8D Report for Scratches

Customer : MITSUI HIGH-TEC (M) SDN. BHD.

2nd April 2019

Quality Assurance Team

1
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D0 : General Information A
Report No 19-012
Suplier Name / Location Poongsan (M) Sdn Bhd Customer Name Mitsui High-tec (M) Sdn. Bhd.
Defect
Coil Damage Material Type /Dimension C194 SH 0.203 X 101.2

Rejected Quantity
615.80Kg Vendor Lot No 80661A0A51-101 & 102
Mfg Date (YY/WW)
21/01/2019 Problem Detected area Mitsui High-tec (M) Sdn. Bhd.

Delivery Invoice / Date 19/03/2019 Sample Quantity 2

Notification date of DMR 19th March 2019 Response -3D
Sample Receipt date
20th March 2019 Response date -8D 2nd April 2019

D1 : Team
Approach

Name Position
Team Leader Mohd Irshahrezal Muhamad Rasidi QA Executive

Khairul Anuar Mat Kassim Factory Manager

Meor Mohd Fairdaus Kamaruzzaman Leader, Production
Team Members
Ridhwan Leader, Packing & Store
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D2 : Verification and AProblem
Description
i.Complaint Justified: Yes □ No □
ii.Defect verified as :- Coil Damage

Surface Inspection : Sample 1 (80661A0A51-102) from MHT.

Coil Damage Detected

Surface Inspection : Sample 2 (80661A051-101) from MHT.

Coil Damage Not Detected
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D3 : Containment Actions
3-1 : Available sample investigation :-
Sample Result
Start No Damage Detected

End No Damage Detected

2 : Returned sample investigation :-

Yes. The sample given appeared to be damage.

• : Description of Containment Action taken:

( Inclusive of in-house stock / stock in transit / next shipment )
No Containment Action
1 Check in house stock with the same lot number to verify the defect on its surface.
Start & Due date : 21st March 2019 Responsibility : QA Executive Status/Result : Done

Location Lot no. Quantity Remarks

80661A0A51
Keep sample 8A526A - There was no damage were detected.
89D25BB
Work in process Nil - -

80661A0A51-101 302.2Kg
Finished Good 8A526A 910.6Kg There was no coil damage were detected.
89D25BB 1106.4Kg
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D4 : Root Caused A
4.1 – Failure Analysis
Mother Coil Slitting Strapping Wrapping Packing
Storage Delivery
Checking Process Process Process Process
• This issue tend to be happens during Packing process.
Pusher

Pusher Layer Pad

Platform “Coil”
Wooden
Spacer
Pusher “Coil”
Coil Wooden Pallet
Pusher Platform Stacker
“Have Gap” Platform

4.2 – Commonality Analysis

• During stacking, the operator had miscount the gap between pusher platform and layer pad. The gap was too high
and it snatch at the edge of FG against end part of pusher platform. Due to this the edge side of FG were damage.
• The gap between layer pad and pusher platform should be “No Gap” in order to get proper stacking of FG itself.
• The mentioned process were conducted manually which been control by operator themselves.
• Hence during finalizing the packing process, the operator(s) had also overlook the defective part of FG and
continue the said process. The said defect also had been loosed during final outgoing checking by relevant PICs as
this defect were small to be seen.
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D4 : Root Caused A

4.3 – Possible Caused

CAUSE & EFFECT DIAGRAM Put in black and bold the most likely contributors (a maximum of three) from each side

WHY DID THIS HAPPEN (Occurrence)? WHY WASN’T IT DETECTED (Escape)?

MAN MACHINE METHOD METHOD

MAN MACHINE

• Error during transfer of FG from

pusher platform onto pallet.

Defect

ENVIRONMENT MANAGEMENT MATERIAL MATERIAL

ENVIRONMENT MANAGEMENT
/ SYSTEM / SYSTEM
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A
D5 : Corrective & Preventive
Action
No Corrective & Preventive Action ( Process )
Since this issue were came from relevant operator(s) with less experience (below than 1 year), will assign
experienced PIC (team leader of the department) to assist and continue train (enhance practical skills & concept
1 understanding) the said operator for the next 3 months (as it would their probation period) before they conducting full
process by themselves.
Start date : 1st April 2019 Responsibility : Production Team Status/Result :Ongoing
QA will not only conduct checking during in-process but also adding checking process during semi FG (before
packing) & pre-shipment (after packing). Any abnormalities detected during this checking process will take picture(s)
2 and request relevant department to rework those FG before ship out to customer side.
Start date : 1st April 2019 Responsibility : QA team Status/Result :Ongoing
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A
D6 : Verification of Effectiveness of Action
taken
No Method
Monitor the effectiveness and give reminder (during morning assembly) to relevant PIC on handling of FG during
packing process especially on transferring of FG onto pallet from pusher platform. The monitoring will take place for
1 6 months period (3 months during operator probation period + 3 months after operator’s probation period).
Start : 1st April 2019 Responsibility : Packing Team Leader/ QA Status/Result : Ongoing
Executive/ Factory Manager
D7 : Prevent Recurrance
Item Yes/No Evidence if Yes
Fan-out No Write down related FAN OUT process #
FMEA No Write down related FMEA review / newly establish#
Specification No Write down related specification review / newly establish#

Work Instruction Yes Inspection method during outgoing checking.

D8 : Congratulate the
team Name Position
Provided by Mohd Irshahrezal Muhamad Rasidi QA Executive
Approved by Khairul Anuar Mat Kassim Factory Manager
Meor Mohd Fairdaus Kamaruzzaman Leader, Production
Ridhwan Leader, Packing & Store