Explanation Topics:
Defect
1 QIC No.
2 Problem Description
3 Analysis
4 Root Cause Analysis
5 Countermeasure
6 Reoccurrence Prevention
Oral complaint informed by Saurabh & Naki san
Qty
Flash noticed in O Ring 43.5 X 2.3 (91301-K0N-D020-M2
Flash noticed in outer & inner diameter - NG
Inspection Method & Inspection parameter not enough
No rule defined in procedure for flash projection.
Less awareness of part criticality to Jayashree team.
Occurrence:
1. Flash projection level is included in the deflashing work instruction.
2. Implementing the automatic deflashing process for tear trim mould.
Outflow:
1.OPL is displayed in the visual inspection table.
2.Defect check point (Flash thickness & Flash projection) added in the final inspectio
instruction.
3.Part was twisted by hand from outer to inner side and do the visual inspection for c
areas.
1.For establishing Inspection method, New process, New Development scientific me
Risk assessment / process characteristics study etc. will be followed & Management
done.
2.Daily work Management for Supervisor, Department manager prepared & Manage
will be done on periodic basis.
3.Relook into all process for process guarantee & identify gaps as per SQM. Improve
gap points plan will be made.
4.Structured & Layered process audit by management started to capture all process v
gaps.
5.Product Audit will be conducted to confirm variation in parts periodically.
 1no.

-M2

work instruction.
ear trim mould.

on) added in the final inspection work

do the visual inspection for coverage the all

w Development scientific method such as

l be followed & Management review will be

manager prepared & Management review

ify gaps as per SQM. Improvement for all

started to capture all process variation &

in parts periodically.
1. Process flow with block diagram – mark with red color where the flash is generated
2. Process wise gap to be identified where the flash generation and the controls on that stage
3. Same as 2 deflashing staging – on the basis of control , why it is not removed , gaps
4. Same as 2 at inspection stage – on the basis of why it is not noticed and control , gaps
5. Mould maintenance activity as per format shared earlier
6. Moulding stage flash addressed or not why
7. Make report for flash thickness and height , as the drawing calls for both
8. Is there any check points available at the molding stage
9. Is loose flash addressed in the process or not , if addressed in which stage
10. Mould bend check report to be added
Completed
Completed
Completed
Completed

Completed
Completed
Completed
 Particular Area #1 Area #2 Area #3
Depth of Short fill 0.26 0.32 0.41
Length of short fill 1.83 2.46 5.23
All dimn. are in mm
Slide No.
4

5.1

5.2

5.3

7.1

7.2

9.1

9.2

9.3

11.1

11.2
11.3
11.4

13

14
 Open points
Oral complaint to be removed

Is the layout is as per mould conditions

WI for inspecting the flash level – available or not available

If the flash checked on PP then pictures of parts with flash

Have you verified any mould offset , ie guide pin worn out, maintenance of mould is it OK, check
sheet to be made as per the previous RPC check sheet
Add mould pictures in the ppt – to know any damages in the flash groove ( if it is tear trim then why
flash not completely removed by hand
Where is the our inspection report – to be added in the ppt – you shared the work instruction for
flash measurement
Mould maintenance check sheet – this is horizontal deployment of previous RPC issue
Since previous PRC is related to flash and this is also flash we have to check the mould flatness
( bend)

As per our process the flash will generate, but to be controlled thru deflashing and inspection
process.What and why gap in the deflashing process ( explain) where is the simulation study report

Have you defined what is proper, improper deflashing, why it is not differentiated

In drawing the allowable flash thickness and projection are provided, how it is get transformed in
the inspection process, check method – if not why this was not addressed

Based on previous slide comments the Occurrence parameter to be added here

Do not provide third party name here – is it possible to add the check method here

How much it costs for the inspection at third party

Is it possible to inspect all future lots
If it is for one time, how r v going ensure in future lots

Why there are few cavities showing you the flash, and rest you are saying zero flash, why you could
not able to maintain the zero flash in few cavities. What is the reason, when it will reach the
alaram limit , how do you monitor the same and detection method

Evidendces for all the countermeasure which has to be closed ( to be filled format)
Do you have DWM sheet , product audit check sheet and the observation you made till now , plan
for the same
Immediate deployment of action for all other parts supplying to HMSI
 Status
Completed

Modified & updated

Avaialable &
updated
Updated the flash
projection

Tool preventive
maintenance report
attached

Yes sir, Updated in

the simulation
report for flash
projection

Modified &
Updated
Removed &
updated
0.1 - 0.2paise
Yes.
Yes.

Ealrier is wrongly
enter the data. Now
corrected

We have doubt,
Need to update