QF-CA-003

TROUBLESHOOTING REPORT (8ds) Rev. C

Pag. 1/2

SOURCE OF PROBLEM: External Internal Supplier (CAR #) : 2020-020

✘
Issue Date: Stages 1 Response Due Date: Stages 2,3 Response Due Date Stage 4 Response Due Date Estimated Date of Closure

10/20/2020 24 HRS after issue Date 1 WEEK after issue Date 45 days after issue Date or as applicable According to ECD Implementation

1.DEFINE TEAM LEADER

TEAM LEADER Rafael Del Rio POSITION Sr QA Engineer DEPARTMENT Calidad
1.2 WORK TEAM
NAME POSITION DEPARTMENT NAME POSITION DEPARTMENT
Adan Aguilar QA Engineer Jr. QA
Blanca Flores QA ASSiSTANT QA
Joaquín Montenegro PRODUCT ENGINEER ENG

2. PROBLEM DESCRIPTION:
Supplier/ Customer: Caterpillar PN: N/A P.O: N/A Lot No.: N/A W.O.: N/A
Problem Description: PHOTOS

PPM from current level of 3150 is below target 500 PPM

What happened?

Our PPM level is below target:

•Current = 3150 PPM
•Target below >500 PPM
A plan to meet the target below 500 PPM is required.

Where was detected

I
N
P With Customer
U
T
3. CONTAINMENT ACTIONS RESPONSIBLE DATE DUE DATE
Validate there are no parts in site with rust. Blanca Flores 4/6/2020 4/7/2020
Validate quality inspectors are using work instructions. Blanca Flores 4/6/2020 4/7/2020

3.1 MATERIAL SORTING

FINISHED GOODS HAS THE SUPPLIER/ HAS TIGHITCO SUSPECT MATERIAL IDENTIFIED ON TRANSIT? YES NO
SITE DATE RESPONSIBLE QTTY INSP LOT WO/PO QTTY OK QTTY NOK LOT WO/PO EAD TIGHitco QTTY INSP QTTY OK QTTY NOK
TIGHitco 2/26/2020 Blanca Flores 2 N/A 249231 2 0 N/A 247901 1 1 1 0
TIGHitco 2 N/A 249227 2 0 N/A 247900 1 1 1 0
TIGHitco 2 N/A 249228 2 0 N/A 247898 3 3 3 0
TIGHitco 2 N/A 249226 2 0 N/A 217899 3 3 3 0
TIGHitco 3 N/A 248543 3 0
TIGHitco 3 N/A 248544 3 0
TIGHitco 3 N/A 248541 3 0
TIGHitco 3 N/A 248542 3 0
TIGHitco 3 N/A 248540 3 0
TIGHitco 2 N/A 247900 2 0
TIGHitco 2 N/A 247901 2 0 HAS THE SUPPLIER/ HAS TIGHITCO SUSPECT MATERIAL IDENTIFIED ON PROCESS? YES NO
Caterpillar 3/9/2020 Trigo SCI Sorting 35 No disponible No disponible 32 3 LOT WO/PO DATE QTTY INSP QTTY OK QTTY NOK
Supp/Cust N/A 250045 2/26/2020 2 2 0
Supp/Cust N/A 249710 2/26/2020 1 1 0
Supp/Cust N/A 250182 2/26/2020 3 3 0
Supp/Cust N/A 250183 2/26/2020 3 3 0
Supp/Cust N/A 250184 2/26/2020 3 3 0
Supp/Cust N/A 250185 2/26/2020 3 3 0

4. DIRECT CAUSE:
D
I Addressing the top offenders for Caterpillar would put the PPM bellow 500. Our top offender 61.9 % was regarding 1 escape of multiple parts that increase our PPM off target, cause was a missing characteristic on drawing
A
G that was added after the escape. This escape was originally assigned to TIGHITCO ATLANTA and accepted by TIGHITCO ATLANTA, then non conformance was assigned to TIGHITCO LATINOAMERICA, because parts were
N produced here, but this non conformance was a missing feature in the drawing. Design features are not in the TIGLA´s capabilities.
O
S
T 4.1 DIRECT CAUSE ACTIONS: RESPONSIBLE ISSUE DATE DUE DATE
I
C Submit the non conformance challenge “NCM 378423 & 379184 - P/N 565-7436” with Caterpillar SQA. This will reduce our PPM to
Adan Aguilar 10/26/2020
A 800.
N
D 5. IDENTIFY ROOT CAUSE: *Análisis to be done with formats on 8d-2
I
M Work instructions need to be improved for personnel involved in hardware operation and inspection.
P
L
Cleaning procedure on electro edge operation needs to be improved to avoid leaving residuals that could enhance the appearance of rust.
E
M
E
5.1 ROOT CAUSE CORRECTIVE ACTIONS: RESPONSIBLE ISSUE DATE DUE DATE
N 9/10/2020
T Visual aid and training on cleaning stage of electro edge to avoid leaving liquid that could promote the appearance of rust. Joaquin Montenegro 8/10/2020
A COMPLETED
T
I Validate all tooling for hardware installation, is adequate and in good state. Joaquin Montengenro 4/6/2020 06/30/2020
O
N
06/30/2020
Verify that all work instructions are calling the correct tooling for hardware installation. Joaquin Montengenro 4/6/2020
COMPLETED

6 VERIFICATION OF IMPLEMENTATION RESPONSIBLE ISSUE DATE DUE DATE

VERIFICA 10/7/2020
Validate changes are updated in system. Blanca Flores 4/6/2020
TION OF
IMPLEME COMPLETED
NTATION
10/7/2020
Validate training was given to all the staff involved. Blanca flores 4/6/2020
COMPLETED

7 EFECTIVENESS CHART
E
F MOE ESCAPES REGARDING TOP OFFENDERS 1
0.9
E
0.8
C
T MONTH SEP OCT NOV DIC JAN FEB 0.7
I 0.6
V 0.5 ESCAPES
E
INDICATOR 0 0 0.4
REGARDI...
N 0.3
E
S
S GOAL 0 0 0 0 0 0 0.2
0.1
0
SEP OCT NOV DIC JAN FEB

8. PREVENTIVE ACTIONS RESPONSIBLE ISSUE DATE DUE DATE

5/20/2020
Improve hardware tooling, replicating the installation of similar production lines Joaquin Montenegro 4/25/2020
COMPLETED
6/20/2020
Improve marking operation to make details of hardware installation clearer for the operators, including critical features as slits. Joaquin Montenegro 6/20/2020
COMPLETED
C 8.1 ASSOCIATED RISK
L
O
S
I
N
G Has the need of update of any associated risk of this CAR been identified? YES NO YES

PFEMA 565-7436
If the need of an update was identified, record the docuemnt modified (exmaple PFEMA XXX, Supplier Risk Evaluation, etc) :
 QF-CA-003
TROUBLESHOOTING REPORT (8ds) Rev. C
Pag. 2/2

5 a) POSSIBLE CAUSES / RESEARCH RESULT:

1.) Fishbone
MAN MACHINE

Effect

MATERIAL
METHOD

2.) Main possible causes

3.) 5 ¿Why's?
Occurrence Detection System

Why did the problem occur? Why did not detect the problem? Why my system allowed this to happen?

Wrong hardware assembly is another top offender

PPM from current level of 3150 is below target 500 PPM. Rust in parts is another top offender (19 %).
(19 %).

Our top offender (61.9 %) was regarding 1 escape of

Work instructions were not followed. Cleaning procedure was not followed
multiple parts that increase our PPM off target.

Work instructions need to be improved for
Escape root cause was a missing characteristic on
personnel involved in hardware operation and
drawing that was added after the escape.
inspection.
Cleaning procedure on electro edge operation
needs to be improved to avoid leaving residuals
that could enhance the appearance of rust.

N/A N/A