4W + 1H ACTION PLAN TO IMPROVE OPEN ISSUE CONDUCTED DURING APF HVPT AUDIT

S/NO WHAT Min. & Max. inventory level need to display. As per system for LM24 color coding is white & blue. But actualfound Mix coding red & blue. For ADC 12 FIFO is not clear (In case of new order) Chemical composition record mentain only one year. But as per our requirement safety characteristics record must be kept min. 13 years. All documents which we are using as a standard need to control & also list of documents with Rev. history need to prepare. WHERE HOW Inventory level to be updated in the display board Matl.Colour coding to be done as per system for LM24 FIFO to be followed as per WI NO:ST/01 WHEN WHO STATUS

Store

11/28/2011

Prabhu

Pending

Store

11/28/2011

Prabhu

Pending

Store

11/28/2011

Prabhu

Pending

QA

NPD/QMS

During material melting, you are using 50%ingots & 50%runner & riser of of APF material. You control by no. of runners. So please study for APF runner weight & address in your documents matrix. Our suggestion is you have weight machine pl. use weight m/c to control mixing ratio. After melting, you are not checking chemical composition. Need to check & address in control plan.

PDC

All runner matl.and ingot matl.to be weighed once in a shift and issued as per requirement.

NPD

Control plan to be updated

kiruba

Pending

Air pressure for Lubrication tank shows 0.4 as per system required 0.6 Need to add check point of air pressure in control plan, daily m/c check sheet. To avoid mxiup of scrap, need to display grade on each scrap container. Melting temp. need to recorded on time & temp. chart. Work procedure in case of power failure, if component struck in die, check point need to clear. Cut section/ x-ray checking and maching result verification need to add in control plan. (frequency/size) For visual inspection need to display limit sample for better under standing like soldering, catching, flows. x-ray work standard need to display partwise, need clear (m/c parameter, location of check, direction of inspection & specification of acceptance areawise & clamping direction. One sample for 1mm hole need to make for daily calibrating the machine & add in daily machine check sheet. x-ray inspector skill need to improve.

Maint

Measuring gauge to be calibrated and replaced. Process parameter to be updated in control plan. Separate colour rej bin to be provided for each grade Temp trend to be updated and displayed. WI to be provided for power failure action

Senthil

Pending

NPD/PDC

Kiruba/Rajeshkum

Pending

10

PDC

RajeshKumar

Pending

11

PDC

RajeshKumar

Pending

12

PDC

Alagappan

Pending

13

NPD

Control plan to be updated

Kiruba

Pending

14

PDC

All defect limit samples to be provided nearer to the machine

Alagappan

Pending

15

QA

16

QA

17

QA

18

Fetling Process: Work Instruction for fettling, location of fettling, sequence & holding location need to make. For visual check point, need to display limit sample. Flow of parts (before and after inspection) Need to clear. Need to prepare location Max. parts on table to freese(one bin before inspection and I bin after insp.) For drop parts during procedure is there , but actual is not implemented (no separate bin and no record) Daily m/c check points/check sheets not available for shot blasting. Process parameter for shotblasting m/c need to address in control plan and need to check daily. WI and limit samples need to make and display at FI. For FI NG parts, counter measure not found need to start. All gauges location need to define and work procedure with sequence need to make. Control chart x bar and R chart need to be display on the line for critical parameter.

PDC

WI to be provided for fetlig process.

19

PDC

Comparison sample to be displayed near visual inspection

Rajeshkumar

Pending

20

QA

Training and WI to be provided for inspection process flow.

Pending

21

PDC

All dropped parts to be collected in separate tray.

Alagappan

Pending

22

Maint

23

PDC

Control plan to be updated and followed.

Rajeshkumar

Pending

24

QA

25

PDC/MC shop

26

QA

27

CLOSED

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SPC study need to be done for all critica parameter. In case of power failure Work procedure need to make and possible interlinkage between machine and rejection Process parameter ,clamping pressure,air pressure ,etc.Need to address in control planand check during daily machine check sheet. Rejection analysis for PDI inspection with counter measure need to be start. Work procedure for APF pinion housing and end housng with limit samples need to be displayed. Cuting procedure for blow inspection need to be make as per discussion(cutting location ,direction and grinding depth)

QA One point lesson to be provided for power failure action.

29

MC SHOP

11/25/2011

Karna

Pending

30

NPD

31

PDC/MC shop

32

QA

33

PDC

WI to be provided for blow hole proof cuttinh parts

Rajeshkumar

Pending