8 - DISCIPLINE REPORT

Customer Concern Number: 053023

Customer Part Number: N/A
Vintech Part Number: 52-9000

1. Team 2. Problem Description Photo(s) /Sketch/Print Section:

a) Problem / Concern:
(Clearly state the problem or concern in one sentence: What is
(1A) Team Contact: the deviation with what part or product)

Name: Venkatesh Palaniappan

Tape sticking to liner
Phone: 905-820-6847
b) Problem Description:
Champion: Venkatesh Palaniappan (Please answer all the questions even with "I don't know)
What: Adhesives is not exposed
Team Members: Venkatesh (Quality), Rajan (Quality), Rui (Production
Team), Amit (Operator)
Why: Liner & adhesive are not fully separating
(1B) Status:
When:
Date Open: 2023-05-30
Where: Customer (Vintech Plastics) location
Status Date: 2023-05-31
Who: Vintech customer
Next status due date: 2023-06-14
How Found: While removing the liner from adhesives
(1C): Concern Initiator:
How Big: Don't Know
Name: Terri Lebow

Phone: 810.724.7400 Is this a repeat issue? Yes No

✘
3. Emergency Response and Containment Action Assignee: Target: Complete? Results:
Issued a quality lock on the machine for upcoming
Created an Non-conformance report (NCR# 202300592) Venkatesh 2023-05-30 Yes production run
Verify the in-house stock Venkatesh 2023-05-30 Yes Zero quantities available on the inventory shelf

Remark: Containment actions can only be removed after the corrective actions have been implemented and their effectiveness has been verified

F-10 Page 1 of 9 Rev. 9; 5/18/22

Retention: 20 Years
 8 - DISCIPLINE REPORT
Customer Concern Number: 053023
Customer Part Number: N/A
Vintech Part Number: 52-9000
4. Root Cause
Cause for Occurrence: Method of Root Cause Verification

Material 9495LE brown liner consists of two layers (silicone & paper). During the machine setup, MTA operator applied a slightly
excessive pressure on the rotary blade, during machine setup. As a result, the blade created a dry edge and penetrated through
the first layer of the liner.
Replicated the problem on the die-cut machine by applying
a slightly excessive pressure on the rotary blade, and we
confirmed that the issue can be reproduced internally
Cause for Escape:
Operator missed to inspect the pieces after the dry edge process step

6. Verification
5. Corrective Action
Responsibility: Target: Completed: Method: Result:
- Quality Alert has been issued to raise awareness about the issue and take
necessary actions to prevent similar occurrences and ensure product quality.

- A quality lock has been put in place, preventing the operators from producing the
product until the issue has been assessed and reviewed by the Quality team or Venkatesh / Rui
Production supervisor. Machine parameters will be reviewed by production 2023-06-05 2023-06-05 Satisfactory
/ Brian
supervisor, before the run.

- To address the issue, work instruction in the production ticket has been updated for
the operators to inspect the random pieces by pulling the dry edge tab.

7a. Effectiveness of Corrective Action Responsibility: Target: Completed: Method: Results:

- Quality lock is working as intended and no issue has been observed in the last
production build (8th June 2023)
Rajan / Amit 2023-06-08 2023-06-08 Visual Satisfactory

7b. Prevention Responsibility: Target: Completed: Method: Results:

Increase the frequency of inspection / Second inspection station to be aware of this
issue and add it to their list of checks. Highlighted the issues on PFMEA and Control
Plan. Visual
Rui/ Amit 2023-06-08 2023-06-08 Satisfactory

F-10 Page 2 of 9 Rev. 9; 5/18/22

Retention: 20 Years
 8 - DISCIPLINE REPORT
Customer Concern Number: 053023
Customer Part Number: N/A
Vintech Part Number: 52-9000
Documents updated:
Documents: Date Updated: Initial when complete:
Layered Audit
✘ Work Instructions 2023-05-30 Ven
✘ Control Plan 2023-06-06 Ven
✘ Pfmea 2023-06-08 Ven
Process Flow
Maintenance Records
Lessons Learned
Plex
✘ Other (Please list) Quality Alert - 2023-06-0 Ven
Other (Please list)

Read Across to Other Areas/Products:

Date Provided to
Can this apply to: Yes No If yes, which product/process? Action if yes
Contact

Other products for this customer ü Review with Quality Engineer

Similar products ü Update Global Lessons learned

Process-specific PFMEA and CP to be updated by Manufacturing

Similar processes ü
and/or Quality
8. Team and Individual Recognition Reported By: Close Date:
Comment:
We want to acknowledge the dedication and meticulousness of our production team in addressing the issue during last production
run

F-10 Page 3 of 9 Rev. 9; 5/18/22

Retention: 20 Years
 8 - DISCIPLINE REPORT
Customer Concern Number: 053023
Customer Part Number: N/A
Vintech Part Number: 52-9000

Ishikawa Diagram Legend:

Root Cause
Material Machine Man

Problem

Method Measurement Environment

F-10 Page 4 of 9 Rev. 9; 5/18/22

Retention: 20 Years
Quality Lock on Machine:

Quality Alert:
 Production Ticket - work instruction:

PFMEA & Control Plan Attached in a separate document

n Ticket - work instruction: