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5 PRINCIPLES

CONTROL NO. -

PROBLEM
STATEMENT

Symptom, content of Who,What,When,Where.


complaint frequency Why, How, How many.

PROBLEM DEFINITION

1-B

PART NO :PART NAME :COLLOR COMP


MODEL :SUPPLIER :Coe Auto industries
PROBLEM :I.D U/S in collar comp swing arm pivot
I,e 11.5
DATE :7/9/2013
HOW IT HAPPEN :It happens due to R/M.material was u/s
HOW IT BECAME :It happens due to U/S.material mixup with OK
HOW MANY :WHERE :-

APPROVED BY

Checked By

Prepared By

REPORT TO
BE
MADE TO

MR.RAJAT SINGH
Name

12/8/2013

Rajat Singh

Azad Singh

APPROVED BY

APPROVED BY

Name

Vikas

Part check results, factor analysis, quality condition of


current part / process

PROBLEM DEFINITION(GRASPING THE FACTS)

5) IDENTIFY ACTUAL CAUSE IN THE PROCESS FLOW CHART

DESPATCHED TO INDO. IDENTIFY THE PROBLEM LOT.

SHOW IN THE PROCESS FLOW CHART WHERE THE PROBLEM ACTUALLY


HAPPENED & HOW IT BYPASSED THE EXISTING CHECKING PARAMETERS.

6/9/2013
4000

LOT QTY
DESPATCH TO UNIT 3

RECVING AT UNIT 3

4000
4000

2)EXTERNAL OVERVIEW OF THE SITUATION.


PLACE

(TABLE 1.)
PLACE
LOT QTY SEG QTY REJ QTY

Gurgaon

Date

1)WRITE HERE THE DESPATCH DETAIL OF THE PROBLEM LOT


Date

11
INDO-AUTO

INDO

Issued ByDate

I.D U/S in collar comp swing arm pivot+Flange loose

1-A

TRIDENT AUTO INDUSTRIES

TAI - PQ

FOR PROBLEM SOLVING WORKSHEET

4000

4000

LOT QTY
4000

SEG QTY
4000

REJ QTY
11

IDENTIFICATION

RED MARKED

3)SHOW ANALYSIS OF THE NG PART


STATUS
Verification of
NG Parts

11 NG

COMPARE SPEC VS ACTUAL & FINAL RESULT.

WRITE QTY:
OK:

3989

NG:

11

PARAMETER

SPEC

OBSD

RESULT

I.D

12.20.2

11.2

NG

6)CONFIRM THRU SIMULATION TRIAL FOR THE OUTFLOW CAUSE


4)THE PROBLEM WHICH HAS OCCURRED ,CAN IT OCCUR IN ANY OTHER COLLAR COMP

IDENTIFY ROOT CAUSE ( QUESTION AND ANSWER ) From Fishbone Chart

2-B

IDENTIFY ROOT CAUSE

2-A
WHY 1

WHY 2

WHY 3

WHY 4

Question and answer analysis problem and occurrence process duplication


test

WHY 5

R/M was U/S


OCCURRENCE

R/M was U/S

U/S material mix-up with ok

checking person not trained

R/M not inspected

R/M not inspected

Checking person not trained


OUTFLOW

U/S material mix-up with ok

3-A

CORRECTIVE COUNTERMEASURE (S)

4 -A

Content of c/m prediction of effects, potential problem analysis.

OCCURANCE COUNTERMEASURE
With RM supplier problem discussed ,Work instrucion dislayed for 100% R/M checking

Resp.

Tgt. Date

Status

AZAD SINGH

11/9/2013

O.K

CONFIRM COUNTERMEASURE(S) Actual effects

5-A

NO FURTHER OCCURRENCES
Tgt Date

PQCT UPDATION
also 100 % inspection as well as marking at our end prior to dispatch.
PFMEA UPDATION

For flange Flange I.D is controlled -0.1 u/s

AZAD SINGH

11/9/2013

11/9/2013

KAKOTORA SHEET UPDATION

100 % flange inspection with snap gauge as well as marking at our end prior to dispatch.
Follow-up Date :

HCTQF QDD 0027/DEC'12

HORIZONTAL DEPLOYMENT

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