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Status Report No 21
8D REPORT Com.Date 12.9.20
Closed VQPR #
Report date
D0 - Symptom of failure (As seen/reported by the customer)
Prepared by Karthikeyan

We received a claim from our large customer Toyota.

The cause was a leakage at the connection at the cylinder bottom.
We can see that the thread is not in line with the sealing surface on
the cylinder bottom.
I think this is the third or fouth time with the same problem (not the
same bottom) Verified by Vijayakumar
This thread must be machined in the same setup as the sealing surface.
This regards all bottoms!!

Aravind jayamohan - MD Muralikrishna - Purchase & stores Approved by Aravind Jayamohan

Vijayakumar - Quality Head Prabhakaran - Final incharge
Subhash - Production Head Manikandan-operator Quality Alert no Date
Vasanth - production Engineer peter-Quality Engineer
43 28.05.2021
Karthikeyan - Quality Engineer
D2 - Problem Description

G3/8 thread is not in line with sealing surface on the cyl bottom .

Details of complaint part

Part# 6485405-01 Supplier Name Emmarkay Automotive Spares Pvt.Ltd.
Part name Botton Ø 28 Date of PPAP approval 09.12.19
Qty supplied 150 Nos
Rejected Qty 1 No
Pictures/Photographs
Problem Photo0 Ok Photo

D3 - Containment actions
Check List Quantity Containment actions planned Resp Action status
3.1 Stocks at Customer 150 Segregation done 1 no found rejection - Complete
3.2 Stocks in transit 0 -
3.3 Finished Goods stock 0 -
3.4 Waiting for FI&T 22 All the available parts inspection done Vijayakumar Complete
3.5 WIP - Inhouse 0 -
3.6 Stocks at Stores 0 -
3.7 WIP - SCs and Vendors NA -
3.8 At other locations if any NA -
3.9 At newtech Stock 0 -

Verification/Validation of containment actions

Verfiy all the available parts Re inspection

*Abbreviations: RPN-Risk priority number, FI&T - Final inspection and checklist, WIP - Work in progress, SC - Sub contractor
email communication hence unsigned
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SCM-CL-73. Rev 0. Dtd: 4-Feb-15. Retention period: 2 years

 Status Report No 21
8D REPORT Com.Date 12.9.20
Closed VQPR #
Report date
D4 - Root cause analysis
Possible Cause Verification Method Result

Predrill hole was not center for tapping Verify VMC operation Found ok

Insufficient part clamping surface and pressure Verify Clamping method & Fixture Significant

Inadaquate operator training for burr clean before every part clamping Cross verify Found ok

Tap worn out Verify Tool condition & Tool life monitoring check sheet Found ok

Sealing surface and threading operation not doing same setup Verify Program Found ok

The detailed study of complete process flow

OP#60-
OP#20- OP#30- OP#40- OP#50-
OP #10 - Number
Band Saw CNC CNC VMC
Incoming punching and
Cutting Turning 1 Turning 2
Inspection engraving

OP#80
OP#-90 Cleaning OP #70 Final
Despatch to oiling and Inspection
Customer packing

Why Why Analysis: On Occurrences

Cause Why 1 Why 2 why 3 Why 4 Why 5
We have used only stoper
After complete sealing surface we have
while Threading operation and clamping pad for VMC
doing threading operation that time parts Insufficient clamping of part operation part holding Initial design
part tilting issue occurred slightly tilted due to high RPM purpose

Root Cause : Part slightly tilted while Threading operation Running due to insufficient part clamping .

Corrective Action: We have implement our part clamping method .We have make part profile fixture instead of clamping pad for VMC operation .

Why Why Analysis: On Detection

Cause Why 1 Why 2 why 3 Why 4 Why 5

We are not aware about perpendicularity

Perpendicularity check point
issue in threading operation .Also
not cover inprocess and final Customer drawing not cover
inspection report perpendicularity value

Root Cause : Perpendicularity check point not cover inprocess and final inspection report .
Corrective Action : We have provide training about thread perpendicularity issue and Impact.We will add thread perpendicularity check point in process and final
inspection Report.

SCM-CL-73. Rev 0. Dtd: 4-Feb-15. Retention period: 2 years

 Status Report No 21
8D REPORT Com.Date 12.9.20
Closed VQPR #
Report date
Verification/Validation of the Root cause Conclusion on the Root cause
While using clamping pad for part holding purpose in VMC Operation
Verify the fixture usage on VMC operation some time chance to part tilting issue That time perpendicularity not 1.06.2021
achive .To avoid this issue we have make part profile fixture .

Perpendicularity inspection not cover inprocess and Final inspection

verify inprocess and final inspection report .We was not verify perpendicularity of thread . 1.06.2021
We will add thread perpendicularity in our inspection report .

Escape points, causes and actions

Escape points Causes Actions planned
while VMC operation
Clamping pad use for holding Profile Fixture unavailability or not implement We have make fixture instead of clamping pad and stopper for part holding purpose on
purpose VMC operation

Inprocess and Final We have plan to add thread perpendicularity checkpoint in our inprocess and final
inspection Not add thread perpendicularity value in our inspection reports inspection report.

D5 - PERMANENT CORRECTIVE ACTIONS Responsibility

& Target date
BEFORE AFTER

Clamping pad we has used for part holding purpose in VMC operation location bore done on 4th axis table to avoid burr holding and
Improve the part clamping pressure To avoid part tilting issue
while Threading operation .

Subhash &
Vijayakumar
/Compleed

We have add thread perpendicularity value in our inprocess and final inspection
No Check point for thread perpendicularity verification report

ACTION PLAN
We have make new fixture for vmc operation
We have add thread perpendicularity value in our inprocess and final inspection report.

We have provide training about thread perpendicular and its impact. Responsibility &Target
date
Display one point lession all the respective areas .

D6 - Updating of documents for sustenance

Revision/correction of following Documents (Wherever applicable)
Design drawings - -
Process sheets - -
PFMEA Yes Vijayakumar/3.06.2021
Control Plan Yes Vijayakumar/3.06.2021
Work Instructions Yes Vijayakumar/3.06.2021
Audit checklists - -
Others if any One point lesson Vijayakumar/01.06.2021
D7 - Actions to prevent re-occurrence on other models
Horizontal deployment taken for all similar parts
D8 - Team/Individual recognition

Problem Identified CAPA agreed CAPA Implemented, Under monitoring Issue closed & signed off
email communication hence unsigned
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SCM-CL-73. Rev 0. Dtd: 4-Feb-15. Retention period: 2 years

 ONE POINT LESSION ISSUES NO 43

THEME PROBLEM:Thread Not inline with sealing surface DATE OF PREPARE 31.05.2021

RELATED TO VMC Deburr :6485405-01 ISSUE IDENTIFY RESPONSIBILITY

BASIC FOR TROUBLE
CLASSIFICATION Customer End Vijayakumar
KNOWLEDGE IMPROVEMENT
Not Ok Ok KEY POINTS
Burr found in two holes meeting area Two holes meeting area should not burr

Here after
dont use
Clamping
Thread
pad for VMC
perpendicular
operation
Value add in
.We need to
Inspection
use only
Reports
Fixture for
VMC
operation

TRAINING RECORD
NAME SIGNATURE DATE TRAINER NAME PREPARED BY
Vasanth Production Engineer Karthikeyan
Manikandan Operator
Kajendran Operator
Sudhen Quality engineer 31.06.2021 Vijayakumar & Subhash
APPROVED BY
selvi Final Inspector
Vijayakumar
Vijayalakshmi Final Inspector
Buvaneshwari Packing