Supplier 8D Ref.

U2-2018/01

8D REPORT Initiated Date : 1/3/2018

Updated: 3/10/2018
Customer Name: Comstar Automotive Technologies Pvt. Ltd Supplier: Necco tools Supplier Code: NE0001
Customer Site : Maraimalainagar Customer Contact (Name / Tel / e-mail): pjayapan@comstarauto.com
Customer Report No: Q411 Customer Part No: CP7C3U 11N060AA1 Description: COIL ASSY
Programme: M2A Quantity rejected: 2464 Nos Quantity at risk: 1 Recurrence: N
D0. Symptoms / Problem definition: D1. Establish Team
Team Leader: Mr.Nelson
High Resistance @ secondary winding, Spec 0.62 TO 0.69 OHMS, Reads 0.885 . Team

D0. Emergency Response Actions: Name Function Title Telephone Email ID

Action: Immediate meeting called & Customer complaint has been communicated Mr.Johnberkmans Quality Manager 9445354587 quality@neccotools.co.in
to Top mgmt , inspectors , operators & 3rd party Inspection . Mr.Paulsingh General Manager General Manager 9381749925 paul@neccotools.co.in
Mr.Arulraj Design Manager 9543797788 design@neccotools.co.in
Verification: Mr.Lineeshkumar Purchase Manager 9382552991 purchase@neccotools.co.in
The defected component is verified on 3rd jan at comstar by
Mr.Kannan Production Incharge 9382552992 productionnecco@yahoo.in
sathasivam
Mr.Ganesh Quality Engineer 9841699050 unit4_neccotools@yahoo.com
Mr.Sathasivam Quality Engineer 9677959788 quality@neccotools.co.in
Validation: Validated with keerthylee meter found 0.885

D2. Describe the problem / Detailed Description of Problem: Key Problem Description Summary (Is / Is Not)

Specification Actual Remarks What High Resistance @ secondary winding, Spec 0.62 TO 0.69 OHMS, Reads 0.885 .
Where At comstar assy line
0.62 TO 0.69 Reads 0.885 Not ok When 1/3/2018
How Big 1
Other Nil

D3. Develop Interim Containment Action ( ICA ) / Plan temporary countermeasures to protect customer

Send back to
Total Rejection Qty Supplier/Sorting acceptance Total Sorted Not OK When % Effectiveness
Containment actions on the suspect lots at Comstar (for sorting at COMSTAR )
end
sorting at comstar by Necco
2464 2464 0 1/3/2018 100%
Person
Quantity Send back to Supplier/Sorting acceptance (for sorting at COMSTAR )
Containment actions on the suspect lots In transit
Nil Nil

Mention the Sorting

method
Total Rejection Qty Total Sorted Not OK When
(Visual/Gauge/Instrument
)

100% Resistance value

Containment actions on the lots at Supplier facility 539 539 0 inspected by keerthyle
meter
1/3/2018

Mention the certified lot details to comstar for the above issue

D4. Internal rejection

Duration For that particular Last month
prodn week
Nil
Nil
Nil Nil
D4. Action for failure of previous PCA (For repeat issues)
Previous concern QR PCA implemented
Root cause PCA Details PCA Status
No/Details Date

NA NA NA NA NA

D4. Root Cause Occur (RCA) / Originating cause of problem (Consider MAN,MATERIAL, MACHINE, METHOD, WHO, WHERE, WHY, HOW)
CAUSE Responsible % Contribution

Since there is No proper layout identified, it leads Rejection part not properly handled during initial machine setup trail , This causes
Mr.Pushparaj 100%
Number of turns is more and found High Resistance @ secondary winding,
VERIFICATION – Test to Prove RCA by switching RCA on and off

It is verified that it’s the cause for high resistance.

D4. Root Cause Escape (RCA) (Consider WHY defect escaped to next stage of process / customer)
CAUSE Responsible % Contribution

Defect not detected at final inspection stage since Keerthely meter checked by manual inspection Mr.Pushparaj 100%

VERIFICATION – Test to Prove RCA by switching RCA on and off

It is verified that defective component not ensured in 100% inspection .

D5. Select Permanent Corrective Actions (PCAs)- Occur / Select permanent corrective action

ACTIONS ACCEPT REJECT

Proper layout & rejection part handling is to be implemented . Yes

VERIFICATION of chosen PCA

After the above correction will be taken for avoid this issue.
D5. Select Permanent Corrective Actions (PCAs)- Escape / Select permanent corrective action
ACTIONS ACCEPT REJECT

Auto inspection for high resistance to be implemented Yes

VERIFICATION of chosen PCA

If we check for 100% , we can able to detect the issue.

D6. Implement Permanent Corrective Actions (PCAs) / Effectiveness confirmation of implemented actions
OCCUR ACTIONS Who When Status

Proper layout & rejection part handling is implemented .

Mr.Necco 10.02.2018 Completed

ESCAPE ACTIONS Who When Status

Auto inspection for high resistance to be implemented Mr.Paul 3/10/2018 Under progress

N
Implementation Documentation (required) Action Responsibility Date
DFMEA
Drawing N
o
PFMEA N
o PFMEA Is to be update Mr.Sathasivam 3/10/2018
Control Plan
✘
N
o Control plan Is to be update Mr.Sathasivam 3/10/2018
Process instructions
✘
N
o
Training Matrix N
o
SCR Submission N
o
Others – specify N
o
VALIDATION – Data / Activity Confirming that PCA is effective over time o
/ cycles and has no adverse effects

NA

D7. Prevent Recurrence Similar Parts and Processes / Occur and Escape Actions implemented to prevent recurrence
Review and update other similar products or lines Action Responsibility Date

Similer part (Globl coil Assy) Proper layout & rejection part handling is to be implemented for followed similar process Necco & Team 10.03.2018

D7. Prevent Recurrence Systemic issues / Actions resulting from Predict root cause analysis for new product introduction and / or Quality Systems
Review and update of quality systems Action Responsibility Date

Similer part (Globl coil Assy) The same System Will be followed for similar Sysytem . Necco & Team 10.02.2018

D8. Recognize Team and Individual Contributions

Team members are appreciated
8D report closure date: 10.03.18 Approved by: Mr.Nelson
Note: All the Blank columns( White colour) should be filled by the supplier

Form No: SO-FR-24 8D Report Coversheet Rev NoDate: 02 27 Apr 2016Retention Period : CY+3 Years
 Cause & Effect Diagram - Probable ca

MAN Method

Manual inspection done by operater

NC part handling
Rework part mix-up

More No: of turns

MACHINE Material

Conclusion : Resistance value manual inspection has taken & No proper layout identified, it leads Rejection part
causes Number of turns is more and found High Resistance @ secondary winding,
m - Probable causes

Resistance manual inspection

Improper turns

High Resistance @ secondary winding,

Spec 0.62 TO 0.69 OHMS, Reads 0.885 .

RM-Wire dia over size

d, it leads Rejection part not properly handled during initial machine setup trail , This
 Possible C

S.no. List of possible Cause

1 Resistance manual inspection

2 Improper turns

3
NC part handling

4 More No: of turns

5 Rework part mixup

6 Manual inspection done by operater

7
RM-Wire dia over size
 Possible Cause

Verification

verified the resistance checking method

during final inspection stage

verified the turns during secondary coil

winding stage

Verified the NC part in assy line .

Verified the defect component and inspected

no of turns found 164 instead of 129

Verified the rework & rejection part .

verified the inspection pepole checking

method during final inspection stage

verified the wire dia thickness checked in

incoming inspection.
se

Comments

Keerthely meter checked by manual inspection

Improper turns can able to controlled by monitor. So

there is no possible for improper turns in the machine.

There is a no proper NC part location & proper red bin

in assy line.

Against the spec it is more , hence high resistance

occurred

This kind of rejection part did't done rework in

recently.

Keerthely meter checked by manual inspection

Wire dia it measured with in drwaing spec

Judgement

significant

insignificant

significant

significant

insignificant

significant

insignificant
 Why Why Analysis sheet
Date: 1/3/2018

Issue title: High Resistance @ secondary winding,

Customer concern: High Resistance @ secondary winding, Spec 0.62 TO 0.69 OHMS, Reads 0.885 .

Defect on part: CP7C3U 11N060AA1

5 Whys Corrective Action

High Resistance @ secondary

O1
winding,

O2 Due to Number of turns is more

initial machine setup trail part

Why did the manufacturing O3
mixup
process not prevent the
defect? Rejection part not properly
O4
handled

O5 No proper
Since layout
there is Noidentified
proper layout
identified, it leads Rejection
part not properly handled
Proper layout & rejection part
during initial machine setup
O-RC handling is to be
trail , This causes Number of implemented .
turns is more and found High
Resistance @ secondary
winding,
High Resistance @ secondary
E1
winding,

Defect not detected at final

E2
inspection stage

Keerthely meter checked by

E3
Why did the quality process manual inspection
not protect Comstar from the
defect?
E4

E5

Defect not detected at final

Auto inspection for high
inspection stage since
E-RC resistance to be
Keerthely meter checked by
implemented
manual inspection
g,

eads 0.885 .

Responsible Due Date

Mr.Paul 10.02.2018

Paul 1/3/2018
 Corrective action/ Preventive action

Before Improvement

No proper layout & NC part handling

in assy line .

Corrective action/ Preventive action

Before Improvement
High resistance value was checked keerthlyee
meter by manualy
reventive action (Occurance)

After Improvement

Proper layout & NC part handling is

implemented in assy line .

Preventive action (Detection)

After Improvement

Auto inspection for high resistance value

Auto inspection for high resistance value
checking to be implemented