Format No.

:PRD-MCN-WI15

Reaction Plan to Handle Abnormal Situations Issue No. :01(01/09/2017)

Rev. No. :01(26/06/2018)

SR. Impact on Impact on Operator

Process Abnormal Situation Reaction Plan Responsibility & Record
No Product Process Instructions
Supervisior / Abnormal
Follow PRD-MCN- In Case of Power Failure for all Machines ( Except VMC ) Follow PRD-
Situation Handling Record
Part May not WI14 MCN-WI14
NG Part May QC-MCN-F23
undergo
Power Failure Move to next
complete
operation Supervisior / Abnormal
operation. Inform to Reject the Part. Put Red Paint on Part and Keep in Red Bin.
Situation Handling Record
supervisor ( FOR VMC ONLY )
QC-MCN-F23

Immediately Press E Stop

Inform to supervisior
Operator/ Supervisior/
Process Need to
NG Part May Manager/ Abnormal
Tool or Insert Broken be Approved Change the tool or Insert
be produced Situation Handling Record
Again
QC-MCN-F23
Check 5 Parts acc to drawing and process sheet. If Found OK put
the part in OK Part bin otherwise mark red paint and keep in
Rejected Part red bin. If NG Part found then check whole parts from
last insert/tool change.

1 Machining 1. Stop the line.

Immediately Inform to Line Inspector
2. Put Part in red
Operator/ Line Inspector/
bin
NG Part May Supervisior/ Abnormal
Found a defect in Previous Process Line Stoppage 3. Inform to check 5 Pcs. for the deviated parameter passed to next process if
be produced Situation Handling Record
supervisior found NG. Put a Hold tag and re inspect lot for the deviated QC-MCN-F23
parameter

1. Maintenance department to repair the machine. Operator/ Line Inspector/

NG Part May 2. Handover to production department. Supervisior/ Abnormal
Machine Breakdown Line Stoppage
be produced 3. Check the part after completing the new cycle. Situation Handling Record
4. Re Approve the set up. QC-MCN-F23

NG Part May Check the part for any damages and for critical dimensions, if Supervisior / Abnormal
Part Fall Down During Any Process of NG Part May
Move to next found NG mark red paint and kept in red bin and if found OK pass Situation Handling Record
Machining be produced
operation it to next operation. QC-MCN-F23

NG Part May
1. Std. Room Incharge will issue the spare gauge. Std. Room Incharge/
be produced 1. Stop the Line
Sudden Failure of Inspection NO Impact on 2. Isolate the lot check it 100%. Abnormal Situation Handling
and escaped 2. Inform to
Gauges/ Measuring Instruments Process 3. Std. Room Incharge will check the gauge and will take Record
to next supervisior
necessary action. QC-MCN-F23
operation

Supervisior / Abnormal
Power Failure NO Impact on Cycle Time Reheat the Ring Gear. Situation Handling Record
Product Increases
QC-MCN-F23
Supervisior / Abnormal
Sudden Failure of Inspection NG Part May 1. Change the Optical Pyrometer.
Line Stoppage 1. Stop the line Situation Handling Record
Gauges Produced 2. Isolate the Lot and Check 100% Gap with Filler Gauge.
2. Put Part in red QC-MCN-F23
Ring Gear
2 bin
Fittment 1.) Isolate the lot. Check 100% Gap with Filler Gauge. Supervisior / Abnormal
NG Part May 3. Inform to
Sudden Failure of Poka Yoke Line Stoppage 2. Get It Repaired. Situation Handling Record
Produced supervisior
3. Start the Production. QC-MCN-F23

NG Part May Check the part for any damages and for critical dimensions, if Supervisior / Abnormal
Part May get
Part Fall Down Move to next found NG mark red paint and kept in red bin and if found OK pass Situation Handling Record
damaged
operation it to next operation. QC-MCN-F23

Supervisior / Abnormal
Power Failure NG Part May
N/A 1. Reject the Ring Gear and Flywheel Situation Handling Record
( At the Time of Ring Fittment ) Produced
QC-MCN-F23

1.) Isolate the lot. Check 100% Gap with Filler Gauge. Supervisior / Abnormal
NG Part May
Sudden Failure of Poka Yoke Line Stoppage 2. Get It Repaired. Situation Handling Record
Produced
3. Start the Production. QC-MCN-F23
1. Stop the line
2. Put Part in red Supervisior / Abnormal
Power Failure NG Part May
3 Assembly N/A bin Re Check the Part. Situation Handling Record
( At the time of Push Off Load ) Produced
3. Inform to QC-MCN-F23
supervisior
Supervisior / Abnormal
Power Failure NG Part May
N/A Re Press The Pins and Check the Part Situation Handling Record
( At the time of Knock Pin Fittment ) Produced
QC-MCN-F23

NG Part May Check the part for any damages and for critical dimensions, if Supervisior / Abnormal
Part May get
Part Fall Down Move to next found NG mark red paint and kept in red bin and if found OK pass Situation Handling Record
damaged
operation it to next operation. QC-MCN-F23

Supervisior / Abnormal
NO Impact on NO Impact on Inform to
Power Failure Start the cycle and balance the part. Situation Handling Record
Product Process supervisor
QC-MCN-F23

1. Check the collet and use the spare collet.

Supervisior / Abnormal
Sudden Problem in balancing NG Part May 2. Re Approve the Setting.
Line Stoppage Situation Handling Record
Fixture Produced 3. Isolate the Lot and Check 100%
QC-MCN-F23
4 Balancing 1. Stop the line 4. Get the collet repaired.
2. Put Part in red
bin 1. Stop Production, Hold Last Shift Stock. Supervisior / Abnormal
NG Part May
Repeatibility NG During Set Up Line Stoppage 3. Inform to 2. Re-calibrate Machine. Situation Handling Record
Produced
supervisior 3. Re-Check all material after re calibration. QC-MCN-F23
NG Part May Check the part for any damages and for critical dimensions, if Supervisior / Abnormal
Part May get
Part Fall Down Move to next found NG mark red paint and kept in red bin and if found OK pass Situation Handling Record
damaged
operation it to next operation. QC-MCN-F23

Operator/ Abnormal
NO Impact on NO Impact on Inform to
Power Failure Again Magnetize the Part and check for crack Situation Handling Record
Product Process supervisor
QC-MCN-F23

5 Magnafluxing
1. Stop the line
NG Part May 2. Put Part in red Check the part for any damages and for critical dimensions, if Supervisior / Abnormal
Part Fall Down Part May get bin found NG mark red paint and kept in red bin and if found OK pass Situation Handling Record
Move to next
damaged 3. Inform to it to next operation. QC-MCN-F23
operation
supervisior

Gauge/
Instrument 1. Check the Instrument/ Gauge
may get 2. Issue the calibrated spare Instrument/ Gauge.
1. Stop the Line Operator/ Abnormal
damaged/ not NO Impact on 3. Check the 5 checked pieces from new issued gauge/instrument.
6 Machining Gauge/instrument fall down 2. Inform to Situation Handling Record
perform as Process 4. Check if Instrument/ Gauge is damaged or not. If Damaged get
supervisior QC-MCN-F23
required NG it repaired and calibrate and if not damaged then also get it
part may be calibrate.
produced

1. Stop line
2. Put Part in red Check the part for any damages and for critical dimensions, if Operator/ Abnormal
NG Part May NO Impact on
Parts fall down during Process bin found NG mark red paint and kept in red bin and if found OK pass Situation Handling Record
damaged Process
3. Inform to it to next operation. QC-MCN-F23
7 Packing supervisior

1. Isolate the
NG Part may Operator/ Abnormal
Parts/ Bin Falls down NO Impact on bin/parts Check the Parts for any damage if found OK pack again otherwise
move to Situation Handling Record
Packing Area Process 2. Inform to mark red paint and keep in red bin
customer QC-MCN-F23
supervisior

Remarks : 1. If Any abnormality occurs apart from abnormal situations define above, immediately stop the line and
inform to supervisior. ( For e.g Different in Color, Different in Noise, Different in odour. )
2. If any of the above abnormal situation occur where qty is not defined,10% of parts need to be verified by the line
inspector produced before the abnormal situation occures.

Prepared By Approved By