Godrej & Boyce Mfg. Co. Ltd.

Locks division CORRECTIVE & PREVENTIVE ACTION FORM

Format. No.: PCWT Machining / F / CAPA
Department : CNC Start Date : May 2012

Rev: 01

Page 1 of

Nature of Non-Conformance (Tick mark of the following):

a) b) c) d) e) f) g) h) i) j) k) l) m) n) Deviation from IMS policy. Process parameters / Objectives & targets deviating more than 10% adversely from the target. Occurrence of incident.. Non conformity observed during internal & external audits. Internal communication received . External communication received from interested parties. Issues raised in Management review meeting. Complaints received from internal & external customers. Non implementation of management programmes . Deviation in monitoring & measurement parameters beyond legal limits. Non compliance with other requirements. OCPs are not followed. Components non confirming to the desired specification/gauges. Any other :

Details of Non conformity

Component Name : Tool No : Non Confirmity : Depth Variation in logo engraving Herculock Body

Root cause of nonconformance:

Problem - components rejected Why 1 Why 2 Why 3 Why 4 Inappropriate depth variation Depth variation was occuring after band sanding operation on the body Probe was used only once at the start of the operation due to which depth variation occured at a later stage during engraving

Why 5 Root Cause How Probe was used only once at the start of the operation due to which depth variation occured at a later stage during engraving

Godrej & Boyce Mfg. Co. Ltd. Locks division CORRECTIVE & PREVENTIVE ACTION FORM
Format. No.: PCWT Machining / F / CAPA Rev: 01 Page 2 of 2

Proposed Corrective Action :

Probe was used in the HAAS VMC machine for setting every depth . This probe was used to determine length of cut and to check every depth .

Implementation Plan:
Sr. No What Who When

1 Checking for problem

May-12

2 Implementing the usage of probe 3 Cheching if the corrective action worked ( taking trials and checking feasability)

May-12 June 12 / July 12

Verification of effectiveness :
Month Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 Production Rej

248 202 354 354

12 2 0 0

CAPA closed on :

14th july 2012

Signature:________________

Co. Ltd.

E ACTION FORM
Rev: 01
Sr. No : 1

Page 1 of

re than 10% adversely from the target.

yond legal limits.

r band sanding operation on the body start of the operation due to which depth during engraving

start of the operation due to which depth during engraving

Co. Ltd.

E ACTION FORM
Rev: 01 Page 2 of 2

every depth . This probe was used to ck every depth .

How

Checking rejection data and finding out the reason for non - conformity with the possible solution to the non conformity Taking the corrective action for the non - conformity Checking for effectiveness of the capa

Remark

Not as per requirement Not as per requirement No rejection No rejection

ture:________________

Godrej & Boyce Mfg. Co. Ltd. Locks division CORRECTIVE & PREVENTIVE ACTION FORM
Format. No.: PCWT Machining / F / CAPA
Department : CNC Start Date : 03/05/2012

Rev: 01

Page 1 of 2

Nature of Non-Conformance (Tick mark of the following):

a) b) c) d) e) f) g) h) i) j) k) l) m) n) Deviation from IMS policy. Process parameters / Objectives & targets deviating more than 10% adversely from the target. Occurrence of incident.. Non conformity observed during internal & external audits. Internal communication received . External communication received from interested parties. Issues raised in Management review meeting. Complaints received from internal & external customers. Non implementation of management programmes . Deviation in monitoring & measurement parameters beyond legal limits. Non compliance with other requirements. OCPs are not followed. Components non confirming to the desired specification/gauges. Any other :

Details of Non conformity

Component Name : Tool No : Non Confirmity : Problem in inserting the cylinder into the housing and wastage of time in manually deburring the housing Astro Housing Cylinder

Root cause of nonconformance:

Problem Why 1 Why 2 Problem in inserting the cylinder into the housing and wastage of time in manually deburring the housing Cylinder does not get inserted into the housing Housing is tight for the cylinder to enter in

Why 3 Why 4 Why 5 Root Cause How

Deburring was done using hand operations to remove the excessive materials

Deburring was done using hand operations to remove the excessive materials

Godrej & Boyce Mfg. Co. Ltd. Locks division CORRECTIVE & PREVENTIVE ACTION FORM
Format. No.: PCWT Machining / F / CAPA Rev: 01 Page 2 of 2

Proposed Corrective Action :

Champering to be done on the housing. This operation will eliminate the manual deburring operation and would be performed in the turning centres . Also this would eliminate the hard entry of the cylinder into the housing

Implementation Plan:
Sr. No What Who When

1 Study of the problem 2 Implementation of the champhering operation

May-12

May-12

3 Checking for remolval of nonconformity and taking trials

Jul-12

Verification of effectiveness :
Month Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 Production Rej

3192 5132 2768 5364

0 0 0 0

CAPA closed on :

August 2012

Signature:________________

Ltd.

ACTION FORM
Page 1 of 2
Sr. No : 1

ev: 01

n 10% adversely from the target.

nto the housing and wastage of time

nto the housing and wastage of time

o the housing enter in

perations to remove the excessive

perations to remove the excessive

Ltd.

ACTION FORM
Page 2 of 2

Rev: 01

nate the manual deburring operation liminate the hard entry of the cylinder

How

Finding the root cause of the Rework Checking the feasability of the turning operation and how it could eliminate the non conformity and thus remove excessive rework comparing with the Rework data prior to implementation of CAPA

Remark

No Rejection No Rejection No Rejection No Rejection

_______________

Godrej & Boyce Mfg. Co. Ltd. Locks division CORRECTIVE & PREVENTIVE ACTION FORM
Format. No.: PCWT Machining / F / CAPA
Department : CNC Start Date: 2nd june 2012

Rev: 01

Page 1 of

Nature of Non-Conformance (Tick mark of the following):

a) b) c) d) e) f) g) h) i) j) k) l) m) n) Deviation from IMS policy. Process parameters / Objectives & targets deviating more than 10% adversely from the target. Occurrence of incident.. Non conformity observed during internal & external audits. Internal communication received . External communication received from interested parties. Issues raised in Management review meeting. Complaints received from internal & external customers. Non implementation of management programmes . Deviation in monitoring & measurement parameters beyond legal limits. Non compliance with other requirements. OCPs are not followed. Components non confirming to the desired specification/gauges. Any other :

Details of Non conformity

Component Name : Tool No : Non Confirmity : no go gauge present to check the dimensional accuracy of the machined component Astro/VB housing dovetail milling

Root cause of nonconformance:

Problem - components rejected Why 1 Why 2 Rejection of components of Astro/VB housing dovetail milling Only go gauges were present to check the components

Why 3 Why 4 Why 5 Root Cause How

Absence of no go gauge to checked the machined components due to which components were rejected

Absence of no go gauge to checked the machined components due to which components were rejected

Godrej & Boyce Mfg. Co. Ltd. Locks division CORRECTIVE & PREVENTIVE ACTION FORM
Format. No.: PCWT Machining / F / CAPA Rev: 01 Page 2 of 2

Proposed Corrective Action :

Implementation of no go gauges to check the dimensional accuracy of the components machined so as to eliminate the rejection

Implementation Plan:
Sr. No What Who When

1 Checking for problem and documenting it 2 Ordering the no go guages and implementing the plan 3 Cheching if the corrective action worked ( taking trials and checking rejection )

Jun-12

Jun-12

Aug-12

Verification of effectiveness :
Month Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 Production Rej

4664 2706 19479 20054 25505 19796

44 96 24 0 0 0

CAPA closed on :

September 2012

Signature:________________

Co. Ltd.

E ACTION FORM
Rev: 01
Sr. No : 1

Page 1 of

re than 10% adversely from the target.

yond legal limits.

dimensional accuracy of the machined

VB housing dovetail milling heck the components

ed the machined components due to

ed the machined components due to

Co. Ltd.

E ACTION FORM
Rev: 01 Page 2 of 2

ccuracy of the components machined so ction

How

Finding out the reason for the rejection and drafting the plan of action Checking the gauges and making sure that they are implemented checking the feasibility of the CAPA and deriving the results out of it .

Remark

Dimensional innacuracy Dimensional innacuracy Dimensional innacuracy No rejection No rejection No rejection

Signature:________________