5 RULE SHEET (PROBLEM SOLVING SHEET)

1. TITLE QFR No : Line rejection.

THEME Bore u/s QFR DATE : 7/5/2016
PART NO. 715-0030
HMCL PLANT : HMCD / HMCG / HMCH
PART NAME GSR P-90
SUPPLIER HI TECH GEARS LTD MANESAR
2. OCCURING CONDITION 3.1 ACTUAL PART CHECKING RESULT 3.2 MASS PRODUCTION PART CHECKING RESULT 3.4 MFG. PROCESS
DATE SHIFT INSPECTION QTY REJ. QTY SN PROC
REMARKS
SEPECIFICATION 8.978-9.005

S.NO DHG 8.05.2016 A 2500 0 1 RAW Material Re

1 OK
8.05.2016 B 3000 0
OBSERVATION 2 OK
GSR P-90 Component rejected due 2 R/w inspection
3 OK
Bore U/S 4 OK 3 Billet cutting
5 OK CONCLUSION:-We Inspected in Final inspection area 5500 nos & found 4 Billet heating
all components ok.
5 Forging
tracking

DATE/PLANT Status. 6 Hardening & tem

7 shot blasting
8.05.2016/Vulcan 12000
8 CNC Turning1st
9 CNC Turning 2 n
10 Final inspection
11 Despatch
CONCLUSION:-we have done containment action done in Vulcan end for
Bore u/s after 100 % material segregation found not ok.

4. ROOT CAUSE ANALYSIS 6. CONFIRMATION TO COUNTER MEASURE

4.1 REGENERATION ( VALIDATION ) 5.1 TEMPRARORY COUNTERMEASURE IMPL. DATE
DATE SHIFT
1. 100 % Checked at CUSTOMER end and KKM end. 07.05.2016

A
8/5/2016
B

Bore U/S Problem due to Air Gauge Unit

problem because air gauge unit filter was
block.Air was not coming properly in air 5.2 PERMANENT COUNTERMEASURE IMPL. DATE
gauge unit.
1. Air Gauge unit changed immediately. 07.05.2016

2. Instruction given to the operator for if any problem face in future

07.05.2016
related this immediate inform to Q.A.Inspector.
 Bore U/S Problem due to Air Gauge Unit
problem because air gauge unit filter was
block.Air was not coming properly in air
gauge unit.

2. Instruction given to the operator for if any problem face in future

07.05.2016
related this immediate inform to Q.A.Inspector.

3. Instruction given to inspector APG will check with master pcs in

07.05.2016
checking frequency time.

4.After Checking the bore black marker mark on Bore Dia. 07.05.2016
4.2 ROOT CAUSE
7. STANDARDISATION
5.Change In gwi of APG Setting. 14.05.2016
Operator Untrained Change In GWI KKM/GWI/91

STEP 1 2 3 4 5
OCCURANCE
4.3 WHY WHY ANALYSIS

CAUSE

Bore U/S Problem due to Air Air Gauge unit filter was Air gauge unit filter blocked so
Bore U/S So air plug Gauge disturbed
Gauge Unit Problem block properly air was not coming.
FLOW CAUSE

The component bore u/s Operator did not checked air

mixed with OK material. plug gauge with master pcs.
BLEM SOLVING SHEET)
DATE
APPD. BY CHECK BY PREP. BY

A.K Singh Chetan Kr. Deepu Pandey

3.4 MFG. PROCESS STUDY AND CAUSE ANALYSIS

PROCESS STATUS KEY OBSERVATION

RAW Material Rec. OK

R/w inspection OK

OK
Billet heating OK

Forging OK

Hardening & temparing OK

shot blasting OK

CNC Turning1st OK
CNC Turning 2 nd NG Bore U/S
Final inspection NG Bore U/S
Despatch OK

6. CONFIRMATION TO COUNTER MEASURE EFFECTIVENESS

INSPECTION QTY REJECTION REMARKS

QTY

2500
0

3000
0
7. STANDARDISATION
Change In GWI KKM/GWI/91

HMCL : REVIEW / VERIFICATION