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

Rahul Saini QC [email protected]

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