8d report - team oriented problem...
TRANSCRIPT
8D REPORT - TEAM ORIENTED PROBLEM SOLVING
Complaint Information:
Complaint No Apex Ref: E252 Complaint Date: 14 September 2012
Complaint
32 nos 20mm L1RF1S SS Cl 150 Flanged Ball Valves, Bore
Dia. in one side of flange found to be 20mm but other side (Insert Side) found to be 13mm.
Customer Name Apex Valves Pvt Ltd, Kolkata
Part No. L1RF1S Part Description DN20 Reduced bore ball valve class 150
Customer Contact Rakesh Manoj Location: Kolkata
Quantity Rejected nil 8D Updation
Revision date NIL
Date Of Root cause Identified
15 September 2012
Date of Permanent Corrective action implementation
20 September 2012
Date Of Permanent Corrective action
verification
21 September 2012
Date Of Closing 25 October 2012
1D – Problem Solving Team:
NAME FUNCTION CONTACT
S.Kannan L& T--Quality control
R. Ganesan L& T--Quality control
L. Harikanth L&T----Production
Rakesh Manoj L&T-----Sales
J.Mahendran SGP-Quality control
A. Paramasivam SGP-Production
Raja SGP-Production
2D- Problem Description:
Problem Summary – Defect Photo/which
Where Reduced bore
No of defects
1
Defect details
Insert side Run bore diameter less
Specification Dia 19/19.5
Observed Dia13.0/13.5
Supplier Reference
L&T valves-VMU
3D – Containment Actions: Product Stock details: In hand qty information for
Date Location Total Stock
Inspected qty
Rejected Qty
Rework Qty
% Of Rejection
% of Confidence
20/09/2012
VMU 160 160 NA 160 NA 100%
Transit information
Skid Nos Where
(in transit / Ware house)
Certification Status
NOT APPLICABLE
Containment Action details for Reduced Bore Dimension variation: Sr No Action Status
1
Machining arranged for available WIP @ SGP, After machining the valve at insert side checked using Go Gauge for dimension, chamfer
Under machining
4D – Identification and Verification Of Root Cause : Identification Of Root Cause: Cause Effect Diagram for Reduced bore dimensional variation
- A team Brainstorming session carried out on 15 September 2012 resulted in the identification of the following possible Root Causes for the problem.
MACHINE
ENVIRONMENT
20mm Reduced bore
Dimensional variation
MAN
MATERIAL MEASURMENT
METHOD
Random inspection –
not done in insert side
Not machined
Not inspected at insert side due to valve
placed opposite to insert side
Program for machining
not available
Interchangeable as per
design
WHY AND WHY ANALYSIS FOR Reduced bore dimension less at insert side
Why the Reduced bore dimension less in insert side, Due to machining not done , interchangeable insert Why machining is not done Separate Machining program is not available for 20mm Reduced l bore Why separate machining program is not available for 20 mm Reduced bore Because the operator is not inspected the machined insert against the relevant drawing no: LT332077M
5&6D - Define, Implementation and Verification of Permanent Corrective Action : Permanent Corrective Action details for Full bore dimension less at insert side in 20mm Reduced bore:
Sr No
Action Responsibilit
y/Target
Implementation date with
Status
1 Operator awareness training Ganesan/
Mahendran 17 Sep 2012
2 Machining program is created Raja/
Paramasivam 16 Sep 2012
3. 100% inspection during assembly and final inspection
Ganesan/ Mahendran
17 Sep 2012
Gauge for 1P DN15 mm Ball valve , 1P DN 20 mm Ball valve
Corrective Action Effectiveness Verification Details:-----Not applicable
First Lot Skid No : Shipment Date : ETA :
Date
Qty/checked produced
Direct Ok
Rejection qty
Audit Result
Verified By
7D – Action to Prevent Reoccurrence: Sr No
Action Yes / No
Responsibility/
Target
Implementation date with Status
1 Have similar parts / processes been considered?
NA
2 Have operator Work Instructions been upgraded?
Yes
Mahendran/ Raja/Ganesan ON 17 SEP
2012
Completed
3 Have all Gauging requirements been considered?
Yes
Mahendran/Ganesan
ON 17 SEP 2012
Completed
4 Have all drawings been upgraded? N/A
5 Has the FMEA been updated? NA
6 Has the Control Plan been updated? NA
7 Others: One point lesson. N/A
8D – Recognize the team effort and Closing:
Reported By S.KANNAN Sign &Date
25 OCT 2012
Customer Appreciation and Conclusion
NA
Customer Sign & Date
NA