8D Problem Analysis Report

[ROTOR BIG ID DEPTH] Updated

Customer: TPIL Date Issue Occurred: 23-Aug-19

Program: RTFTH-55 REGN 4D Due Date: 23-Aug-19
Product: ROTOR 8D Due Date: In Process
Issue #: ROTOR BIG ID DEPTH OVER Date Issue Closed: 1-Sep-19
Champion Name Champion Title Champion Phone Number Champion E-mail Address
Kuldeep Singh QUALITY ENGINEER 8126866800 quality@poojametalprocessors.com
Additional Team Member Name(s) Title(s) Phone Number(s) E-mail Address(es)
Dharamveer Singh PLANT HEAD 9582220163 production@poojametalprocessors.c
1. Team Members Dinesh QUALITY ENGINEER 9050905122
Dharmendra PRODUCTION 8010404101

2. Problem Description
3. Interim Containment
4. Root Cause
Description (Describe issue in terms of what, where, when and how many)
Rotor Big ID Depth over observed 26mm instead of 22.20 - 23.40 , At tecumseh on 23-08-2019 , 35 pcs
Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..)
Production Losses/Line interruptions
Facilities Involved (Customer, Tecumseh Products and any Suppliers)
Pooja metal and Tecumseh Products
What actions were taken to immediately protect the customer and contain any suspect inventory?
No Material at PMP we checked Exixting Material at our End
Other Product/Platform at Risk ? Identification of certified material ?
Check all existing Identified with OK Tag
Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)
Pooja Metal Have No such material
Sorted Defect # Interim Containment Start Date
All Material 0 9/3/2019
ROOT CAUSE
Why Made & How Verified
1. Rotor Big Id depth made over size, As machine is programmed for the cutting of big ID on the appropriate lamination to cut but the cylinder stopped
working in between. Big Id depth will be checked by ID gauge that has been implemented on the line.
Why Shipped & How Verified
Material Big Id depth is checked by vernier at FPA and hourley Basis it’s the neglegency of the Operator not to detect the NG parts.
Permanent corrective action
Corrective Action for Why Made

Machine Operator will ensure and will check the cylinder on hourley basis wethear the cylinder is working or not.
5. Permanent Corrective
Action Corrective Action for Why Shipped

In the final inspection stage the Big ID will be checked by gauge and no rotor will be shipped with out checking the Big id depth.

Verification of Corrective Action: Has the issue been turned on and off? How? Verification through statical evidence / hypothesis testing. Verification of
corrective action for each why made and why shipped is required.

We start the production first of we FPA then continue the production. Cross verification by Line Engineer for inspected Parts in every hour per shift (5 Nos).

6. Verification of Corrrective Action Owner Name C.A. Owner Phone Number C.A. Owner E-mail Address Target Completion Date
Corrective Actions
Dharmendra 8010404101 9/4/2019

Build Date for Certified Material How Will New Parts Be Identified?
8/4/2019 by putting identification on packing
How will this issue be avoided in the future?
Cross verification by Line Engineer for inspected Parts in every hour per shift (5 Nos).
Other Facilities or Platforms At Risk
Name Part Number C.A. Owner for Follow Up Due Date
Due Date
Affected Document Owner for Update Date
7. Prevention DFMEA
PFMEA
Has the necessary documentation been Control Plan kuldeep Singh 9/27/2019
updated? Process Flow
Operation Instructions
Drawing
Design Standards
Closure Statement
8. Closure & Team Celebration
Identify the Root Causes (What caused the defect to produced (occurren

Why was this defect made (occurrence)? Why -1

Big Id Depth Over

Why was this defect shipped (escape)? Why -1

Inspector was
not aware of such
Problem

Why was this not recognized (System)? Why -1

At Inspection
stage material
not checked
sed the defect to produced (occurrence), shipped (escape) and to bypass System)

Why -2 Why -3 Why -4

Cylinder stopped at Machine Programming

punching stage Fault

Why -2 Why -3 Why -4

As in FPA the
Big Id depth once set
sample pieces are
does not vary
checked

Why -2 Why -3 Why -4

Inspector skipped
the Big ID Inspection
ass System)

Why -5

Why -5

Why -5
 POOJA
CONTROL PLAN
PROTOTYPE PRELAUNCH PRODUCTION Key contact/phone :-Head Operation
CONTROL PLAN NUMBER : CP/ROTOR/TCM Cr.Team Members:Production,Quality,Tool room
PART NUMBER : 35,40,45,51,55(REGN) Plant approval/ date :
PART NAME : Rotor(Casted & Machined)
CUSTOMER SUPPLIER CODE : - Other approval / date (if reqd) :
Part/ Process Name/
Machine, Device CHARACTERISTICS Special
Process Operation Jig,Tools Char.
No. Description For Mfg. No. PRODUCT PROCESS

Raw
Material
10 ---- 01 Weight /Qty. ---- Mn
Receving/In
spection

---- 02 Material ---- Mn

---- 03 Appearance ---- Mn

04 Coil Packing ---- Mn

---- 05 Sheet Thickness ---- Mj

06 Width ---- Mj

Lamination
20 Pneumatic Press-220T 01
Punching
Appearance ---- Mn

02 Sheet Thickness ---- Mj

02 Sheet Thickness ---- Mj

03 O.D. ---- Mj

04 No.of slots ---- Mj

05 Dimension ---- Mj

06 Stack Height ---- Mj

07 Dimension ---- Mj

08 Dimension ---- Mj
 09 Eccentricity ---- Mj

12 Skew Angle 35mm ---- Mj

13 Skew Angle 40mm ---- Mj

14 Skew Angle 45mm ---- Mj

15 Skew Angle ---- Mj

16 Skew Angle 55mm ---- Mj

30 Aluminum 01 Mn
Vertical Die Casting (60 ton) Appearance ----
Die Casting
30 Aluminum 01 Mn
Vertical Die Casting (60 ton) Appearance ----
Die Casting

04 O.D.endring height ---- Mn

05 Endering Height ---- Mn

09 Big i.d.depth ---- Mn

13 No.of fins ---- Mn

40 Gate 01 Mn
Hydraullic Press
Pressing

Gate Pressing

50 I.D 01 Mn
Drill Machine Dimension ----
Chamfering
 01 Small ID ---- Mj

60 I.D. 02 Mj
Honning Machine Taper & ovality
Reaming

03 Big ID ---- Mn

01 Outer dia. ---- Mj

70 O.D.Turning SPM Lathe

02 Taper ovality ---- Mj

80 Blueing Blueing Furnace 01 Blue Oxide Formation ---- Mn

Drill M/C
90 Buffing With Wire 1 Rust Remove
Brush ,

Wash in M.T Oil

MT Oil &
100 Tank & Air 01 Dust & Rust Remove Mj
Air Pressure
Cleaning
 Final Plug
110.a inspection gauge/Mar 01 I.D Mj
(I.D) poss

Final
110.b Inspection( T.I.R GAUGE 02 T.I.R Mj
T.I.R)

Final
110.c inspection( O.D GAUGE 03 Outer dia. Mj
O.D)

final
110.d
inspection ROTO SCOPE 04 Mj
(bar M/C
broken)

120
Packing & Manual 01 As Per Packing Standard
Despatch

Abbreviation used for class:C=critical,Mj=Major(Fit Function),Mn=Minor(Normal)

TROL PLAN
/phone :-Head Operation DOC.NO.:PRD/10 REVISION NO.:02
mbers:Production,Quality,Tool room ISSUE:01 DATED:27.09.2019
val/ date : Customer Engineering approval:
Customer Quality approval:
val / date (if reqd) : Other approval:
METHODS
Product / Process Evaluation/ SAMPLE
CONTROL REACTION PLAN
Specification/ Measurement
SIZE FREQ. METHOD
Tolerance Technique

Supplier TC.
Stock
As Per Challan 100% Per Lot Inform to Supplier
Register

Lab Report

Supplier TC. 01Pc. Per Lot

Receiving
As per Spec. Inspection Reject and Return to supplier

Lab Report 01Pc. 6Month

Receiving
Free From Burr , Dent , Scratch, Line ,Crack Visual 01pc. Per Lot Reject and Return to supplier
Inspection

Coils To be Stacked Vertically in Proper Packing Receiving

Visual 01pc. Per Lot Reject and Return to supplier
In O.D.And I.D. Inspection

Receiving
0.5mm ± 0.01 Micrometer 01pc. Per Lot Reject and Return to supplier
Inspection

Vernier Receiving
208.5mm -0.1mm 01pc. Per Lot Reject and Return to supplier
Caliper Inspection

04pc. set up

Inprocess
Free From Burr , Dent , Scratch, Line ,Crack Visual Inspection Reset and Verify

02pc. 4hrs.

04pc. set up

Inprocess
0.5mm ± 0.01 Micrometer Inspection Reset and Verify
 Inprocess
0.5mm ± 0.01 Micrometer Inspection Reset and Verify

02pc. 4hrs.

04pc. set up

Vernier Inprocess
61.01mm Inspection Reset and Verify
Caliper

02pc. 4hrs.

04pc. set up

Inprocess
28+2 Visual Inspection Reset and Verify

02pc. 4hrs.

04pc. set up

Inprocess
15.857mm-15.87mm Plug Gauge Inspection Reset and Verify

02pc. 4hrs.

04pc. set up

Vernier Reset and

model/As per Drg Reset and Verify
Caliper Verify

02pc. 4hrs.

04pc. set up

Inprocess
29.35mm-29.38mm Plug Gauge Inspection Reset and Verify

02pc. 4hrs.

04pc. set up

Vernier Inprocess
59.45mm-59.5mm Inspection Reset and Verify
Caliper

02pc. 4hrs.
 04pc. set up

Inprocess
0.05mm Max. Dial Gauge Reset and Verify
Inspection

02pc. 4hrs.

04pc. set up

Dial Height
Gauge+Bevel Inprocess
12.30 0- 14.30 0 Inspection Reset and Verify
protector

02pc. 4hrs.

04pc. set up

Dial Height Inprocess

11 0- 13 0 Gauge+Bevel Reset and Verify
protector Inspection

02pc. 4hrs.

04pc. set up

Dial Height Inprocess

9.30 0- 11.30 0 Gauge+Bevel Reset and Verify
Inspection
protector

02pc. 4hrs.

04pc. set up

Dial Height Inprocess

model/As per Drg Gauge+Bevel Reset and Verify
protector Inspection

02pc. 4hrs.

04pc. set up

Dial Height
Inprocess
9 0 - 11 0 Gauge+Bevel Reset and Verify
Inspection
protector

02pc. 4hrs.

04pc. set up

Vernier Inprocess
Free From Burr , Dent mark , Die cast defect Reset and Verify
Caliper Inspection
 Vernier Inprocess
Free From Burr , Dent mark , Die cast defect Reset and Verify
Caliper Inspection

02pc. 4hrs.

04pc. set up

Height Inprocess
15mm-15.50mm Reset and Verify
gauge Inspection

02pc. 4hrs.

04pc. set up

Height Inprocess
9.3mm-9.7mm Reset and Verify
gauge Inspection

02pc. 4hrs.

04pc. set up

Depth
Inprocess
22.2mm-23.4mm gauge/Verni Reset and Verify
Inspection
er Caliper
02pc. 4hrs.

04pc. set up

Inprocess
7nos. Visual Reset and Verify
Inspection

02pc. 4hrs.

04pc. set up

Inprocess
Gate Pressed or not Visual Reset and Verify
Inspection

02pc. 4hrs.

Inprocess
0.45mm-1.15mmX45 0 Visually 100% Reject/Rework
Inspection
 04pc. set up

Marposs Inprocess
15.872mm-15.880mm Reset and Verify
Gauge Inspection

02pc. 4hrs.

04pc. set up

0.007max. Marposs Inprocess

Inspection Reset and Verify
Gauge

02pc. 4hrs.

04pc. set up

Vernier
Inprocess
29.11mm-29.62mm Caliper/Plug Reset and Verify
Inspection
gauge
02pc. 4hrs.

04pc. set up

Inprocess
60.30mm-60.35mm Dial Gauge Reset and Verify
Inspection

02pc. 4hrs.

04pc. set up

Inprocess
0.030mm Micrometer Reset and Verify
Inspection

02pc. 4hrs.

Adjust
Parameter,Pr
As per attached Process. Visually 100% if not OK Re-process
ocess
Logsheet

No Rust & NO Chips Visually 100% 100% if not OK Re-process

No Dust & Rust Visually 100% 100% if not OK Re-process

 15.872-15.880 plug gauge 100% Per Lot PDIR Segregate and Verify

0.050 mm T.I.R GAUGE 100% Per Lot PDIR Segregate and Verify

60.30-60.35 mm Snap Gauge 100% Per Lot PDIR Segregate and Verify

No bar broken Roto Scope M/c 100% Per Lot PDIR Segregate and Verify

As Per Packing Standard 01Box Per Lot PDIR Re-Pack and Verify