Extra material on end Chamfer

Analysis Record [Analysis

Report]

Part No. Pin-A

Part name 002-C46-129
Situation of occurrence (phenomenon/content of complaint/number of
occurrences/details of disposition)

Issuing Dept.

Theme

08

ROHTAS FASTENER

(M)

9 (D)

16 (Y)

Approved

Reviewed

Prepared

Parveen

Vikas

Devander

Fact checking (parts check result/factor analysis/product quality status)

Problem Statement:- Without Thread

Complaint Receipt Date: 21.07.16
Place of Occurrence:- Nissin Brake
Reject Qty.:-01 Nos
Lot No./Lot Identification

Identification of causes (mechanism of occurrence/reproduction test/5-whys analysis)

Countermeasure effect check (effect achievement)

Appropriateness of countermeasure (details/expected effects/PPA)

Date of countermeasure determination

Cold Forging:- OK

Countermeasure determined by

7 /

16

Vikas Kumar

Grinding:- OK

1. Quality alert and awareness training given to all concern

sorter for defect.

CNC-1 & CNC-2 :- OK

Thread Tapping :- Not Ok As both material Tapping &
without Tapping material kept close to each other so it is the
most preferable chance to get mix without Tapping part to
Tapping Parts.

2.Product & process Audit frequecy revised for Nissin Pars.

3. 100% visual sorting activity started after Tapping.

Flat Extrusion:- OK
Heat Treatment:- OK
Final Inspection:- NOT OK
After analysis it is observed that the defect part flow to
customer due to unawarness of defect by final inspection
sorter.

Withou
t
Tappin
g Parts

5-Whys analysis (Conduct 5-whys analysis covering all factors to extract problems.)
1
2
Step
Description

060130

Feedback to source (content reflected in system/framework)

Tappin
g Parts

Packing & Storage - OK

Without Tapping

Pcs jumped from holder & fall on the kept ok

material Trey nearby to hand.

Inadequae working method.

Without Tapping

Not check the part carefully

Inadequate Training to sorter

Production certified material to be identified with an ok

shipped label

Change of standards

Retention period for original:

(M)
(Y)
<<Record Form Registration No. QS-1303-3-01>>
Feb. 11, 2011

ROHTAS FASTNERS LTD.

QUALITY ALERT

PART DESCRIPTION

Pin A

CUSTOMER

M/S NBI

FINISH

Plated

AREA/ RESPONSIBILITY

Thread taping/Final inspection

DATE

25.07.16

QUALITY ALERT REPORT: Serious customer complaints .

NOT OK
COMMENTS:
Whithout
Thread Taping PIN-A.
Pin -A
I
THIS IS A CUSTOMER COMPLAINT.

OK

COMMENTS:
With Th
Taping of PIN A.


I

PREPARED BY:
Davender

APPROVED BY
Vikas Kumar

ASTNERS LTD.

Pin A
M/S NBI
Plated
Thread taping/Final inspection
25.07.16

er complaints .

OK
COMMENTS:
With Thread
Taping of PIN A.
A

I

APPROVED BY
Vikas Kumar

SR. NO.

SYMBOL

PROCESS DESCRIPTION

10

Incoming Raw Material Inspection & Stor

20

Cold Forging & Line Inspection

30

Grinding & Line Inspection

40

CNC Turning -1 & Line Inspection

50

CNC Turning -2 & Line Inspection

60

Thread Tapping & Line Inspection

70

Flat Extrusiont & Line Inspection

80

Heat Treatment & Line Inspection

90

100

Grinding -2 & Line Inspection

Surface Treatment

110

Final Inspection

120

Packing, Storage & Despatch

SYMBOL TO BE USED

FINAL INSPECTION

OPERATION

OPERATION WITH
SIMULTANEOUS INSPECTION

SS DESCRIPTION
Material Inspection & Storage

& Line Inspection

e Inspection

1 & Line Inspection

2 & Line Inspection

g & Line Inspection

t & Line Inspection

nt & Line Inspection

Line Inspection

ment

ge & Despatch

BE USED

STORAGE/ DESPATCH
TRANSPORTATION

FISHBONE DI
FISHBONE DIAGRAM FOR DEFECT: Extra material on end Chamfer

MACHINE

MAN

MATERIAL

Uncontrolled
worn out
Unawareness

Process

Extrusion
Die
Damage

Operator
New Operator

Chemistry low of
spec..
R.M.
Not Followed
Chemistry More
than Spec.
Within Spec
Decarb Level

Work
Instuction
Not Available

Material Fal
Material strike on
outlet wall

More than
Spec.
MATERIAL

mix with ok pa

METHOD

MEASUR

SHBONE DIAGRAM
Date :

MATERIAL HANDLING

18.07.2016

Home

Uncontrolled
Process
Not Effective
Not Frequented
Maintenance
Not Effective

mix with ok parts

Material Falling

Process
Specification

ial strike on
wall

Product
MEASUREMENT

Without
Thread

One Point Lesson

Without
Tapping
Parts

Tapping
Parts

I

I

Wrong Method for Working