QDH No. Plant Resp dept Unit QDH Date Month & Year Part No. Part Desc.

Part Desc. Mat. GRP Source of Defect Type Defect Desc. Def Qty Def Qty
Complaint (External) (Internal)
220991875 H001 SUPPLIER QA- 8/16/2018 August-2018 420955700 HEX SCREW DM-Forging 2-QJO/Major WIDTH O/S Spec:12.73/13.00m 3.000 10.000
3WHEELER M8X40 8.8 ZNB linecomp m,Act:13.12mm
420955700 3.000 10.000

220998598 HOS SUPPLIER QA - PL1 8/31/2018 August-2018 8200120 CRPH SCREW DM-Forging 2-QJO/Major PROFILE NOT OK bit seating area 0.000 0.000
M5*12 linecomp excess material
221039017 HOS SUPPLIER QA-PL1 12/14/2018 December-2018 8200120 CRPH SCREW DM-Forging 3-Line complaint INCOMPLETE Gun bit not seating 0.000 0.000
M5*12 OPERATION
8200120 0.000 0.000

K6110840 0.000 0.000

220997723 HOS SUPPLIER QA - PL2 8/29/2018 August-2018 N5200170 HEX FL BOLT DM-Forging 2-QJO/Major FITMENT NOT OK flange area not ok 0.000 0.000
M6x35 linecomp
221039774 HOS SUPPLIER QA - PL2 12/18/2018 December-2018 N5200170 HEX FL BOLT DM-Forging 2-QJO/Major FITMENT NOT OK flange not ok 0.000 0.000
M6x35 linecomp
N5200170 0.000 0.000

221037827 HOS SUPPLIER QA - PL1 12/10/2018 December-2018 R1200500 HEX FL BOLT M6 DM-Forging 2-QJO/Major WRONG THREAD thread not ok 0.000 0.000
X 10 linecomp
R1200500 0.000 0.000

221012928 HOS SUPPLIER QA-PL2 10/5/2018 October-2018 N5200170 HEX FL BOLT DM-Forging 1-Lot Complaint THREAD MISSING 0.000 0.000
M6x35
221031600 HOS SUPPLIER QA - PL1 11/22/2018 November-2018 K6110840 BRAKE CAM DM-Forging 2-QJO/Major WRONG PART part mixup&lenth 0.000 0.000
REAR - WEGO linecomp SUPPLIED not ok
Det Why-1 Det Why-2 Det Why-3 Det Why-4 Det Why-5 Occ Why-1

Thread miss Not detected during visual inspection Low occurrence Without Rolling part

wrong Part Mixup Problem not Detected During Final inspection Low occurance wrong Parts Mixup during Final inspection stage
Occ Why-2 Occ Why-3 Occ Why-4 Occ Why-5

Without rolling part got mix up. Without process part kept on machine during rolling machine setting. Material Handling NG

Another Parts Kept Near by same area Defined for Segrigation Inadequate insp.Method
Sys Why-1 Sys Why-2 Sys Why-3 Sys Why-4 Sys Why-5 MAN-2 MAN-3

New operator Unskilled operator deployed on machine

Area not standardised for simillar appearance Parts segrigation Defect awareness not Proper
MAN-4 MAN-5 Machine-1 Machine-2 Machine-3 Machine-4

Less awareness New operator Vibrator bowl speed more More gap between railing of rolling machine Play in pusher Vibrator bowl speed more

Part Dia under Size

Machine-5 Material-1 Material-2 Material-3 Method1 Material-4

More gap between railing of rolling machine No contribution No contribution Work instruction not available on machine

Poor Handenbility Area not defined for Simillar appearance Parts

Method3 Material-5 MET3 Measurement1 Method4

Operator not follow work instruction Without process parts kept on machine during rolling machine setting No contribution Work instruction not available on machine

identification not Proper Checking Method not Ok insp.std.not followed

Measurement2 Method5 Measurement3 Measurement4 Measurement5 Mat. Handling1 Mat. Handling2 Mat. Handling3 Mat. Handling4

No contribution Operator not follow work instruction Material Handling NG Material Handling NG

Material Keeping Method not followed

Mat. Handling5 Effect QA Matrix Score-1 QA Matrix Score-2 QA Matrix Score-3 QA Matrix Score-4 QA Matrix Score-5 Identification Mark

Thread miss 3 4 OK STAMP PUT ON PACKING LABEL

Wrong Part Mixup 4 4 4 SORTER NAME MENTIONED ON PACKING SLIP

Importance of the problem Action on Stock M2 Actual Date

Assembly not done with thread miss part 100% visual inspection done for thread miss. 10/6/2018

Fit/fun issue Generate 100% material segrigated, 11/28/2018

Add. temp. Detect. cntrl M2 Lot Invoice No. Theme & Target

After 100% visual inspection quality inspector do sampling inspectionfrom each box before dispatch 4300 To eliminate defect of thread miss.

Insp.Method Improved, 6068 To Improve Mixup issue

Defective Samples Displayed
Observation M3 Plan Date Lead time for M3 Closure

After process and data verification it is analyzed that during settingof rolling operation without process parts kept on machine. 10/26/2018 0

it is Obsd.that simillar appearance Parts segrigation area should beSeperated 12/13/2018 0

Updated by Updated on

VIKAS 12/5/2018

06.12.2018 12/6/2018
What-1

Awareness given to the operators about the occurrence of the defect andquality inspector will ensure to scrap all the parts kept on machine during set up approval and during process

Now Table has been Fixed, Brake cam Sorting will be done on Table no.6so that no similar type Mixup in o.k.Material
When-1 WHO-1 How-1 What-2 When-2 WHO-2

10/8/2018 VIKAS Through on job training 100 % visual inspection is to be done for the reported defect 10/6/2018 ANIL

12/3/2018 AJIT SINGH Table arranged & provided at concern area Another Component will be sort after proper cleaning the existtingMaterial. from Table 12/4/2018 AJIT SINGH
How-2 What-3 When-3 WHO-3 How-3 What-4

Through optical sorting machine

Component List Displayed for proper Awareness Awareness ahs been given to all concern Persons by Poison Test 11/29/2018 AJIT SINGH 100% visual inspection strengthen
When-4 WHO-4 How-4 What-5 When-5 WHO-5 How-5 Stnd. Action1

Work instruction revised and point added that without process or settingparts kept on machine should kept on machine.

WORK INSTRUCTION REVISED & DISPLAYED AT CONCERN AREA

Stnd. Action2 Stnd. Action3 Stnd. Action4 Stnd. Action5 Stnd. Actual1 Stnd. Actual2 Stnd. Actual3 Stnd. Actual4

One point lesson made that M6 parts should check by optical sorting 10/15/2018 10/8/2018

PQCS & PFMEA TO BE REVISED 12/1/2018 12/7/2018

Stnd. Actual5 Stnd. Plan1 Stnd. Plan2 Stnd. Plan3 Stnd. Plan4 Stnd. Plan5 Check

10/15/2018 10/8/2018 Monitoring of defect re-occurrence for 3 months after implementation ofcorrective action.

12/3/2018 12/6/2018 STSREM STANDARDISATION

HD Actual HD Plan Horizontal Deployment

12/25/2018 10/25/2018 Optical sorting for all M6 parts

12/30/2018 12/6/2018 ACTION IMPLEMENTATION TO BE DONE ON SIMILAR APPEARNCE PARTS

Supp. Comment Approved by Approved on

It is concluded that if without process part kept on machine and do notscrap immediately then chances of mix-up without operation parts with OK parts. VIKAS 12/5/2018
Act. M3-Implented date TVSM Comment Verified by Verified on Vendor

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