I have looked into the product record and conducted a study.

The study was conducted looking at all the fundamentals without taking any consideration of
known contrarian or defending or accusing any party.
It is a purely a root cause analysis asking why when the going’s does not seem logical or reasonable.
It would be a platform to ask our self what we can do better. Its about PIC, Responsibly and Accountability.

The RED FLAG shows how our respond can be better.

Moving forward

1) Can we produce this product to the Customers’ Specification with what we have in terms of equipment, skills and supervision?
2) We need to tighten Process and Quality Control of this product.
3) Can we be more Proactive, more disciplined in our control ?

a) Production Record

JN P/D Qty Cust Reject # of roll Screening result RED FLAG

screened

64017 10/1/2018 100 Sentienx 10 --- 10 Screening on 18/01/2018 50 % of Screening found

rolls 115 rolls % 1) 1 roll - 4 black gel (3 joints) problems.

2) 5 rolls - No report of issue 1) Why problem was not

3) 4 rolls - a lot of black gel >= 0.6mm detected during production ?

2) At 50 % Reject why No 100

% Screening of the lot?
3) Who makes the decision?

4) Why QA not informed of the

situation?
1) 5) How Even the 4 rolls
rejected during screening
were sent
64018 18/1/18 48 0 (48 rolls) was put On-Hold due to black gel 1) Why wait until 4 months to
rools issue and line was stopped for die cleaning conduct investigation ?

After Customer Reject:

On May-18, screening was conducted on the 48
rolls put On-Hold and disposition was made to
scrapped these 48 rolls due to excessive black
gel issue.

64062 16/3/2018 200 Terang Nusa 4 1) 3 rolls no

rolls 371 rolls issue 2)
1 roll - 1 black gel & 1 white gel. ( 1 joint)
100
10/4/2018 3 Black gel
64135 rolls 1
64136 9/5/2018 200 1 2 joints - 2 black gel
rolls Currently 30 rolls on-hold due to customer
complaint
30 rolls with Oil Mark
100 Found Black & White Oil mark during production.
64147 11/4/2018 rolls 61 Roll 1 to 60 was put on-hold for screening.
64190 16/5/2018 200 0
rolls

Summary of the rejected lots from Terang Nusa

a) 371 rolls rejected out of 600 rolls produced (62%)
b) 1 lot produce in March-18 and 2 lots produced in May-18.
c) March Production – Screen 4 rolls. 3 rolls no report of issue.
d) May Production – Total 400 rolls produced. Screened 1 roll – Reported 2 black gel

Summary of the rejected lots from Sentienx

a) 115 rolls rejected out of 300 rolls produced (38%)
b) 1 lot produce in January-18 and 2 lots produced in April-18.
c) January Production – Screened 10 rolls
d) April Production – Total 200 rolls produced. Total screened 62 rolls.
For JN 64147 – 61 rolls was put on-hold due to Oil Mark. No reported of Gel issue during the screening for Oil mark.