ABNORMAL SITUATION & REACTION PLAN

Product abnormal situation Process abnormal situation

Power Disruption
1 3 2
Abnormal Absenteeism more Gauge / Instrument
Resp Rejections more than 5 Defects 1nos related Un known defect / Material shortage Fire
Situation than 10% Mix-up of NG parts & OK Breakdown / Assy tool fallen or damaged
Un identified parts Fallen parts nos / Repeated defects to safety / critical new defect related to Poke yoke not working ( Raw material &
parts brakage and Inspection Air pressure low / leakage
in a shift charcteristics function Packing Material ) power failure
equipement NG (oil & Air)/ Noise/Vibration

Part get rejected because Part get rejected Incomplete Operation Incomplete Operation
Parts may Not Ok & leads to Not ok parts may mix-up with ok
Impact on product - Parts may get damaged Parts get rejected parts get rejected of un known defect Parts may get rejected - Parts may not be produced because of Parts may get damaged
customer complaint parts
rejection Gauge/Instrument error parts may get rejected parts may get rejected

Not ok parts may get

Not ok parts may get passed to
Planned output cannot Not ok parts may get passed Not ok parts may get Not ok parts may get passed to next operation Not ok parts may get Not ok parts may get passed to Not ok parts may get passed to
Impact on process next operation & leads to Line stoppage Line stoppage - Line stoppage Line stoppage
be achieved to next operation passed to next operation passed to next operation & leads to customer passed to next operation next operation next operation
customer complaint
complaint

# Stop the machine & Inform to # Stop the machine & inform to
maintenance/production supervisor maintenance supervisor /
# Stop the machine & and record it in abnormality record. Production supervisor
# Stop the machine & # Press the emergency stop
# Put the un identified parts in Inform to supervisor Inform to maintenance
# Put the fallen parts in # Stop the machine & button. # Inspect the part with QA
rework bin with proper supervisor/ Production # Press the emergency stop button
fallen parts blue bin with # Record in abnormality register Inform to supervisor # If part is OK then get it iinspector and
identification and Inform to # Inspect the part as per the supervisor and walk with maximim speed
proper identification and about parts mix-up and inform to approval from QA and then if part is Ok then go to next
supervisor # If critical part running inspection standard & get through emergency exit.
Inform to supervisor superviser. # If part is OK then get it use the part operation.
station even 1nos got approval from QA # Inform to Line # Once the machine breakdown
the first of approval from
# Check the part and if OK then rejected stop the machine Leader/Supervisor solved check the working # Handover the Gauges / # Go to emergency assembly point
Reaction Plan / # If part is OK then get it # Check the part and if OK then get QA and then use the part # After the poke # If part is not OK then reject # If part is not OK then reject the
get it approval from QA and & inform to supervisor # start the machine after QA condition of machine with Start Instrumemt to Production and
Disposition / Operator - first of approval from QA the first of approval from QA and yoke corrected check the poke yoke the part & put in the rejction part & put in the rejction bin/chute
then use the part inspector & supervisor # Start the production for up & Poke Yoke check sheet Supervisor/ QA Follow safety officer instructions
Action paln and then use the part then use the part # If part is not OK then with master sample & record the bin/chute with rejection tag with rejection tag
# Reject the part & put the confirmation next paln as per supervisor Supervisor
reject the part & put in the status in abnormal record sheet (*applicable for morthan
# If part is not OK then reject rejection red bin / chute instruction # Once the Fire put off start the
the part & put in the rejection
# If part is not OK then # If part is not OK then reject the rejction red bin/chute with
with rejection red tag 20min breakdown) # Once the power resumes # Once the pressure reaches with production,check the part as per
reject the part & put in the part & put in the rejection red rejection red tag # If part is OK then get it approval start the production,check the in specification then start the
red bin/chute with rejection red # If part is not OK then inspection Standard & get first of
rejection red bin/chute with bin/chute with rejection red tag # feedback has to give for # Inspect the part as per the part as per inspection Standard production & inspect the part as
tag reject the part & put in the from QA through first off approval approval from QA before using
rejection red tag cause processer and record inspection & then use the part inspection standard & get first of & get first of approval from per inspection standard
rejection red bin/chute with
approval from QA QA before using
rejection red tag
# If part is not OK then reject the
part & put in the rejction bin/chute
with rejection tag
# Check the process parameter,poke
yoke working condition and then
verify abnormality record sheet.
# Check the process
# Hold the mix-up lot and qudrantine # Record break down
# Take the part from fallen parameter & m/c setting. # Do the random check for # If the gauge Ok then get # Coordinate with m/c
the parts. # Do the random check for # If part is OK then get it approval notification.Coordinate with m/c
# Take the part from rework parts bin and check as per produced parts and confirm from QA and then use the part. approval from QA, Then maintenance people and correct
# Put overtime for produced parts and confirm maintenance people and correct
parts bin and check as per the the inspection standard . # If part is OK then get it the parts quality. start production. the problem # After put off fire check all the
employees. # Immidiatly give training about the parts quality. the problem
inspection standard approval from QA and then # If part is not OK then record the # Followup with purchase parts available in shop for any
impact of ok & not ok parts mix-up # When power resumes switch
# If part is OK then get it use the part. # Do the cause analysis rejection quantity in rejection chart. dept to arrange for the # Update the downtime # Check the pressure level damage.
# Discuss with mktg and to operators. # Do the cause analysis # Check the working condition on the machine and start the
# If part is OK then get it approval from QA and then about sc/cc rejecion with material or Change of plan and rejection qty in
Action Plan/ Supervisor / plan the prodn in Sunday. about unknown defect and of machine & Update the production
approval from QA and then use use the part. # If part is not OK then CFT and conclude the and start the production . production Log # Update the downtime and # Check for any damages to
Record QAD # Record in log book and conclude the downtime and rejection qty in
the part # If part is not OK then record the rejection quantity countermeasure and record. # Discuss with quality rejection qty in production Log machines
# Record it in communicate to relivers during shift countermeasure and record. production Log # Update the downtime and
record the rejection quantity in rejection chart. # Discuss with quality # Discuss with quality team # Update the downtime in # Discuss with quality team and team and allocate QA # Discuss with quality team and
absenteeism monitoring change. # Discuss with quality team rejection qty in production Log
# If part is not OK then record in rejection chart. # Discuss with quality team team and allocate QA production Log. inspector for retroactive allocate QA inspector for # Update the downtime and
chart. # Discuss with quality team and and allocate QA inspector and allocate QA inspector for allocate QA inspector for
the rejection quantity in # Give training to operators and allocate QA inspector inspector for retroactive retroactive check of previous parts check of previous parts retroactive check of previous rejection qty in production Log
allocate QA inspector for retroactive for retroactive check of retroactive check of previous
rejection chart immidiatly about fallen parts for retroactive check of check of previous parts produced in that particular station. produced in that particular parts produced in that particular
check of previous parts produced in previous parts produced in parts produced in that particular
impact. previous parts produced in produced in that particular station station
that particular station that particular station station
that particular station station

3
Retroactivity Supervisor /
- -
Confirmation QAD

Note : Retroactive confirmation:

Parts produced before the abnormal situation and after last ok condition parts to be quarantined and re-checked for part quality.

Rev.No Rev.Date Revision Details PREPARED BY REVIEWED BY APPROVED BY

0 26.05.2019 Initial Release Vallatdhuraja Mohammed Moien Abilash