534096140.

xls Printed: 07/28/2021

PPSR_Revision Record

Date Name Worksheet Name Update Description

Change 'X' out button to Green and
Red buttons to highlight production
04/14/06 Joe Koss Page 2 days.
04/14/06 Joe Koss New Added Revision Record
TBK INDIA PVT. LTD.,
DEFECT ANALYSIS & PREVENTIVE ACTION

SUPPLIER :M/S OMCO ENTERPRISES PVT LTD DATE :- 22.07.2021

PROBLEM FOUND AT
PART NAME :Thermostat Plug TBKI
:-
PART NO. :966145 QTY. REJECTED : - 1 Nos.

PROBLEM REPEATED : YES NO GRR NO. & DATE :-

(1) TEAM FOR PROBLEM SOLVING : Mr.Puneet Kaushal ,Mr. Tijendra Singh, Mr. Mitesh Kumar,Mr.Ravneet ,Mr. Brijesh

(2) Problem Description (General): (4) Sketch: (Actual Part / Process Flow)
Hexagonal Profile Operation Miss

(3) Problem Definition (Real Problem):

Unprocess Part mixed with Processed part

(5) Containment Action : Who Target Date Completed On

Brijesh
All fg stoc & wip quaranteed and found ok. 21.07.2021 21.07.2021
Kumar

MAN MEASUREMENT MACHINE, EQUIPMENTS

& TOOLING PROBLEM

Operator Not Instrument jig fixture

Calibration condition
Awareness

Inspector Not Instrument Tool die machine

Awareness Selection Maintenance Maintenance
Hexagonal Profile
Operation Miss
Inspection Method Material Dimentional
Part mixing specification
Inadequate
Material Grade
Separate Location for N.A
WIP

METHOD MOTHER NATURE MATERIAL

Note : Following points should be considered during Brainstorming --

* Are control plans & work instructions posted & followed. Yes * Are parts stocked in correct place. yes
* Are operator trained, do they understand standards & quality out comes. yes
* Are there any abnormal events. No
No Gap between Thread
Roller and Part Face
(7) Root Cause Analysis: In the first Why write down the Most Probable Cause from the cause & effect diagram

WHY WHY MADE WHY WHY DELIVER

Why Why? Why Why?

Haxagonal profile operatione miss in part. Part could not detected during 100 % visual inspection at

Why Why? Why Why?

Part visual inspection partmenter was based only on part
Process part and one unprocess part mix up with each other.
dent burr crack scartches etc.
Why Why? Why Why?
Operator was not know operation miss should be check in
Process and unprocess part kept on same place.
aware about that.
Why Why? Why Why?
No separate location provided for process and unprocess part for keep sepratly to
Operation miss parameter was not include in visual inspe
ech other.
Why Why? Why Why?

Operator was unaware about what should he do to keep part separtly. Inspection method was inappopiate at PDI stage.

Root Cause: No gap maintained between process and unprocessed part Root Cause: Inspection Method inappopiate at PDI s
which caus lead to the both categaory part got mixed to each other.

(8) Intermediate Action Plans (not containment) : Who Target Date C

Brijesh
All FG stock & WIP quaranteed and found ok. 21.07.2021 Ta
Kumar

(9) Long-Term Corrective Actions (Preventive) : Who Target Date C

1.-Separate location provided for the WIP (Unprocessed ) and Proccesed part. 2.- Brijesh Next
R
Training also provided for the operator for material handling. Kumar Production

1.- Awareness traning provieded to PDI inspector for visual inspection method.
Brijesh Every dispatch
2.- FIS update for the pervious operation chack in every part during visual inspection. R
Kumar lot
3.- Quality alert made and displyed at PDI stage .

IF MORE THAN ONE CAUSE FOUND IN CAUSE & EFFECT DIAGRAM, REPEAT SR. NO. (7), (8) & (9) FOR ALL CAUSES

(10) Verification of Corrective Action taken (Lots after corrective action taken) :- Yellow Paint marker will be provided to verify the part is 100% visual ch
Page 1)

SUPPLIER USE TBKI USE

SR. NO. DATE LOT QTY. REJECTION QTY. REJECTION QTY. DATE V

RELATED DOCUMENTS UPDATED

1) CONTROL PLAN

2) WORK INSTRUCTIONS

3) PFMEA
4) Inspection check sheet Revised
Is problem solved satisfactorily? YES NO
ISSUE CLOSED DATE :

PREPARED BY : CLOSED / APPROVED BY :

ble Cause from the cause & effect diagram

WHY WHY DELIVER

Why Why?

Part could not detected during 100 % visual inspection at PDI stage.

Why Why?
Part visual inspection partmenter was based only on part apperance defect such as
dent burr crack scartches etc.
Why Why?
Operator was not know operation miss should be check in part.PDI inspector was un
aware about that.
Why Why?

Operation miss parameter was not include in visual inspection cherectristcs in FIS.

Why Why?

Inspection method was inappopiate at PDI stage.

Root Cause: Inspection Method inappopiate at PDI stage for the part for TBK

Completed On

Task Completed

Completed On

Regular practise

Regular practise

REPEAT SR. NO. (7), (8) & (9) FOR ALL CAUSES

:- Yellow Paint marker will be provided to verify the part is 100% visual checked by Harish (Refer Part pic in

TBKI USE
VERIFIED BY