8D - PROBLEM RESOLUTION REPORT

Part Name Governor Cover JCB-310 Customer Part No 28214705

Drawing No 28214705 Complaint date 20.06.2012

1 PROBLEM AWARENESS

Problem Scope Problem Severity Problem Source % Defect Process History

New Safety X In-House MFG / Line PPAP - Ppk ---

X ---
Regulatory X RPN Rating ---

Existing Functional P Customer Present Ppk / Cpk ---

P ---
Aesthetic X Present PPM ---
Internal process audit
Reopened X Reliability X Field Domestic/Export --- rating /Score ---

Process Deployment
Others X PDI --- ---
Sheet

2 PROBLEM DEFINITION (Attach Photographic details of failure, Attach Trend data, Pareto analysis, Warranty etc)

Attachments P

Photo / Sketch X

Trend chart X
Concentricity 0.2 measures up to 0.30.
Pareto analysis X

Control Chart X

Warranty data X

3 CONTAINMENT ACTION / SHORT TERM ACTION

No Immediate Action Taken Date Responsible Break Point Status

100% segregated the pipeline components both DTVS and KKR.

4 ROOT CAUSE ANALYSIS - WHY ~ WHY .. ANALYSIS (Attach Ishikawa diagram-Cause & Effect)

Probable
Root Cause Analysis P/
Cause 1 Cause 2 Cause 3
Tools used X
Cause's

Mounting Hole Pin broken In Die

1 WHY ? --- --- Brainstorming P
Casting.

Due to Pin Broken Loading not

2 WHY ? --- --- Pareto analysis X
properly done.

Idle Shaft Bore operation and

3 WHY ? chamfer operation done in two --- --- Histogram X
steps.

4 WHY ? --- --- Ishikawa - Fish Bone X

5 WHY ? --- --- Scatter dia X

% Contribution Control chart X

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 5 CORRECTIVE ACTIONS / LONG TERM ACTION (Attach Photographs of actions taken)

Identified Root Cause from

Corrective Actions Planned / taken Error - Proofing Responsible Date
5th WHY
100% Inspection introduced in Line and
Idle Shaft Bore operation and Idle Shaft bore and chamfer operation
Final stage inspection and also
chamfer operation done in done in same machine using Back Chamfer Mr.V.Murugan 23.06.2012
planned Concentricity gauge
two steps. Tool.
(TgtDt:30.07.12)
6 MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW)
Date of
No Corrective Actions Taken Target Actual Result of Action
Review

Idle Shaft bore and chamfer operation done in

1 22.06.2012 23.06.12 Implemented 23.06.2012
same machine using Back Chamfer Tool.

7A PREVENTION (List other similar processes & products with the potential for the same defect)

No Processes / Products Preventive Action Error Proofing Date

Not applicable

7B REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)

Pif
No QMS Document Responsible Planned Date Actual Date Status
Yes
1 Drawing / Process Flow Diagram
2 PFMEA / DFMEA / PPAP
3 Control Plan
4 Work Instruction/Calibration Plan
5 Others(specify)

8 PROBLEM CLOSURE & SIGN-OFF

PROBLEM PROGRESS SUMMARY CLOSURE SIGN-OFF

No Phase Start Date Completion Team Member Area Sign-off

1 Problem Definition 20.06.2012 20.06.2012 KK Ramesh KKR Metals

2 Containment Action 20.06.2012 20.06.2012 Sathysseelan KKR Metals

3 Root Cause analysis 20.06.2012 20.06.2012 P.BALASUBRAMANI KKR Metals

4 Corrective Action 22.06.2012 23.06.2012

5 Solution Confirmation 23.06.2012 23.06.2012

6 Closure 23.06.2012 23.06.2012

Total Time required for rejected product analysis in days = 4

(Determination of root cause, corrective action & monitoring effectiveness of implementation)

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 8D - PROBLEM RESOLUTION REPORT

Part Name Customer Part No

Drawing No Complaint date

1 PROBLEM AWARENESS

Problem Scope Problem Severity Problem Source % Defect Process History

New Safety X In-House MFG / Line PPAP - Ppk ---

X ---
Regulatory X RPN Rating ---

Existing Functional X Customer Present Ppk / Cpk ---

X ---
Aesthetic X Present PPM ---
Internal process audit
Reopened X Reliability X Field Domestic/Export --- rating /Score ---

Process Deployment
Others X PDI --- ---
Sheet

2 PROBLEM DEFINITION (Attach Photographic details of failure, Attach Trend data, Pareto analysis, Warranty etc)

Attachments P

Photo / Sketch X

Trend chart X

Pareto analysis X

Control Chart X

Warranty data X

3 CONTAINMENT ACTION / SHORT TERM ACTION

No Immediate Action Taken Date Responsible Break Point Status

4 ROOT CAUSE ANALYSIS - WHY ~ WHY .. ANALYSIS (Attach Ishikawa diagram-Cause & Effect)

Probable
Root Cause Analysis P/
Cause 1 Cause 2 Cause 3
Tools used X
Cause's

1 WHY ? --- --- Brainstorming X

2 WHY ? --- --- Pareto analysis X

3 WHY ? --- --- Histogram X

4 WHY ? --- --- Ishikawa - Fish Bone X

5 WHY ? --- --- Scatter dia X

% Contribution Control chart X

Page 3 of 4
 5 CORRECTIVE ACTIONS / LONG TERM ACTION (Attach Photographs of actions taken)

Identified Root Cause from

Corrective Actions Planned / taken Error - Proofing Responsible Date
5th WHY

6 MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW)

Date of
No Corrective Actions Taken Target Actual Result of Action
Review

7A PREVENTION (List other similar processes & products with the potential for the same defect)

No Processes / Products Preventive Action Error Proofing Date

Not applicable

7B REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)

Pif
No QMS Document Responsible Planned Date Actual Date Status
Yes
1 Drawing / Process Flow Diagram
2 PFMEA / DFMEA / PPAP
3 Control Plan
4 Work Instruction/Calibration Plan
5 Others(specify)

8 PROBLEM CLOSURE & SIGN-OFF

PROBLEM PROGRESS SUMMARY CLOSURE SIGN-OFF

No Phase Start Date Completion Team Member Area Sign-off

1 Problem Definition

2 Containment Action

3 Root Cause analysis

4 Corrective Action

5 Solution Confirmation

6 Closure

Total Time required for rejected product analysis in days =

(Determination of root cause, corrective action & monitoring effectiveness of implementation)

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