Format No.
:- G4/03
G8D REPORT
Complaint
Title Date Opened Date Updated
Date
CAPA Report 22/3/2024
Product/ Process Information Organisation Inormation
Part Name :
Part No. : MM2028541-012 & MM1538995 Deep Steel
Customer : Metso
D 0 Symptoms ( s ):
Wrong Manufacturing process
D 0 Emergency Response Action ( s): Suspected Qty Verification date
100 % Rejected parts at deep steel end. 7
22/03/2023
D1 Team (Name, Deptt, Phone) Champion:
Name of Team Members Deptt. Contact No. Email ID Problem Description
MM2028541-012 which is required 1856 mm in length, physically found
6 pcs of 900 mm length in the shop floor,
Ramjee Kumar Prod.
[email protected] Defective Sample Photographs
Defective sample details.
Suspected
Rec. No. Inv. No. / Date Batch No.
Qty.
D3 Interim Containment Action( s): % Effective: Date Implemented:
100 % Rejected at manufacturing parts and Procured new raw material for manufacturing this parts
23/03/2024
Checking
Location Sorted Qty.
Method
Ok Qty:
At Customer end Rej. Qty.:
Total Qty :
Ok Qty: 0
At Supplier end Visual Rej. Qty.: 7
Total Qty : 7
Contained Lot Dtails:
Inv. No./ Date Qty. Batch No. Mode of Transp. Identified As
D4 Root Cause Analysis : Wrong Manufacturing Process used for manufacturig parts Responsible :
Occurrence :
Wrong method selected for manufacturing this parts Wajib Khan
Non Detection :
Wrong manufaacturing process Approved by quality person Rahul Saini
Format No. :- G4/03
D 5 Chosen Permanent Corrective Action(S): Manufaturing process decided by team Responsibility : Target Date :
For every new parts a team decide to define the manufacture process Rohitash kumar
Occurrence : 23/03/204
Non Detection :
D 6 Implemented Permanent Corrective Action ( S): Effectiveness % : Date Implemented
100%
Occurrence : For every new parts a team decided for define the manufacture process . 23/03/204
In this team a Person from quality department and 2 person from production
Non Detection : department are there to define the manufacturing process.
D7Prevention of recurrence of the non-conformity (Update for QM-System (FMEA, Procedure-Instructions, Control Plan
Responsibilty : Date Of Updation :
etc.):
D 8 Team and Indivisual Recognition :
Team members : Date : Signature :
Format No. :- G4/03
Format No. :- G4/03
Fishbone Diagram
MACHINE MAN
Unskilled Operator
Roller loosening
Insufficient wire
Pin Gap feed
more
CAUSE
length Oversize
Rusted material used Machine setup not verified
Pin Gap not Decided
waviness in wire
Wrong Inspection
procedure
MATERIAL METHOD
Conclusion :
Relevancy for consideration
Sr. No. Category Cause Item Description (relevant root cause, Reason for excluding
or to be excluded from analysis)
1 Man Possible cause Unskilled Operator Not Valid Verified and found OK
2 Machine Possible cause Loosening of Rollers Not Valid Roller Pressure Verified and found OK
Verified and found that gap was 3.50 mm which causes slipping
3 Machine Most Probable cause Pin Gap more Valid Point
of wire
4 Material Possible cause Rusted or waviness in wire Not Valid Verified and visual appearance of Raw material was OK
Verified and found that no gap was decided in machine setting
5 Method Most Probable cause SetUp approval not verified Valid Point
card
6 Method Possible cause Wrong Inspection Procedure Not Valid Verified and found that procedure was OK on machine
Format No. :- G4/03
WHY WHY ANALYSIS
3 Legged 5 Why Before After
Problem Description: Length Oversize
Explain why the problem occurred: Pin Gap was more
wire slipped
How problem was created
b/w these two
Why: Pin Gap was not decided pins
Why:
Why:
Spinner View
Why: (The root cause of non conformance)
Problem Description: Length Oversize
Explain why the problem was not detected:
No 100 % inspection was carried before.
Why problem was not detected?
Why: Final Inspection was done on the basis of sampling inspection
No Check Gauge
Why:
Why:
Why:
Format No. :- G4/03
wire slipped
b/w these two
pins
