Issue Details :- Tata body Cable inner hard movement

Tata body Cable - 542481106010

Location - TATA Line
100 nos inner hard movement Cut Outer
found by operator
Issue Date - 05.01.2024
Containment action

ACTIVITIES Remarks

1. 100% Check all suspected material. Done

Analysis of NG part

Specs - Outer dia Spec - 5±0.1 Specs -Spring OD Spec - 4+0.1 Specs-No of coils spec -51~56

Observation - Observed 4.92 Observation -Observed 4.02 Observation-Observed 52

Result- FOUND OK Result-FOUND OK Result-FOUND OK

Fishbone Diagram : Probable Cause Identification
:

METHOD MAN

Chamfer extra Set up approval New Operator Unskilled operator

material go into outer not done correctly

Inspection not
done as per std.
Tata body
Cable inner
hard
Foreign particles in Burr in Casing cap Machine movement
during crimping Parameter NG Spring od u/s
Linear RM
Inner od
oversize Linear id U/S No of coils high

MATERIAL
MACHINE
Potential Cause Validation

S. No Category Potential Cause How to validate Status

Unskilled operator We checked the training record for

1 Man Not Valid
Suresh skilled Level 4 Operator

2 Man New Operator No new operator deployed as per data Not Valid

Chamfer extra material

3 Method go into outer No chips found in linear Not Valid

Inspection not done as After do gemba visit we found operator doing

4 Method Not Valid
per std work as per Work Instruction
Set up approval not
5 Method done correctly Setup found ok Not Valid

Foreign particles in
6 Material Checked and found As per specification Not Valid
Linear RM

7 Material Inner od oversize Found As per specificatio Not Valid

Potential Cause Validation

S. No Category Potential Cause How to validate Status

Burr in Casing cap

8 Material during crimping No burr found in analysis Not Valid

Machine Machine Parameter found ok as per Setup

9 Machine Parameter NG Not Valid
sheet

10 Machine Linear id U/S Linear id Found ng Valid

11 Machine Spring od u/s Spring od found ok Not Valid

12 Machine No of coils high No of coils found as perspecification Not Valid

Why - why analysis for causes & detection

Cause of concern Cause of non-detection

WHY ? Tata body Cable inner hard WHY ? Hard movement Part found at tata line .
movement .
WHY ? Linear id found under size . WHY ? Inspection not done as per std in mfg area
negligence of inspector .

WHY ? Extrusion machine produce under size WHY ? Over burdon on operator 2 Manpower
part operate 17 m/c

WHY ? Sizer was not clean proper WHY ? Hr Management Policy

WHY ? Size cleaning instruction and frequency WHY ?

not defined
Permanent Corrective Action & preventive Action .
S.no Action Taken Resp. Target Date Status
1 Training Provided to operator Satbir & 05.01.2024 Done
Mahinder –
Production
2 Sizer clean Frequency checksheet Made Pankaj 05.01.2024 Done
Thank You!