8D REPORT

QDH Number: 203063863 / 31.10.2022 Date Opened: Last Updated:

Title: 29.10.2022 05.11.2022

M6 insert missing observed.
Part Name Part Number Supplier
BRKT PANEL FRONT CENTER - N282 2184B0820 MAJESTIC POLYMERS
DØ Symptom(s):
1. Final inspection Rejection part mixup with the ok part

DØ Emergency Response Action(s): % Effective: Date Implemented:

1.Q.Alert for Insert flash issue displayed in PDI as well as machine area & training provided.
100% 29.10.2022
2.Man power deputed at SACL for segreation

D1 Team Name, Dept, Title, Phone D2 Problem

Champion: Mr.Mamalaivasan Operation Head 9066357339 Problem Description / Problem Statement
Team Leader: Mr.Nagesh Production in charge 9972573870 M6 Insert missing issue
Inspection: Mr.Mutheshwaran Quality In charge 8680808301
Team Members: Mr.Saranya Asst MR 8778670931
Mrs.Anu Purchase/Store In char9019533058

D3 Interim Containment Action(s): Colour ID % Effective: Date Implemented:

Customer: 100% Re-checking available stock @customer end White Mark with I Ok 100% 29.10.2022

Supplier : 100% Re-checking available stock @our end White Mark with I Ok 100% 29.10.2022

Verification / Validation: OK NOK Total checked

Dimension check by template(like snap gauge) .
a) Qty Checked at Customer End 1,040 0 1,040

b) Qty Checked at In-House 700 0 700

D4 Root Cause(s) and Escape Point(s): % Contribution:

List Potential root causes (s) - See 5 why tab to ensure root cause is found
100%
1. the final rejects are bagged near the final inspection area,So rejected parts are mixed with the good parts in the final inspection stage.

Escape Point:
1.100% fully inspected and dispatched, But the final rejects are bagged near the inspection area, so the rejected parts are mixed with the good 100%
parts.

D5 Chosen Permanent Corrective Action(s): % Effective:

1. Available stock has been re- inspected & insert missing components not found at our end 100%
2. 100% inspection done effectively by putting "OK" mark on the component. 100%
3. OK parts are identified by putting White colour "OK" mark on the part 100%
4. The method of handling final inspection rejects should be change from bags to red bins 100%
Verification:
Audited as per above points verified and found ok.

D6 Implemented Permanent Corrective Action(s): Date Implemented:

1.Awareness given to operators and inspectors through Q- Alert same displayed near machine & Pdi Area 29.10.2022
2.100% Pdi Inspection To Be Carried Out effectively. 29.10.2022
3. The method of handling final inspection rejects was changed from bags to red bins 29.10.2022

Validation:
Audited as per above points verified and found ok.

D7 Prevent Actions: Yes / No Date Implemented:

1.Available stock has been re- inspected & insert missing components not found at our end Visual Aid Yes 29.10.2022
2.Quality Alert & visual defect standard updated & displayed near machine area & PDI area. Schedule
Schedule Maitainance
FMEA
Control Plan
D7 Systemic Prevent Recommendations / Lessons Learned: Responsibility:
1.On job training provided and Q- Alert displayed near machine & Pdi Area Saranya
2.Visual inspection standard are updated. Saranya

D8 Team and Individual Recognition: Date Closed: Reported by:

Appreciated our Team to resolve the issue and came out with solution

FQA 190 / A 1 of 14 637743571.xlsx 8D Summary

 Stairstep down to find true root cause

D4
DIRECT CAUSE

#REF!

Why 1 - What caused above to occur?

M6 thread insert missing

Why 2 - What caused above to occur?

Due to improper final inspection rejection handling

WHY 3 - What caused above to occur?

5 WHY

WHY 4 - What caused above to occur?

WHY 5 - What caused above to occur?

ROOT CAUSE:

the final rejects are bagged near the final inspection area,So rejected parts are mixed with the good parts in the final inspection stage.

FQA 190 / A 2 of 14 5 Why's

  Problem Statement:

‚ Problem Logically could be but Information

IS IS NOT
Description Required

What Object
WHAT

What Defect
Where on object
WHERE

Where first observed

Where seen since
WHEN

When first observed

What pattern since

How many affected
HOW BIG

What size

Defects per object

Trend

FQA 190 / A 3 of 14 637743571.xlsx D2 - Is - Is not

 Fishbone Diagram

People Machines Environment

Process parameter

What could have caused

M6 Thrad insert missing

KEY:
Rank for Potential Root Cause
9 Highest probability
5
1 Lowest probability
improper final inspection rejection
handling method

Materials Methods Measurements

Root cause identification

S No Cause Genba analysis Remarks

FQA 190 / A 4 of 14 637743571.xlsx D4 - cause and effect

 Process Flow Chart

Details of operation
Op No TUFNYL SXXIC Black (PA6 UNFILL) U69-
1172S0020 will be recived from the supplier &
Raw material receipt incoming inspection to be carried out as per plan

Op No Storing the RM as per the Location & Issue the RM

as per the Production planning
Storage of raw material

Op No Hopper dryer cleaned as per sop

Unloading of previous left over material
from hopper dryer

Op No RM Preheating will be done as per chart

Raw material preheating

Op No Process setting will be carried as per Standard

process parameters
Mould change over & Process setting

Injection Moulding

Set up Approval & Patrol inspection

Degating /Deflashing

FQA 190 / A 5 of 14 637743571.xlsx Flow chart

 Process Flow Chart

Visual inspection will be carried as per visual

Visual Inspection
inspection standard

Final Inspection

FQA 190 / A 6 of 14 637743571.xlsx Flow chart

 o
QDH. Nº
Supplier
Part Nº
Part Name
203063863 / 31.10.2022
Majestic polymers
2184B0820
BRKT PANEL FRONT CENTER - N282
Date:
Code:
29.10.2022

f
c
o
FQA 190 / A
Before only OK mark was available

7 of 14
White pencil mark with I OK, Inspector
initial & date on the part
637743571.xlsx QR Photo
 QDH Photo description Traceability Data

FQA 190 / A 8 of 14 637743571.xlsx QR Photo

 White pencil mark with I OK, Inspector
initial & date on the part
FQA 190 / A 9 of 14 637743571.xlsx QR Photo
 Traceability Data

FQA 190 / A 10 of 14 637743571.xlsx QR Photo

 QDH. Nº 203063863 / 31.10.2022 Date: 29.10.2022
Supplier Majestic polymers Code:
Part Nº 2184B0820
Part Name BRKT PANEL FRONT CENTER - N282

1st delivery No White 100% checked labels on packaging ref. QDH No

Photo of Qualified Parts Identification

Photo of concern
Please use "GREEN" as Insert ok

your OK Identification mark

on the part Inspector Initial
with Date

FQA 190 / A 11 of 14 637743571.xlsx OK ID Photo

 203063863 / 31.10.2022

fied Parts Identification

of concern
"GREEN" as
ntification mark
he part
FQA 190 / A 12 of 14 637743571.xlsx OK ID Photo
Uncontrolled Copy

QDH
No CCAR: Latest Update: 16-Jun-04

Priority
Rating:
Status
10 = High
Item No 5 = Med Op. No Line Open / Concern Corrective Action and Recommendations Resp Date Opened Target Date 10 20 30 40 50 60 70 80 90 100 Remarks
1 = Low Closed

Date Printed: 01/10/2023 03:34:54

FQA 190 / A Page 13 of 14
 Timeline

Timeline of Events around concern - How many parts were produced before / after the date in question?
How many rejects were found "internally" before / after the date in question?

No of parts No of parts No of parts

Date Process/Product Changes Actions Required
produced rejected potentially @ Risk

No of parts produced - During concern period

12

10

FQA 190 / A 14 of 14 637743571.xlsx Timeline