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WORK INSTRUCTION FOR ABNORMAL SITUATIONS Annexure:-
Rev :- Date:-
ACTIVITIES TO BE DONE
Sr. No. ABNORMAL SITUATION ACTION TAKEN SETUP RETROACTIVE CONTAINMENT
REMARKS RESPONSIBILITY
APPROVAL INSPECTION ACTION

1.Take set up approval

Stop Production. Take corrective Quality &
Tool/Machine producing 2.Check all the parts produced by the
1 action and restart the production Yes Yes Yes Production
defective parts continuously machine since last check
after Setup Approval 3.Take containment action Supervisor

1.Take set up approval

Operator produces defective Stop Production. Educate the Quality &
2 parts continuously (Operator operator and restart the production Yes Yes Yes 2.Check all the parts produced by the Production
machine since last check
carelessness/mistake) after Setup Approval Supervisor
3.Take containment action

Stop Production. Take corrective

action in previous process, Educate 1.Take set up approval Quality &
Operator detects defects 2.Check all the parts produced by the
3 the operator of previous process Yes Yes Yes Production
produced by previous process machine since last check
and restart the Production after Supervisor
Setup approval 3.Take containment action

Stop inspection, Give training & 1.Check all the parts checked by the
4 Inspector failled in poison test follow the instruction as per WI SE- No Yes Yes inspector Quality
WI-29 3.Take containment action

1.Take set up approval

Poka-yoke does not detect Stop Production. Take corrective Quality &
2.Check all the parts produced by the
5 defective parts(Poka-yoke not action and restart the production Yes Yes Yes Production
working) after Setup Approval. machine since last check Supervisor
3.Take containment action

Check the part which is produce at the time Quality &

6 Power Failure Start the machine when power No No No of power cut, if part reject then scrap the Production
comes
part. Supervisor

Shift all the fallen parts to suspected Quality &

7 Parts fallen down No No No Check all the parts falled down Production
part area Supervisor

Quality &
Shift whole bin material to
8 Bin fallen down No No No Check all the parts falled down Production
suspected part area
Supervisor

Put red stciker till Calibration & Re- Quality &

9 Instrument fallen down No No No Don't check any part with this instrument Production
Calibration the instrument Supervisor

Quality &
Put red sticker till Validation & done Production
10 Gauge fallen down No No No Don't check any part with this gauge
the Re-Validation of the gauge
Supervisor
1.Take set up approval
Machine parameter found out Stop Production. Start production 2.Check all the parts produced since last Quality &
11 of spec. during routine Yes Yes Yes Production
checking after resetting the parameters check of parameters Supervisor
3.Take containment action for 1 day
Stop Production. Move all the parts
Quality &
to suspected parts area and start Reject all material & discuss with Top
12 Different grade material used Yes Yes No Production
production with ok material after management & Customer Supervisor
Setup approval

1.Take set up approval Quality &

13 Production started with lower check all material produce by lower Yes No Yes 2.Take containment action for lower capacity Production
capacity m/c capacity machine
m/c Supervisor

1.Take set up approval Quality &

Production started with under check all material produce by under
14 skilled operator skilled operator Yes No Yes 2.Take containment action for under skilled Production
operator Supervisor

1.Take set up approval

2.Check all the parts produced by the Quality &
15 Production started with Shift whole bin material to Yes Yes Yes machine since last check Production
temporery repaire suspected part area 3.Take containment action for temporery Supervisor
repaire

Stop Production. Take corrective 1.Take set up approval Quality &

Machine producing abnormal
16 noise action in the machine and restart Yes Yes No 2.Check all the parts produced by the Production
the prodcution after Setup approval machine since last check Supervisor

Any type of accident in Stop Production. Take corrective 1.Take set up approval Quality &
action in the machine/tool and
17 machine/tool during running restart the production after Setup Yes Yes No 2.Check all the parts produced by the Production
production machine since last check Supervisor
Approval

Stop Production. Tight the clamp of 1.Take set up approval Quality &
Loose the clamp of tool tool and start the production after 2.Check all the parts produced by the Production
18 Yes Yes No
during running production
Setup approval machine since last check Supervisor

Found without identification Send the all material/parts in Check all the parts which is found without Quality &
19 material/ parts in shop floor No No No Production
and anywhere in company suspected part area identification Supervisor

Repeated breakage of 1.Take set up approval

Stop Production. Take corrective Quality &
20 production action and restart the production Yes Yes Yes 2.Check all the parts produced by the Production
equipment(machine,die and machine since last check
tool) after Setup Approval 3.Take containment action Supervisor