Format No.

F-QA-08
QUALITY PROBLEM REPORT Rev. No./Date 02/15.02.2018
(QPR) Issue Date
QPR NO. :
15.02.2018

ORIGINAL : TO KEEP IN PRODUCT FILE AT LINE QUALITY STATION Problem Occurrence Stage

Concern Details (To be filled by the Department who is raising the QPR ) Customer -

Production -
RECORD THE FOLLOWING DETAILS & DISTRIBUTE QPR IN DAILY RED BIN MEETING RQA
Customer : Part Name : Part Number : I/H Manufacturing

HI-LEX CASING CAP AC4C171F00

Lot Qty. Qty. Rejected (How many) : Part/s given for analysis Is it a Repeat Problem -

Yes Yes
74000 976
No No
Description of condition (Problem reported ?) : QPR Raised by -

Date-
casing cap O.D Oversize.
Sign.
QPR recd. By
Date
Sign.
Below fields to be filled by the Department receiving the QPR
Defect Confirmation (HOW) :- (Recd. Part Observations)
(With Photo if Available)
DURING FINAL INSPECTION

Interim Containment Action (WITHIN 3 HRS. OF PROBLEM RECEIVING):

checked and varfied the all material at finel inspection.

Notification to Customer required - Yes No

If Yes, Responsibility and Target Date - Impl. Date -
Stock Sort details as below: (TO BE INITIATED AFTER SEGG. OF PROBLEM RECEIVING)
Parts Checked Qty. Identification
[Link]. Date Resp. B'Code O.K N.G. Remarks
Location Checked Mark
1 Customer PDI

2 Customer Assy line

3 Customer Stores

4 Transit to Customer

5 In Process

6 PDI

7 Main Stores

FISH BONE DIAGRAM

MAN MACHINE
operator negligence. Tool (Die)wear
out

machine fingre tool was

loose
Operator illness

OD OVERSIZE

wire over size

maximum
drill Size was Wrong drawing used
using.

MATERIAL METHOD
 DATA ANALYSIS (USING WHY-WHY APPROACH)
Occurance. Detection
1 Casing Cap AC4C171F00 O.D oversize 1 Casing Cap AC4C171F00 O.D oversize
Inprocess inspection Freqency done on
2 Die Size increase During production 2
Sampling Basis

3 During production burr genrete inside machine die area

During setting changed machine die area not cleaned

4
properly.

5 Check point was not added in WI

ROOT CAUSE
For Occurrence

Casing Cap AC4C171F00 O.D oversize due to burr genrate inside Machine Die Area During Production During
Setting changed Die area not Cleaned Properly.

For Out Flow

Inprocess inspection Freqency done on Sampling Basis.

COUNTERMEASURE (C/M) TAKEN

Effective
[Link] Countermeasures Resp. Tgt. Date Impl Dt
Batch Code
For Occurrence

during setting changed clean the Machine die inside area check point added in
1 vulcan 04/01/2023 04/01/2023
WI

2 training given to operators and line quality inspector for problem. vulcan 04/01/2023 04/01/2023

3 opl displayed near by machine.

For Flow Out

1 Defect updated in eye chart. vulcan 04/01/2023 04/01/2023

inprocess inspection freqency increase for next 3 lot(2 hour to one Hour)
2 vulcan 04/01/2023 04/01/2023

STANDARDIZATION CHECK
[Link] Activites Yes/No Rev. No. Date Remarks
1 CRN raised
2 PFMEA updated
3 Process Flow
4 Poka Yoke Implemented
5 Poka Yoke Verification Sheet
6 Control Plan
7 Drawing updated
8 WI updated
9 PIS updated
10 PDQA updated
11 Master samples updated
12 Horizontal deplyment reviewed
13 Lessons Learned
14 Others, pl. specify eye chart,training sheet.
EFFECTIVENESS CHECK (6 Lots)
1st 2nd 3rd 4th 5th 6th
Dispatc
h Date
Qty.
Status
Prepared By Verified By Approved By
Date 04/01/2023 04/01/2023

Sign

NOTE - Please attach the back up data with the same sheet