PROBLEM SOLVING

Final Date of closure :

PROBLEM SOLVING SHEET NO.

Cross function Team -

1- Defect : CUT MARK OBSERVED IN JO2C PART 4- ANALYSIS RESULT :
Name

Reported By : IN HOUSE REJECTION Nos. Reported : Where Plant

MAN MACHINE
Date of Occurrence : Date of Initiation Repeat in
current Ist time IInd time
Part Name : W/S OUTER FR/RR Part No : SHARP EDGES year Vendor/ Plant Plant
SEMI SKILLED
Batch Code : Model : JO2C NOTCHING DIE Root Cause Man Machine Prepared By Verified By Approved By in charge QC HEAD
SKILL LEVEL
2- IMMEDIATE ACTION OK (4M) Material Method
UNSKILLED
OK SHARP EDGES
Parts Checked at Date OK NG Batch Code Id Mark Remarks
EXCESS MOULDING LIP CUTTING 5- Process Flow : NG Process Sketch / Photo
APPLIED OPN MOLD UNSKILLED
CAVOTY
In-house _ _ _ _ _
PROBLEM TAKEN FROM PARETO (INTERNAL CUT
REJECTION) MARK EXTRUSION FLOCKING NOTCHING

Supplier End _ _ _ _ _ _ TIGHT INSERTTION OF PART MOULDING

IN NOTCHING NG
3- Actual Defect sketch / Photo
PROFILE OF PART PART HANDLING
OK INSPECTION AND PACKING
PART TOUCH WITH KNIFE AND
BURR CUTTER DURING
MOULDING
6-Effectiveness Monitoring of Corrective action fortnightly.

MATERIAL METHOD Sl No Part Name / Date Remarks

Details:-

7- Study of Cause & Simulation of Defect & 5 Why Analysis 9- Countermeasures

11. Verification/Checkpoints
(Implementation of Countermeasures in Process & Documentation with Date)
Sl. No Process Test Result Sl. No Countermeasure Date

1 SKILL OF TEAM MEMBER FOUND OK AS PER MULTI SKILL CHART 1 OVER SIZE OF INSERT PIN REDUCED 2/3/2015 Checkpoints / Standardization
Remarks (if Yes then
Sl No Target Date the doc no , if no then
Reason for the same)

2 NOTCHING DIE FOUND OK Document to update Yes / No

3 LIP CUTTING MACHINE FOUND OK 1 PFMEA

CUT MARK OBSERVED ON PART AFTER DISTURBANCE

4 EXCESS MOULDING APPLIED ON MOLD CAVITY 2 PROCESS FLOW DIAGRAM
OF MOULDING TAPE

PART TOUCH WITH KNIFE AND BURR CUTTER

5 PART HANDLING FOUND OK 3 CONTOL PLAN
DURING MOULDING

6 PROFILE OF PART FOUND OK 4 INSPECTION STANDARD

10-Horizontal Deployment 5
STANDARD OPERATING
PROCEDURE

6 FINAL INSPECTION STANDARD

8- Why - Why Analysis

9
Step 1 2 3 4 5

EXCESS MOULDING TAP APPLICATION

Occurrence INSERT PIN SIZE OVER 10
IN MOULDING CAVITY

Flow 11

F : MFGC : 045 - 04; 18 Nov'14

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