CAUSE AND EFFECT DIAGRAM

PART NAME :- MLD 02

ISSUE :- Screw rod broken
C 1. Before reaching the temperature actual value 1. In melt temperature tolerance may not 1. Sprue push may blocked
to set value material may be purged. kept as low as possiple
A
U 2. Wrongly set the temperature.
S
E

A
N
D

M
MA

ET

MO
N

HO

U
E

LD
DS
F
F
E

T
RY

EN
L
RIA

M
NE
C

N
O
I
CH
TE

R
T

VI
MA

MA

EN
D 1. Wrong material may put in barrel. ( Ex: If set 1. Manufacturing defect in screw rod. NIL
set temperature is for PC, but put material
I Nylon)
A 2. Mix of foregin material along with raw material 2. Blow hole in screw rod.
( Ex: other plastic resin, chips, matal piece)
G
R 3. Crack in screw rod.
A
M
REJECTION DETAILS FOR COVER LENS

QTY REJECTED
SL NO DATE SHIFT OPERATORS QTY PRODUCED % PURGE IN KGS
IN NO

DAY SHIFT M.BALAJI 2729 75 2.74% 0.71

1 2-Dec-04

NIGHT SHIFT VIVEK 975 345 35.38% 0.03

DAY SHIFT M.BALAJI 12386 62 0.50% 0.15

2 3-Dec-04

NIGHT SHIFT VIVEK 16022 14 0.09% 0

DAY SHIFT THIRUMAL 14880 1080 7.26% 0

3 4-Dec-04

NIGHT SHIFT S SURESH 16230 94 0.58% 0

DAY SHIFT THIRUMAL 16892 52 0.30% 0

4 5-Dec-04

NIGHT SHIFT ARUMUGAM 11497 91 0.79% 0

DAY SHIFT ARUMUGAM 9870 108 1.09% 1.1

5 29-Dec-04

NIGHT SHIFT THIRUMAL 16254 98 0.60% 0

DAY SHIFT ARUMUGAM 15604 16 0.10% 0

5 30-Dec-04

NIGHT SHIFT THIRUMAL 15917 93 0.58% 0

DAY SHIFT ARUMUGAM 15521 23 0.09% 0

5 31-Dec-04

NIGHT SHIFT THIRUMAL 16352 12 0.07% 0

5 31/
DAY SHIFT ARUMUGAM 15604 12 0.10% 0

NIGHT SHIFT THIRUMAL 15971 90 0.58% 0

212704 2265 1.06% 1.99

REJECTION DETAILS FOR COVER SEAT TRACK

SL NO DATE SHIFT OPERATORS QTY PRODUCED QTY REJECTED IN NO % PURGE IN KGS

DAY SHIFT M.BALAJI 10160 184 1.81% 0.8

1 3-Dec-04

NIGHT SHIFT VIVEK 6111 25 0.40% 0.03

DAY SHIFT VIVEK 1520 80 5.29% 0.7

2 20-Dec-04

NIGHT SHIFT BALAJI 3776 0 0%

21567 289 1.34% 0.38

 CAUSE AND EFFECT DIAGRAM
PART NAME :- DATE
ISSUE :-
C
A
U
S
E

A
N
D

M
MA

ET

MO
N

HO

U
E

LD
DS
F
F
E

T
RY

EN
L
RIA

M
NE
C

N
O
I
CH
TE

R
T

VI
MA

MA

EN
D
I
A
G
R
A
M
 CAUSE AND EFFECT DIAGRAM
PART NAME :- COVER LENS
ISSUE :- REJECTION % & PURGING % MORE THAN TARGET
C
1.DURING STARTING MOULD IS NOT 1.MOULD IS NOT CLENED BEFORE
A CLENED PROPERLY LOADING
U
2.M/C IS STOPED IN BETWEEN 2.IN RUNNING EJECTOR SYSTEM IS
S PRODUCTION JAMMED
E 3.MOULD SIZE IS BIG

A
N
D

M
MA

ET

MO
N

HO

U
E

LD
DS
F
F
E

T
RY

EN
L
RIA

M
NE
C

N
O
I
CH
TE

R
T

VI
MA

MA

EN
D 1.MATIRIAL IS MIXED WITH OTHER GRADE NIL
1.MOULD OPENING SIZE IS NOT
I SAFISIANT
A 2.MATIRIAL IS NOT DRIED PROPERLY
G 3
R
A
M
 CAUSE AND EFFECT DIAGRAM
PART NAME :- DOOR FILM EC 100
ISSUE :- WARPAGE
C (1)COOLING TOWER WATER MAY BE (1) PACKING METHOD (1) WATER LINE MAY BE BLOCKED
A STOPPED DURING STARTUP OR MOULD (2) DURING PACKING POLYETHYLENE (2) SECOND EJECTION MAY BE NOT
U CHANGE OVER COVER MAY BE AFFECTING THE WORKED DURING EJECTION
S COMPONENT SHAPE.
E (3) COOLING TIME IS LESS
(4) PACKING TIME MORE IN PROCESS
A
N
D

M
MA

ET

MO
N

HO

U
E

LD
DS
F
F
E

T
RY

EN
L
RIA

M
NE
C

N
O
I
CH
TE

R
T

VI
MA

MA

EN
D (1) THE GRADE OF THE MATERIAL MAY BE (1) CUSHION MAY BE NOT NOT EVEN NIL
I CHANGED (2) NRV VALVE MAY BE FAILED
A
G
R
A
M
 CAUSE AND EFFECT DIAGRAM
PART NAME :- LATCH FILM DOOR EC 100
ISSUE :- REJECTION % IS1.4 % & purge 0.57%
(1) OPS OR SUP IS CHANGE THE
C PARAMETER (1) SAMPLING METHOD IS NOT OK (1) IN HOT SPRUE MATERIAL IS BLOCKED
(2) M/C IS RUN CANTINUASLY WITH DEFECT
A PART (2) HOT SPRUE TEMP IS LESS
U 2. IN BETWEEN M/C IS STOPED (3 ) HOT SPRUE IS NOT OK
S (3) SUP NOT DIGONISED CAUSE OF
REJECTION & HE NOT CHANGED WHAT HE
E WANT TO CHANGE

A
N
D

M
MA

ET

M
N

HO

O
UL
E

DS

D
F
F
E

T
RY

EN
L
RIA

M
NE
C

N
O
HI
TE

R
C
T

VI
MA

MA

EN
(1) OPS IS PUTTED WRONG MATERIAL OR
D GRADE 1) NRV OF M/C IS FAILED OR WORN OUT NIL
I
(2) MATERIAL IS MIXED WITH SOME OTHER
A MATERIAL
G
R
A
M
REJECTION DETAILS FOR EC 100 LATCH FILM DOOR

SL NO DATE SHIFT OPERATORS QTY PRODUCED QTY REJECTED %

DAY SHIFT P.SURESH 12880 420 3.26%

1 18/12/2004

NIGHT SHIFT BALAJI 16376 912 5.57%

DAY SHIFT VIVEK 16144 152 0.94%

2 19/12/2004

NIGHT SHIFT BALAJI 30680 0 0%

DAY SHIFT VIVEK 30720 8 0.02%

3 20/12/2004

NIGHT SHIFT BALAJI 29360 0 0%

DAY SHIFT VIVEK 29640 42 0.14%

4 21/12/2004

NIGHT SHIFT BALAJI 14328 1100 7.67%

180128 2634 1.46%

TOTAL
APPROACH TO PROBLEM SOLVING

RESPONSIBILITY

IDENTIFYING PROBLEM RN &MKM

TEAM FORMATION RN &MKM

TEAM LEADER RN

UNDERSTAND THE HISTORY

ALL TEAM MEMBER
OF ISSUES

DEFINE/QUANTIFY THE ISSUE

ALL TEAM MEMBER
(5W & 1H)

CONDUCTING THE CAUSES &

ALL TEAM MEMBER
EFFECT ANALYSIS

IDENTIFY THE MAJOR ROOT

ALL TEAM MEMBER
CAUSES

DEFINING THE ACTION PLAN ALL TEAM MEMBER

MONITORING & REVIEW OF

TEAM LEADER
ACTION PLAN

COMPARE WITH OLD DATA TEAM LEADER

IF IMPROVMENT OBSERVED
TEAM LEADER
STANDARDIZE THE SAME
REJECTION DETAILS FOR EC 100 DOOR FILM SCRATCHES OF THE MONTH OF OCTOBER

QTY REJECTED SCRATCHED

SL NO DATE SHIFT OPERATORS QTY PRODUCED REMARKS
(SCRATCH) COMPONENT %

DAY SHIFT NIL NIL NIL NIL KRONE TRIAL

1 1-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL LEAVE
2 2-Oct-04
NIGHT SHIFT NIL NIL NIL NIL LEAVE
DAY SHIFT NIL NIL NIL NIL LEAVE
3 3-Oct-04
NIGHT SHIFT NIL NIL NIL NIL LEAVE
DAY SHIFT RAVI/JOGI 3220 27 0.8385093168 DOOR FILM
4 4-Oct-04
NIGHT SHIFT SURESH/JBR 3298 29 0.8793208005 DOOR FILM
DAY SHIFT RAVI/JOGI 3310 102 3.081570997 DOOR FILM
5 5-Oct-04
NIGHT SHIFT SURESH/JBR 4530 41 0.9050772627 DOOR FILM
DAY SHIFT RAVI/JOGI 4164 76 1.8251681076 DOOR FILM
6 6-Oct-04
NIGHT SHIFT SURESH/JBR 2536 22 0.8675078864 DOOR FILM
DAY SHIFT NIL NIL NIL NIL NO LOAD
7 7-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
8 8-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
9 9-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
10 10-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
11 11-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL D-LINK TRIAL
12 12-Oct-04
NIGHT SHIFT NIL NIL NIL NIL D-LINK TRIAL
DAY SHIFT SURESH/JBR 2840 117 4.1197183099 DOOR FILM
13 13-Oct-04
NIGHT SHIFT RAVI/JOGI 4220 202 4.7867298578 DOOR FILM
DAY SHIFT SURESH/JBR 2502 156 6.2350119904 DOOR FILM
14 14-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
15 15-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
16 16-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
17 17-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
18 18-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL NO LOAD
19 19-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NO LOAD
DAY SHIFT NIL NIL NIL NIL TAPS TRIAL
20 20-Oct-04
NIGHT SHIFT NIL NIL NIL NIL TAPS TRIAL
DAY SHIFT NIL NIL NIL NIL TAPS TRIAL
21 21-Oct-04
NIGHT SHIFT NIL NIL NIL NIL TAPS TRIAL
DAY SHIFT NIL NIL NIL NIL TAPS TRIAL
22 22-Oct-04
NIGHT SHIFT NIL NIL NIL NIL DASARA LEAVE
DAY SHIFT NIL NIL NIL #VALUE! DASARA LEAVE
23 23-Oct-04
NIGHT SHIFT NIL NIL NIL #VALUE! DASARA LEAVE
DAY SHIFT NIL NIL NIL #VALUE! DASARA LEAVE
24 24-Oct-04
NIGHT SHIFT NIL NIL NIL #VALUE! DASARA LEAVE
DAY SHIFT NIL NIL NIL #VALUE! DASARA LEAVE
25 25-Oct-04
NIGHT SHIFT NIL NIL NIL #VALUE! DASARA LEAVE
DAY SHIFT NIL NIL NIL #VALUE! NO LOAD
26 26-Oct-04
NIGHT SHIFT NIL NIL NIL #VALUE! NO LOAD
DAY SHIFT SURESH/JBR 3816 132 3.4591194969 DOOR FILM
27 27-Oct-04
NIGHT SHIFT RAVI/JOGI 3800 36 0.9473684211 DOOR FILM
DAY SHIFT SURESH/JBR 3880 37 0.9536082474 DOOR FILM
28 28-Oct-04
NIGHT SHIFT RAVI/JOGI 3324 35 1.0529482551 DOOR FILM
DAY SHIFT SURESH/JBR 3186 49 1.5379786566 DOOR FILM
29 29-Oct-04
NIGHT SHIFT RAVI/JOGI 3118 79 2.533675433 DOOR FILM
DAY SHIFT SURESH/JBR 2812 39 1.386913229 DOOR FILM
30 30-Oct-04
NIGHT SHIFT NIL NIL NIL NIL NIL

31 TOTAL DAY SHIFT NIL 54556 1179 2.16% DOOR FILM

 CAUSE AND EFFECT DIAGRAM
PART NAME :- DOOR FILM EC 100
ISSUE :- SCRATCHS
C (1) REWORK HAS TO COMPLETE FASTER (1) PACKING COVER MUST BE GOOD (1) MOULD HAVING 8 AREA OF FLASH
A (2) PACKING COVER SHOULD BE GOOD CONDITION (2) FLASH CORRACTION TO BE DONE
U (3) RAW MATERIAL & BOXES BE ARRANGED IN MOULD
S BY SHIFT INCHARGE
E

A
N
D

M
MA

ET

MO
N

HO

U
E

LD
DS
F
F
E

T
Y

EN
L

ER
RIA

M
C

N
IN

O
CH
TE

R
T

VI
MA

MA

EN
D (1) PLATEN SIZE SHOULD BE BIGGER.SO T(1) AREA OF REWORK IS VERY LESS.
I NIL MOULD CAN LOAD HORIZONTALLY
A
G
R
A
M