Problem Reporting & Resolution (Notice)

PR&R#：

Supplier name：
Part name：
Recipient name：

Position： Quality head

Part No:
Tel/Email：

PRR requirements :
1. Supplier shall complete containment actions immediately to ensure no outflow to MGI production line
2. Supplier shall submit intermediate corrective actions within 24 hours
3. Supplier shall submit permanent corrective actions within 7 working days
4. Corrective actions effectiveness shall be monitored for a period of one month and PRR shall be closed if found effective
5. Non conforming qty mentioned in this form subject to change based on segregation results
6. Contact respective SQE engineer for addtional information
7. Evidence of intermediate and permanent actions to be attched in evidence sheet1, sheet2 etc.

Problem Description information

问题信息Problem

Problem Image :

Appearanc dimensi performa

Issue Type： e on ✘ material
nce

Concern
Source： Severity :
Date:

Model: Variant Affected VIN :

Occurrence time:1
NG Material
Quantity :
Batch code : Over 2
First Second
times
Segregation Transfer
Production line SPS Kitting Area MGI Warehouse Supplier warehouse
Status warehouse

Conformity

Non conformity

Issued by : Makrand patil

SQE Name : Jaydip parmar

 Author: Phone No: Date:
Practical Problem Solving Report Problem found by:

Safety People Quality Responsiveness Cost Environment Others VS/SIP: ___ CARE: ___ Maintenance____ Production _____ Other_____
Shift: GCA _______ PR # __________________
Issue Number:
Mark Sections or Questions that do not apply "N/A" Yard Check: # of Vehicles Checked _____________ # Items Found _______
Problem Description: Sketch:

Vin No : Model :

Problem Definition:(Real Problem)

Point Of Cause: (where problem is first occurring, not where first detected):

Team Member/Responder Input

Quality Breakdown Impact on other metrics (SPQRCE)

Standard: PPH: Start Time:
Deviation: End Time:
How Often: Duration:

Containment: Who Date Status Break Point

Start:
Finish:

Start:
Finish:

Start:
Finish:

Process/Part Check: (Quality Problems answer Detailed First 4 Diamond Questions.) Quality Diagnostic sheet available: ( optional )
Summarize results below Is there a Diagnostic Sheet available to support solving this problem?
Y N Y N Yes: No: ______
1 Is correct process followed? Do the parts support quality ?
​ 4

Is correct tool being used? If Yes, which one? Used? _____

2
​
3
Is correct part being used?

If Yes for all 4 Diamonds proceed to Most Probable Cause Analysis: If answer to Diamond 1-4 is No, complete 5 Why Analysis on page 2.
Determine the Root Cause for the specific "No" answer in the Diamonds 1-4 Questions using the 5 Why Analysis:
Most Probable Cause Analysis:
MAN MACHINE

PROBLEM
DEFINATION

MATERIAL
METHOD

Most Probable Cause(s):

Root Cause Analysis: In the first Why write down the Most Probable Cause from the front.(use additional sheets if more than one probable cause)

Why?

Why?

Why?

Why?

Why?

Root Cause:

Proposed Solution: Brainstorm possible solutions. Select the most efficient, effective solution.

Trial Run: Confirmation trial to test proposed solution:

Date: Sequence #'s

Team Members Supporting Problem Owner

Date: Name:
Name: Area: Signature:

Intermediate Action Plans (not containment) Who Due Date Break Point Status

Long-Term Corrective Actions Who Due Date Break Point Status

1- Identified 2- Implemented 3- Feedback 4- Closed

Follow-Up Verification (Did we effectively resolve the problem?)

Verification Process (How did you verify the countermeasure worked?)
Has a Quality Alert been posted? Yes No N/A Countermeasure tracking -
Have PFMEAs been completed/updated ? (Failure mode comprehended Yes No N/A working days defect free
Old RPN#_____________ New RPN#____________ 1 2 3 4 5
S______ O_______ DS______ O_______ D____ 6 7 8 9 10
Was the Control Plan adequate? Yes No N/A 11 12 13 14 15
Was the Control Plan followed? Yes No N/A 16 17 18 19 20
Has Error Proofing been reviewed and verification completed? Yes No N/A *Color green for no repeat or red if defect reoccurs
Have the job instructions, SOS/JES/PQS been updated ? (Including "finessYes No N/A
Has JIT Training been completed? Yes No N/A
Have the Layered Audits been updated? Yes No N/A
Have the check sheets or other forms been updated? Yes No N/A
Is change management applicable? Has Change Request been raised? Yes No N/A
The results/changes were communicated to all Team Members on all shif Yes No N/A

YES Issue closed

Issue resolved satisfactorily?
NO Issue escalated to:
Lessons Learned: "Send Copy of Problem Solving Form to"

Could the communication of this problem and its

fixes possibly prevent other departments from Press/Stamping Body Paint Powertrain Supplier Other
G.A.
incurring the same problem?
If Yes, Which Area?
Yes_____ No_______

Date/ Signature: Author (required for closure) Group Leader/Shift Leader (info only) Area Manager (info only)

Shift:

Shift:

Shift:

Shift:
 Problem Tracking Database(MID) Information:

Problem Solving Database Issue # ________________Plant/Build Bucket___________________________Report #________________Plant Issue Team__________________Area/Dept.____________

Date________________Operation Address______________________________Shift: 1/A 2/B 3/C Severity: 1 2 3 4

(Severity Code 1- No Build/Safety; 2 - Major Customer dissatisfier, labor or cost issue; 3 - Minor issue; 4 - Annoyance/Continuous Improvement)

Body Style________________________Vehicle #____________________________Engine__________________Assigned To:__________________________________Phone:____________________

Part#__________________________________________Part Name____________________________________________________Champion_____________________________________________

Pad#_____________________________________PIMREP Trouble Code___________________________Location on Vehicle _______________________________________________

Diamond 1 - Correct Process

Owner:_________________________ Phone:___________________ Date Completed:______________
Y N N/A Are the correct Best People Practice Sheets/JES/ALBS posted/available?
Y N N/A Are the completed vehicle inspection sheets/quality standards identified and followed?
Y N N/A Are the operators' job instructions being followed?
Y N N/A Are there visual aids present, current and being followed?
Y N N/A If there is a mandatory sequence identified, Is it being followed?
Y N N/A Was the operator properly trained on this operation?
Y N N/A Can the operator detect the issue/problem?
Y N N/A Does Operator know how to communicate issues/problems?
Other Process Causes:

Diamond 2 - Correct Tools

Owner:_________________________ Phone:____________________ Date Completed:_____________
Y N N/A Are the correct tools/fixtures being used?
Y N N/A Are the tools set to the specified torque?
Y N N/A Are the tools properly calibrated? Last calibration date___________________
Y N N/A Are any bits or sockets worn or not in proper working condition?
Y N N/A This is the correct length of air hose with no extra sections added?
Y N N/A Are the tools rails, controllers, flow regulator lines correct?
Y N N/A Is the tool tied to the ANDON System properly?
Y N N/A If Errorproofing is present,is it working correctly?
Y N N/A Does the work place layout allow the Operator to work efficiently?
Y N N/A Has any required planned maintenance been performed?
Y N N/A Is the equipment working properly now?
Other Tooling/Machine Causes:

Diamond 3 - Correct Material

Owner:________________________ Phone:_____________________ Date Completed:_____________
Y N N/A Do the Part numbers match the PAD/PIM sheets?
Y N N/A Are the correct part numbers being used?
Y N N/A Are the correct part numbers identified on the material racks?
Y N N/A Are the correct parts in the correct locations on the material racks?
Y N N/A Do the part numbers on the boxes agree with the parts in the boxes?
Y N N/A If a Temporary Work Order has been issued, Is it still in effect?
Y N N/A Can the parts be selected correctly on a consistent basis?
Other Material/Workplace Organization/Evironment Causes:

Diamond 4 - Parts Quality

Owner:_________________________ Phone:___________________ Date Completed:_____________
Y N N/A Problem follows part when swapped between Best of Best/Worst of Worst vehicles?
Y N N/A Is the current blue print/math data available?
Y N N/A Do the parts meet specification?
Y N N/A Has a PR&R been issued and supplier contacted? PRR#________________
Y N N/A Are the parts within specification and still causing the problem?
Other Part Quality Issues:
 Format No.: FMT/PRD/BDS/O3/A
Purging Report Revision No./Date: A /

Date: Problem Reported:

Problem Identified & Informed By : MGM

Sr. No. Area VIN Status Remarks Value

OK / NOT OK ( If Applicable )

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41
 42

43

44

45

46

47

48

49

50

51

52

53

54

Total Checked
Qty Checked By :

Found OK Submited By :

Found Not OK Date Submited :

Evidence Sheet