Same lot Qty 100
nos Supplied to Kobelco dated 17/11/17 and accepted. QA 17-Nov-17

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow Waseem 18-Nov-17

PFMEA Waseem 18-Nov-17

Control Plan Waseem 18-Nov-17

Poka-Yoke

Drawing

PPAP

Horizontal Deployment

Work instruction

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Shakti Prasad Waseem Pasha Ajay mourya

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI
 Format No. KCEI / CAR / 07
Rev. No. 1
G8D No.

CORRECTIVE ACTION REPORT DATE 28.11.2017

CELL 7411203744
Referance
KCEI-2017-1997
Report No.

D1 Form the Team (Establish a team of people with product/process knowledge)

Team Leader : Waseem Pasha Team members : Sunilkumar,Shaktiprasad,Arun,Dinesh,Ravi Kumar

D2 Problem statement (Specify the problem by identifying in quantifiable terms)

Part # LC72E01049P1 Part Desc. Plate QTY. 96 Nos

Supplier ACE

Nut not Enter in stud M10X1.5, Poor entry chamfer, thread Damage

Problem

D3 Containment Action / Interim Action (Select an interim containment action)

Varification / Validation--> Considering whether Customer is protected or not+A33
Sl. No. Action Resp. Target Dt.
1) Segreated at KECI Qty 96 nos found Not Ok.& Checked @ ACE ZERO Stock. QA
2) Replacement Done Qty.96 Nos 28.11.2017

D4 Find and verify Root cause(s)

Develop potential root cause list. Verify the Root causes one by one.
Identify the control point capable of detecting the problem.
Sl. No. Cause

Transit damage
Root
Cause

Escape
Point

D5 Corrective Action(s)
(Select Permanent Corrective Action plan)
Verification--> What evidence do you have that this will resolve the problem at the
root-cause level?
Sl. No. Corrective Action Plan Resp. Target Dt.
 1 To over come this Issue Implemented Nut /tightened the nut on the Bolt. QA 28.11.2017

D6 Implement & Validate Best Permanent Corrective Action Plan

Develop an action plan for implementation. Discontinue the interim containment action
Sl. No. Corrective Action Implementation Resp. Target Dt.
Same procedure Implemented as tightening the bolt on the threaded surface and
QA 28.11.2017
dispatched to KCEI dated 9/11/17 & Accepted.

D7 : Preventive Recurrence / Standarisation ( Identify what allowed problem to occur

and escape. Modify the applicable documentation, operation systems, practices and
procedures to prevent recurrence of this and all similar problems
Not
Related Document Updation Yes No Resp. Target Dt.
applicable
Process Flow Waseem 28.11.2017

PFMEA Waseem 28.11.2017

Control Plan Waseem 28.11.2017

Poka-Yoke

Drawing

PPAP

Horizontal Deployment

Work instruction

D8 Congratulate the team

Monitor the effectiveness of all the above action taken & IMPLEMENT Internal quality audit also. Congratulate the Team

Periodic audit is carried out to check the given solution/Corrective action is effective.

Shakti Prasad Waseem Pasha Ajay mourya

Prepared by (Supplier) : Closed / Approved by (Supplier): Final Approval : Head QA - KCEI