5W1H SHEET

HONDA MOTORCYCLE & SCOOTER (INDIA) PVT. LTD. TQPQ - FOO - 0002

Documentation Instruction Analysis record [ Problem Analysis Sheet ] Department or supplier name Date ( 19/08/14 ) Date

HMSI
Stumpp Schuele& Somappa
Resp Check Make Approval Check
Springs Pvt. Ltd.
V.K.S. (SSS) S.CHAUHAN SANTOSH (SSS)

Theme Spring Profile NG.

Part number 22815-428-0001
Part name Spring Clutch Lever
[ Situation Event Symptom, Complaints, Number of occurrences, actions ] [ Identified facts result of verification, cause analysis, manufacturing quality status on the applicable date ]

1. Theme :- Spring Profile NG

2. Place of Occurrence :- HMSI Line
3. Frame NO. :- NA PFD :- RAW MATERIAL FORMING TEMPERING
OILING INSPECTION PACKING
4. Engine NO. :- NA
5. KM covered :- NA
6. Date of occurrence :- 13/08/2014
7. NG Qty. :- 6 Nos
8. QIC NO. :- NA
9. Dealer Name :- NA

FACTS VERIFICATION CAUSE ANALYSIS

10. ACTION TAKEN :- MATERIAL SEGREGATED AND DETAILS AS MENTIONED BELOW

SR.
NO
POSSIBLE CAUSES VERIFICATION RESULT OCCURANCE
STOCK
S.NO
LOCATION
QTY CHECKED NG QTY. STANDARD ACTUAL GAP PROBLEM
1 Whithout Tempering Checked found all OK O
1 HMSI STOCK 10000 6

2 VENDOR Stock 15000 0 No. of coil Observed Wrong position of sensor Due to loosening of the
No. of coil 8.50 8.25 nut
3
2 Setting part Mixup Verify the process in Assy found all OK as per spec O
OUTFLOW
4
STANDARD ACTUAL GAP PROBLEM
After investigate the cause of problem arise in part we found that some
During forming some of the
of the pieces were made in less coil & found that the wrong position of
3 pieces were made in less
sensor due to loosening of the nut provided and mixed with OK part on X In every hour no check
coil
machine. Could,t detected as per with gauge during winding On the Maching
Part check as per Sampling sampling plan Final only manualy count of parameter gauge not
plan inspection. total no. of coil provide at forming stage.

Root Cause of Problem ( How the Problem occurred, duplication test, problem analysis ) Confirmation of effectiveness ( Actual Results After Counter Measure Taken )
1. OCCURRENCE ROOT CAUSE 1. OCCURRENCE COUNTERMEASURE TARGET DATE S.NO. DATE INVOICE NO. LOT QTY. STATUS REMARK

1 20.08.14 4000 OK
After investigate the cause of problem arise in part we found that some of the
Chuck nuts provided for positioning of sensor.
1A pieces were made in less coil & found that the wrong position of sensor due to 1A 18.08.14
loosening of the nut provided and mixed with OK part on machine.

In every hour the pieces will check with gauge during winding ( New gauge made
1B 1B 18.08.14
) Gauge photographs attached here for your reference.
Incase of abnormal situation Strictly instruct operator should report to leader
1C 1C 18.08.14
ASAP, Abnormality will be mentioned in the PMC also

Also we are doing 100% gauging before dispatched. --- Gauge photographs
1D 18.08.14
attached here for your reference.

2. OUT FLOW ROOT CAUSE 2. OUT FLOW COUNTERMEASURE

Final inspection to be done after 100% sorting with gauge before dispatched. ---
2A COULD ,T DETECTED AS PER SAMPLING PLAN FINAL INSPECTION. 2A 18.08.14
Gauge photographs attached here for your referance.
NO CHECK POINT AT ON THE MACHINE PARAMETER GAUGE NOT PROVIDE
2B 2B
AT FORMING STAGE.

3C Feedback (Contents to be reflected in the systems / procedures )

3D

3E

On the Machine Parameter checking gauge After Tempering checking gauge

Problem analysis q q
Step 1 2 3 4 5

Profile NG due to Spring Loose the nut and mixed

C Occurrence Wrong position of sensor
Total No. of Coil Less. with OK part
o
n
t
e
n
t COULD ,T DETECTED AS NO CHECK POINT AT ON THE
s Outflow PER SAMPLING PLAN MACHINE PARAMETER GAUGE NOT
FINAL INSPECTION. PROVIDE AT FORMING STAGE.