CAPA

QUALITY PDI COMPLAINT REGISTER
AMW
Sl.No Date of receipt Date of Complaint Logged Plant/Line Part Name / Part Number Probem Details
PDI Complaint Register

Received Qty (Nos) Problem faced QTY (Nos) Photo No. of time Occuranc e the same problem with same part every batch Effectiveness CAPA Responsibi Received lity on CAPA Status Ist Month 2 nd Month 3 rd Month Remarks
17/09/2010
17/09/2010
STYLE M-300 WCC047 WELDING
PROSITY
2160
215
ANIL MISHRA/ YOGESH
open
17/09/2010
17/09/2010
STYLE M-300 WCC047 WELDING
GRAINDING MARK
2160
100
ANIL MISHRA/ YOGESH
10/9/2010
10/9/2010
ASSY LINE-2
GMI-WCC023
SINGLE WELD MISSING
2016
ANIL MISHRA/ YOGESH
9/9/2010
9/9/2010
PRESS SHOP
ITL-WTF004
WRONG BOLT HOLE POSITION
469
HEMANT SINGH/ YOGESH
21/08/2010
21/08/2010
PRESS SHOP
MSIL WCC046
VENT HOLE DAMAGE
1400
18/09/2010
18/09/2010
PAINT SHOP
MSIL WCC046
WRINKLES
830
500
BK THAKUR
10/9/2010
10/9/2010
RIM LINE
MSIL RCC023
TOOL MARK
1800
150
RAJKUMA R/YOGES H ANIL MISHRA/ YOGESH
15/09/2010
15/09/2010
ASSY LINE-2
M-200 WCC023 WITHOUT LPM DOT
456
45
15/09/2010
15/09/2010
PRESS SHOP
M-200 DCC012
DISC PITTED
350
25
10
20/09/2010
20/09/2010
ASSY LINE-2
M-300 WCC047 WITHOUT LPM DOT
650
63
ANIL MISHRA/ YOGESH
11
20/09/2010
STYLE 20/09/2010 M-300 WCC047 WELDING
INTERMITENT WELDING
900
ANIL MISHRA/ YOGESH
12
20/09/2010
20/09/2010
ASSY LINE-2
M-200 WCC023
WITHOUT SPATTER CLEANING
450
250
ANIL MISHRA/ YOGESH
13
22/09/2010
22/09/2010
RIM LINE
M-200 WCC023
VALVE HOLE DAMAGE
845
ANIL MISHRA/ YOGESH
14
23/09/2010
23/09/2010
PAINT SHOP
M-200 WCC023
OIL DROPS
422
27
BK THAKUR
15
25/09/2010
25/09/2010
STYLE M-300 WCC047 ALL WELD MISSING WELDING
1350
48
ANIL MISHRA/ YOGESH
16
24/09/2010
24/09/2010
PAINT SHOP
M-300 WCC047
PAINT DROPS FROM BOTTON
850
45
BK THAKUR
17
1/9/2010
1/9/2010
ASSY LINE-2
M-200 WCC023
WELD SHIFT
1,460
100%
ANIL MISHRA/ YOGESH
18
1/9/2010
1/9/2010
RIM LINE
M-200 WCC023
TOOL MARK RIM
1,145
50%
RAJKUMA R/YOGES H
19
29/09/2010
29/09/2010
RIM LINE
FORCE MOTORS BUT WELD WCC040 THROUGH CRACK
1008
Baskaran, M./RAJKU MAR/YOG ESH ANIL MISHRA/ YOGESH
20
10/1/2010
10/1/2010
ASSY LINE-2
FORCE MOTORS SINGLE WELD MISS WCC040
1008
21
30/09/2010
30/09/2010
RIM LINE
M-200 WCC023
DOUBBLE VALVE HOLE
1440
RAJKUMA R/YOGES H HEMANT SINGH/ YOGESH
22
25/09/2010
25/09/2010
PRESS SHOP
WTF002
BOLT HOLE DAMAGE
131
23
24
25
Format No:- F/WR/QC/37
Month & Year of Release with Revision Level:-Sep'10/R0
Counter Measure For PDI Complaints

Problem Description: Porosity in WCC047 welding Cause: 1. Inspection of unpainted wheel is not effective
Corrective Actions: Detection can be done only by visual. 1. Associates at unpainted wheel inspection to be trained for requirements Yogesh Srinivasan
Preventive Actions: 1. Training to the associates on Wheel Defects Yogesh Srinivasan 2. Immediate Inspection after welding Machine operator 3. Incoming discs and Rim should be free from oil - Mr. Yogesh Srinivasan 4. Patrol Inspection - Mr. Alpesh & Mr. Karthikeyan

Problem Description: Single Weld Missing in M200(WCC023) Cause: 1. Inspection of unpainted wheel is not effective
Preventive Actions: 1. Training to the associates on Wheel Defects Yogesh Srinivasan 2. Sensor for weld miss detection to be incorporated - Mr. Baskaran 3. Patrol inspection Mr. Alpesh & Mr. Karthikeyan

Problem Description: Tool Mark in MSIL Rim RCC023 Cause: 1. Inspection of unpainted wheel is not effective
Corrective Actions: Detection can be done only by visual. 1. Associates at rim and unpainted wheel inspection to be trained for requirements Yogesh Srinivasan
Preventive Actions: 1. Training to the associates on rim Defects Yogesh Srinivasan 2. Associate at rim line to be taught on requirements - Mr. P. N. Bhatt & Mr. Rajkumar 3. Patrol inspection Mr. Alpesh & Mr. Karthikeyan

Problem Description: M300 Deep Grinding Mark Cause: 1. Inspection of unpainted wheel is not effective
Preventive Actions: 1. Training to the associates on Wheel Defects Yogesh Srinivasan 2. Associate at rework to be taught on requirements - Mr. Anil Mishra 3. Patrol inspection Mr. Alpesh & Mr. Karthikeyan
Date : 21.09.2010 Concern / Problem / Area for improvement:
Initiated by : B.K.Thakur
To reduce the Paint overflow, blackness & paint dust defects in MSIL wheels from 3.6% to1.0 %. Current Situation: . Presently we are getting 1.0% paint defect.
ASIA MOTORWORKS LTD.
Corrective & Preventive Action Form

Format No. : F/WR/MR/009 Ret. Period : 3 Years
Correction Action: 1. Training given to all painters for manual spray painting after the auto reciprocator painting in manual booth.( WI W/WR/PP1/022) 2. Training given to operator for proper cleaning of wheels before painting. 3. Training given to painter for bore area cleaning & touch up painting before final inspection.(W/WR/PP1/51).
SIGN : DATE : Team members Leader : BKT, Mr. Vipul, Mr. Chintan, Mr. Kuldeep
Target Date :
31.10.2010
Actual Date :
Root cause : 1. Unskilled painter. 2. Line stoppage during the power failure & tea break.
SIGN : Attach sheets / Fish bone Diagram / Parts Analysis etc. if reqd. Correction Action : Sr. No. Action Training given to all painter 1 2 Stable painter (min. 6 no.)
DATE :21.09.2010
Responsibility BKT BKT
Date immediate 21.09.2010
FISH BONE - PAINT DEFECT ANALYSIS
enviroment
man
booth temp. booth balance
painter touch up
Paint Defect ( overflow, blackness & bore Dust) manual gun paint viscosity application process Setting cleaning
material
method
Reciprocator
DATE : 08.10.10
Corrective & Preventive Action Report - 8D

SHIFT : G
CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Gutter pit crack Corrective Actions Planned / taken 100% parts will be checked NA Error - Proofing Responsibility V ikas Garg
Date of Im plem entation
Next lot
MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken 100% parts will be checked Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status
7A
REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)

# 1 QMS Document Control Plan 2 3 4 5 6 7 8 Process sheet Drawing / Process Flow Diagram PFMEA / DFMEA / PPAP Acceptance Standard PM Checklist Work Instruction/Calibration Plan Other (Specify) In-house Supplier No No No No No NA P if Yes No Responsibility Planned date Actual Date Status
7B
PREVENTION/LESSONS LEARNED (List ot her similar processes & product s wit h t he pot ent ial for t he same defect ) Sr 1 Processes / Products Inspection shall be carried out 100% Corrective Actions Error - Proofing Responsibility V ikrant Date of Imple
# 1 2 3 4 5 6
PROBLEM CLOSURE & SIGN-OFF PROBLEM PROGRESS SUMMARY Phase Start Date Actual Date Problem Definition Containment Action Root Cause analysis Corrective Action Solution Confirmation Closure 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10
Completion 20.09.10 20.09.10 20.09.10 20.09.10
Closure Sign-off Team Member Function Vikas Garg Vikrant Mfg Quality
Sign-0ff
Total Time required for rejected product analysis in days
= PA GE 2OF2
(Det erminat ion of root cause, correct ive act ion & monit oring effect iveness of implement at ion) MANAGEMENT VERIFICATION & CLOSURE Sign Date Name Head MFG
Prepared By Vikas Garg FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level
QA & Materials
Prodn
PPC
Tool Eng.
Approved By
Other
M ay'08/R0
DATE : 08.10.2010

SHIFT : G
Part Name Part No Drg Ref Date

1
WHEEL WTK005 WTK005
Vehicle Model Chassis No Customer
17.09.2010
Feedback from
AMW PDI
Problem Awareness Problem Scope New Problem Severity Safety Regulatory Functional Existing Aesthetic Reliability Reopened Others PDI Field Com plaints Dom estic / Export Line
Wheel rim line no. 5
Problem Source
Yes
Yes
MFG Shop AMW Wheel Rim Supplier
WHEEL RIM
% defect 1%
Part Nos
% defect
PROBLEM DEFINITION (At t ach Phot ographic det ails of failure, At t ach T rend dat a, Paret o analy sis, Warrant y et c)
Butt wel d Cr ack
CONTAINMENT ACTION / SHORT TERM ACTION
Implementation Sr Actions Planned / taken

CONT A I NMENT : Exist ing lot w ill be checked for 100%
1 17.09.2010
Start Date
End Date
17.11.2010
Responsibility
AMW
Break Point
SHORT T ERM A CT I ON:Next lot w ill be t aken care by 100% inspect ion
2 Next lot AMW
ROOT CAUSE ANALYSIS
(At t ach Ishi kaw a di agram -Cause & Ef f ect ) WHY ~ WHY... ANALYSIS Root Cause Root Cause
Voltage Drop 1 WHY ?
Increase in load 2 WHY ?
3 WHY ?
4 WHY ?
5 WHY ?
Prepared By Prashant Varia FORM AT NO : F/W R/M R/007
Approved By
M onth& Year Of Release with Revision level
M ay'08/R0
DATE : 08.10.10

SHIFT : G
CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Butt weld Crack Corrective Actions Planned / taken Capacitor bank put in operation NA Error - Proofing Responsibility A run Tidke
Next lot
MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken Capacitor bank put in operation Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status
7A

7B
# 1 2 3 4 5 6
Completion 20.09.10 20.09.10 20.09.10 05.10.10
Closure Sign-off Team Member Function Prasshant Varia Vikrant Arun Tidke Mfg Quality Electrical
Sign-0ff
= PA GE 2OF2
Prepared By Prashant Varia FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level
QA & Materials
Prodn
PPC
Tool Eng.
Approved By
Other
M ay'08/R0
DATE : 08.10.2010

SHIFT : G

1
WHEEL WTK005 WTK005
17.09.2010
Feedback from
AMW PDI
Problem Source
Yes
Yes
WHEEL RIM
% defect 1%
Part Nos
% defect
Butt wel d deep pi tti ng mar k

1 17.09.2010
Start Date
End Date
17.11.2010
Responsibility
AMW
Break Point
2 Next lot AMW
ROOT CAUSE ANALYSIS
Flash cutting top Clam p blocks not ok 1 WHY ?
2 WHY ?
3 WHY ?
4 WHY ?
5 WHY ?
Prepared By Prashant Varia FORM AT NO : F/W R/M R/007
Approved By
M ay'08/R0
DATE : 08.10.10

SHIFT : G
CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Butt weld deep pitting mark Corrective Actions Planned / taken Reconditioning done for the top clamping blocks NA Error - Proofing Responsibility Prashant v aria
Next lot
MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken Reconditioning done for the top clamping blocks Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status
7A

7B
# 1 2 3 4 5 6
Completion 20.09.10 20.09.10 20.09.10 20.09.10
Closure Sign-off Team Member Function Prasshant Varia Vikrant Mfg Quality
Sign-0ff
= PA GE 2OF2
Prepared By Prashant Varia FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level
QA & Materials
Prodn
PPC
Tool Eng.
Approved By
Other
M ay'08/R0
DATE : 08.10.2010

SHIFT : G

1
WTK004 WTK004
17.09.2010
Feedback from
AMW PDI
Problem Source
Yes
Yes
WHEEL RIM
% defect 1%
Part Nos
% defect
T yr e seat ar ea bur r

1 17.09.2010
Start Date
End Date
17.11.2010
Responsibility
AMW
Break Point
2 Next lot AMW
ROOT CAUSE ANALYSIS
Jobs put in final roll form er without cleaning grinding dust. 1 WHY ?
2 WHY ?
3 WHY ?
4 WHY ?
5 WHY ?
Prepared By Vikas Garg FORM AT NO : F/W R/M R/007
Approved By
M ay'08/R0
DATE : 08.10.10

SHIFT : G
CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Tyre seat area burr Corrective Actions Planned / taken Grinding dust will be cleaned before feeding jobs for final roll former. NA Error - Proofing Responsibility V ikas Garg
Next lot
MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken Grinding dust will be cleaned before feeding jobs for final roll former. Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status
7A

7B
# 1 2 3 4 5 6
Completion 20.09.10 20.09.10 20.09.10 05.10.10
Closure Sign-off Team Member Function Prasshant Varia Vikrant Mfg Quality
Sign-0ff
= PA GE 2OF2
(Det erminat ion of root cause, correct ive act ion & monit oring effect iveness of implement at ion) MANAGEMENT VERIFICATION & CLOSURE Sign Date
Name Head MFG

Prepared By Prashant Varia FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level M ay'08/R0
QA & Materials
Prodn
PPC
Tool Eng.
Approved By
Other
BOLT SHIFTED
45
BOLT SHIFTED
OVER PENETRATION
WELD PENETRATION IN RIM
45
G DISC ASSY(WTR024)
65

Problem Description: Porosity in stiffner welding.3Nos Cause: 1.Oil found in disc 2.Inspection not carried out after stiffener welding however done at disc rework & after assembly
Corrective Actions: Detection can be done only by visual. 1. Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel 2. Incoming disc quality to be improved - Resp Mr.Anandha Perumal
Preventive Actions: Immediate Inspection after stiffener welding. 1. Incoming discs for stiffner welding should be free from oil-Resp.Mr.Anantha Perumal 2. Machine operator to be taught on requirements - Resp. Mr.Aravindhan 3. Patrol Inspection - Resp Mr.Chetan Patel

Problem Description: Rear Side Marking.1Nos Cause: 1.Wrong positioning / handling of rims at Rim Line
Corrective Actions: Detection can be done only by visual 1.Associates at rim line to be taught on requirements - Resp. Mr.Dilip 2.Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel
Preventive Actions: Training to the operators on rim handling 1. Machine operator to be taught on requirements Resp.Mr.Dhanshuk 2. Patrol Inspection - Resp Mr.Chetan Patel

Problem Description: Uneven Lug Weld & Over Penetration.2Nos Cause: 1.Process not stabilized
Corrective Actions: Detection can be done only by visual 1. Associates at lug welding to be taught on requirements - Resp. Mr.Dilip 2. Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel
Preventive Actions: Standardizing welding parameters 1. Process Qualification - Resp Mr.Aravindhan

Problem Description: Bolt Twist Problem. Cause: Fixtures worn out
Corrective Actions: Detection can be done only by visual. 1. Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel
Preventive Actions: Mistake proofing fixtures 1. Fixtures to be reconditioned - Resp Mr.Tharun / Mr.Aravindhan

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QUALITY PDI COMPLAINT REGISTER

PDI Complaint Register

STYLE M-300 WCC047 WELDING

ANIL MISHRA/ YOGESH

STYLE M-300 WCC047 WELDING

ANIL MISHRA/ YOGESH

SINGLE WELD MISSING

ANIL MISHRA/ YOGESH

WRONG BOLT HOLE POSITION

HEMANT SINGH/ YOGESH

VENT HOLE DAMAGE

HEMANT SINGH/ YOGESH

RAJKUMA R/YOGES H ANIL MISHRA/ YOGESH

M-200 WCC023 WITHOUT LPM DOT

HEMANT SINGH/ YOGESH

M-300 WCC047 WITHOUT LPM DOT

ANIL MISHRA/ YOGESH

STYLE 20/09/2010 M-300 WCC047 WELDING

ANIL MISHRA/ YOGESH

WITHOUT SPATTER CLEANING

ANIL MISHRA/ YOGESH

VALVE HOLE DAMAGE

ANIL MISHRA/ YOGESH

STYLE M-300 WCC047 ALL WELD MISSING WELDING

ANIL MISHRA/ YOGESH

PAINT DROPS FROM BOTTON

ANIL MISHRA/ YOGESH

TOOL MARK RIM

FORCE MOTORS BUT WELD WCC040 THROUGH CRACK

Baskaran, M./RAJKU MAR/YOG ESH ANIL MISHRA/ YOGESH

FORCE MOTORS SINGLE WELD MISS WCC040

DOUBBLE VALVE HOLE

RAJKUMA R/YOGES H HEMANT SINGH/ YOGESH

BOLT HOLE DAMAGE

Format No:- F/WR/QC/37

Month & Year of Release with Revision Level:-Sep'10/R0

Counter Measure For PDI Complaints

Counter Measure For PDI Complaints

Counter Measure For PDI Complaints

Counter Measure For PDI Complaints

Date : 21.09.2010 Concern / Problem / Area for improvement:

ASIA MOTORWORKS LTD.

Corrective & Preventive Action Form

Responsibility BKT BKT

Date immediate 21.09.2010

FISH BONE - PAINT DEFECT ANALYSIS

booth temp. booth balance

Corrective & Preventive Action Report - 8D

REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)

Completion 20.09.10 20.09.10 20.09.10 20.09.10

Total Time required for rejected product analysis in days

Corrective & Preventive Action Report - 8D

Part Name Part No Drg Ref Date

WHEEL WTK005 WTK005

Vehicle Model Chassis No Customer

MFG Shop AMW Wheel Rim Supplier

CONTAINMENT ACTION / SHORT TERM ACTION

Implementation Sr Actions Planned / taken

ROOT CAUSE ANALYSIS

Voltage Drop 1 WHY ?

Increase in load 2 WHY ?

Prepared By Prashant Varia FORM AT NO : F/W R/M R/007

M onth& Year Of Release with Revision level