Part Name Governor Cover JCB-310 Customer Part No

Complaint date
1 PROBLEM AWARENESS
Problem Severity
New Safety X In-House MFG / Line PPAP - P
pk
Regulatory X RPN Rating
Existing Functional P Customer Present P
pk
/ C
pk
Aesthetic X Present PPM
Reopened X Reliability X Field Domestic/Export
Others X PDI
2 PROBLEM DEFINITION (Attach Photographic details of failure, Attach Trend data, Pareto analysis, Warranty etc)
P
Photo / Sketch X
Trend chart X
Pareto analysis X
Control Chart X
Warranty data X
3 CONTAINMENT ACTION / SHORT TERM ACTION
No Immediate Action Taken
4 ROOT CAUSE ANALYSIS - WHY ~ WHY .. ANALYSIS (Attach Ishikawa diagram-Cause & Effect)
Probable
Cause's
1 WHY ? Brainstorming P
2 WHY ? Pareto analysis X
3 WHY ? Histogram X
4 WHY ? X
5 WHY ? X
X
28214705
Drawing No 28214705 20.06.2012
Problem Scope Problem Source % Defect Process History
X ---
---
---
P ---
---
---
---
Internal process audit
rating /Score
---
---
Process Deployment
Sheet
---
Concentricity 0.2 measures up to 0.30.
Attachments
Date Responsible Break Point Status
100% segregated the pipeline components both DTVS and KKR.
Cause 1 Cause 2 Cause 3
Root Cause Analysis
Tools used
P /
X
Mounting Hole Pin broken In Die
Casting.
--- ---
Due to Pin Broken Loading not
properly done.
--- ---
Idle Shaft Bore operation and
chamfer operation done in two
steps.
--- ---
--- --- Ishikawa - Fish Bone
--- --- Scatter dia
% Contribution Control chart
8D - PROBLEM RESOLUTION REPORT
Page 1 of 4
5 CORRECTIVE ACTIONS / LONG TERM ACTION (Attach Photographs of actions taken)
6 MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW)
No
1
7A PREVENTION (List other similar processes & products with the potential for the same defect)
No
7B REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)
No Status
1 Drawing / Process Flow Diagram
2 PFMEA / DFMEA / PPAP
3 Control Plan
4 Work Instruction/Calibration Plan
5 Others(specify)
8 PROBLEM CLOSURE & SIGN-OFF
No Phase Sign-off
1
2
3
4
5
6
Total Time required for rejected product analysis in days =
(Determination of root cause, corrective action & monitoring effectiveness of implementation)
Identified Root Cause from
5
th
WHY
Corrective Actions Planned / taken Error - Proofing Responsible Date
Idle Shaft Bore operation and
chamfer operation done in
two steps.
Idle Shaft bore and chamfer operation
done in same machine using Back Chamfer
Tool.
100% Inspection introduced in Line and
Final stage inspection and also
planned Concentricity gauge
(TgtDt:30.07.12)
Mr.V.Murugan 23.06.2012
Corrective Actions Taken Target Actual Result of Action
Date of
Review
Idle Shaft bore and chamfer operation done in
same machine using Back Chamfer Tool.
22.06.2012 23.06.12 Implemented 23.06.2012
Processes / Products Preventive Action Error Proofing Date
Not applicable
QMS Document
Pif
Yes
Responsible Planned Date Actual Date
PROBLEM PROGRESS SUMMARY CLOSURE SIGN-OFF
Start Date Completion Team Member Area
Problem Definition 20.06.2012 20.06.2012 KK Ramesh KKR Metals
Containment Action 20.06.2012 20.06.2012 Sathysseelan KKR Metals
Root Cause analysis 20.06.2012 20.06.2012 P.BALASUBRAMANI KKR Metals
Corrective Action 22.06.2012 23.06.2012
Solution Confirmation 23.06.2012 23.06.2012
4
Closure 23.06.2012 23.06.2012
Page 2 of 4
Part Name Customer Part No
Complaint date
1 PROBLEM AWARENESS
Problem Severity
New Safety X In-House MFG / Line PPAP - P
pk
Regulatory X RPN Rating
Existing Functional X Customer Present P
pk
/ C
pk
Aesthetic X Present PPM
Reopened X Reliability X Field Domestic/Export
Others X PDI
2 PROBLEM DEFINITION (Attach Photographic details of failure, Attach Trend data, Pareto analysis, Warranty etc)
P
Photo / Sketch X
Trend chart X
Pareto analysis X
Control Chart X
Warranty data X
3 CONTAINMENT ACTION / SHORT TERM ACTION
No Immediate Action Taken
4 ROOT CAUSE ANALYSIS - WHY ~ WHY .. ANALYSIS (Attach Ishikawa diagram-Cause & Effect)
Probable
Cause's
1 WHY ? Brainstorming X
2 WHY ? Pareto analysis X
3 WHY ? Histogram X
4 WHY ? X
5 WHY ? X
X
---
---
Problem Source % Defect
---
---
---
---
---
Control chart
Date
---
---
Break Point
Process Deployment
Sheet
Attachments
Status
---
Root Cause Analysis
Tools used
P /
X
---
---
---
Process History
---
Problem Scope
X
Drawing No
---
---
Internal process audit
rating /Score
Ishikawa - Fish Bone
---
Scatter dia
Responsible
---
---
---
X
Cause 2 Cause 3 Cause 1
% Contribution
8D - PROBLEM RESOLUTION REPORT
Page 3 of 4
5 CORRECTIVE ACTIONS / LONG TERM ACTION (Attach Photographs of actions taken)
6 MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW)
No
7A PREVENTION (List other similar processes & products with the potential for the same defect)
No
7B REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)
No Status
1 Drawing / Process Flow Diagram
2 PFMEA / DFMEA / PPAP
3 Control Plan
4 Work Instruction/Calibration Plan
5 Others(specify)
8 PROBLEM CLOSURE & SIGN-OFF
No Phase Sign-off
1
2
3
4
5
6
Total Time required for rejected product analysis in days =
(Determination of root cause, corrective action & monitoring effectiveness of implementation)
Identified Root Cause from
5
th
WHY
Closure
Containment Action
Root Cause analysis
Corrective Action
Responsible Corrective Actions Planned / taken
Solution Confirmation
Pif
Yes
Responsible Planned Date Actual Date
Date
Not applicable
Result of Action
Date
Completion Start Date
CLOSURE SIGN-OFF
Processes / Products
Team Member
Problem Definition
Error Proofing
Area
PROBLEM PROGRESS SUMMARY
Date of
Review
Target
Preventive Action
Error - Proofing
QMS Document
Corrective Actions Taken Actual
Page 4 of 4