Presentation Qc Department

7/29/2019 Presentation Qc Department

1/33

No. of

Test

Equipt.

Calibration

Planned

Calibration

Achieved

35 35 35

Analysis - Calibration Report of Test Equ

35 35

0

5

10

15

20

25

30

35

40

No. of Test Equipt. Calibration Planne

Analysis - Calibration Report of T


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pments

35

Calibration Achieved

st Equipments

Series1


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MonthTotal No. of Times

Received Materials.Jul-12 44

Aug-12 38

Sep-12 85

Oct-12 68

Analysis - Incoming Inspe

4438

2 2

0

10

20

30

40

50

60

70

80

90

Jul-12 Aug-12


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Total Rejection

2

2

1

1 1stOct-15th Oct.

ction (PVC + Copper+MB)

85

68

1 1

Sep-12 Oct-12

Analysis - Incoming Inspection (PVC +

Copper+MB) Total No. of Times

Received Materials.

Analysis - Incoming Inspection (PVC +

Copper+MB) Total Rejection

Linear (Analysis - Incoming Inspection

(PVC + Copper+MB) Total Rejection)


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Months Total Prd In ''Mtr''

Total Rejection in

Mtrs. ppm

Jul-12 739,798 23Aug-12 646052 1015

Sep-12 657056 556

Oct-12 285650 0

Total 2328556 1594 685


Total Rejection in

Mtrs. ppmJul-12 84,688 0

Aug-12 89,732 45

Sep-12 156201 25

Oct-12 56,358 5

Total 386979 75 193.8

PVC Cable Production- Inprocess Rejection

Nyvin Cable Production -Inprocess Rejection


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84,68889,732

156201

56,358

0 45 25 50

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

Jul-12 Aug-12 Sep-12 Oct-12

Total Prd In ''Mtr''

Total Rejection in Mtrs.

739,798

646052 657056

285650

23 1015 556 00

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000





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Total Rejection in

Mtrs. ppm

Jul-12 739,798 23Aug-12 646052 0

Sep-12 657056 0

Oct-12 285650 0

Total 2328556 23 10


Total Rejection in

Mtrs. ppmJul-12 84,688 0

Aug-12 89,732 0

Sep-12 156201 0

Oct-12 56,358 0

Total 386979 0 0

PVC Cable Production- Final Rejection

Nyvin Cable Production - Final Rejection


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739,798

646052 657056

285650

23 1015 556 00

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000




84,688 89,732

156201

56,358

0 45 25 50

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000





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Month No.of Breakdowns RectifiedJul-12 0 0

Aug-12 0 0

Sep-12 2 0Oct-12 0 0

No.Of Breakdown / Error Analysis - Tes

0 0

2

00 0 0 00 0

1

00

0.5

1

1.5

2

2.5



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Un Rectified0

0

10

Equipments

No.Of Breakdown / Error Analysis - Test

Equipments No.of Breakdowns


Equipments Rectified


Equipments Un Rectified


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CUSTOMER COMPLAINT REGISTER

PRR.NO. DATE CUSTOMER PART NO. REP. STATUS

CCN-1 1.10.12 HI-COOL

22 AWG BC X 1 CORE

UL-1007 WIRE. BLACK

COLOUR

CCN-2 16.10.12 E.K.ELECTRONICS

0.50 SQMM BC X 1

CORE ROHS & REACH

WIRE

CCN-3 22.10.12 Ramson Engineering

1.00 SQMM BC X 1CORE PVC INS. WIRE

GREY -300 Mtrs. &

2.50 SQ MM BC X 1

CORE GREY 200

MTRS.

CCN-4 6.11.12 BSA

0.50 SQMM BC X 2

CORE (Inner Yellow,

Brown) FLRY B

SHIELDED CABLE

Outer BLACK-500 Mtrs.

CCN-5 6.11.12 BSA

0.75 SQ MM BC X 1

CORE FLRY B WIRE

WHITE COLOUR -1200

Mtrs. ATAMBERNATH

PLANT


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CUSTOMER COMPLAINT ROOT CAUSE IMMEDIATE ACTION PLAN

NO PRINTING ON 4 N0s OF

COILS & COILING NOT

PROPER PRINTER NOT SET PROPERLY Visited at HI-COOL

0.189,0.188,0.190MM

SIZE BC COPPER FOUND

They required +_ 0.002

mm Tolerance only.

INSTEAD OF 0.20 MM

BC , USED 0.193MM BC

COPPER

On daviation basis this

time customer

accepted the material.

BLACK COPPER ISSUE IN

BOTH SIZE OF WIRES.

Without inspection of QC

Person materials were

dispatched

REPLACEMENT GIVEN

TO CUSTOMER By Mr.

Rajendra on Dtd.

22.10.2012

OUTER SHEATHING OPEN ISSUE

OUTER SHEATH THICKNESS

NOT MAINTAINED PROPERLY.

FRESH LOT PRODUCTION

TAKEN & SENT THE

MATERIAL TO CUSTOMER.

Diameter Variation 1.90 MM TO

2.30 MM

NOT SETTING DIAMETER

PROPERLY ON EXTR. M/C


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CA/PA ACTION DATE & RESP. CLOSED/OPEN

Instructed to operator for care taking

on printing matter. 1.10.12 OPEN

Before taking the production ,

first approval should be taken

from QA & MD 17.10.12 CLOSED

PROCESS IT IS INSTRUCTED

TO BUNCHING M/C OPERATOR ,

TO SELECT ONLY BRIGHTANNEALED COPPER & ALSO

BEFORE DESPATCH ALL

MATERIALS SHOULD BE

FINALLY CHECKED BY QC

PERSON. 22.10.12 CLOSED

INSTRUCTION GIVEN TO OPERATOR

FOR PROPER MAINTAINING OF OUTER

SHEATH THICKNESS 7.11.12 CLOSED

7.11.12 OPEN


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DOC. ENCLOSED


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NC REGISTER QC & PROD.

Sr. No. Date Description of Non-Conformity

2 May-12

3 Jun-12

Emerson export 28core x 1.0sqmm 2nd lay stranding

defect ( core damage) due to wrong selection of Die _

Yogesh reworked -100Mtr

4 Jun-12

On Reliance item FRLS not printed on cable as per

customer requirement, QTY : 3000M-black -Multicore-

cable,1.50sqmm x 3 core BC - Vinod -operator

5 Jun-12

2CORE not printed on multi core 0.75 sqmm BC cable

HIREL-grey cable -1700Mtr, Reworked Kumar -operator

6 Jun-12

Wrong production taken , 50/42swg ATC White -

5000Mtr instead of White/Red.

Anna/Rajendra

7 Jun-12

Bobst items- 22 AWG BC X 11core 1st

lay wrong

stranding -100mtr,

Reworked - Kamlesh

8 Jun-12 ESSEL1.50 sqmm x 4core wrong stranding 50 Mtrs.

Without Drain wire Tape Shielded 200Mtr Reliance-

0.5sqmmx 4Pair Manish-Taping m/c.

Wrong production taken , BSA 16awg Green colour -

10000Mtr. ANNA1 May-12


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Kamlesh

9 Jun-12

THYSEN 0.75sqmm x 3core Flat cable Wrong outer PVC

sheathed instead of HOFR pvc sheathing pvc used.-

Ambernath Harness .

Vinod.

10 Jul-12 ESSEL-1.50 SQ MM BC X 4 CORE

ROHS CABLE PRINTING MISTAKE.-

VINOD

11 Aug-12 Emerson H.W.

10.00 Sq mm ATC X 1 core FRLS . Red.

Prakash Patil

12 Sept.2012 Quality Automation

1.00 sqmm x 4 core BC .

200 Mtrs.

Sambhajeet / Patil/Anna/Rajendra/Kumar


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13 Sept. 2012 Quality Automation

1.00 sqmm x 2 core BC .400 Mtrs.


14 Sept. 2012 Quality Automation

1.00 sqmm x 2 core BC .400 Mtrs.


15 Sept. 2012 Harness Dept.

Uninyvin wire Like size-12 & 14 appx.-

25 Mtrs

16 Nov. 2012 KUSHAL UDYOG

0.50 SQMM ATC X 6 CORE BRAIDED CABLE. - 22 MTRS.


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Reason for Non- Conformity Corrective Action Taken

No availability of cable Continuity on

core to core shorted

Removed & Rectified V The 2nd Lay

Stranding

By over view & wrong setting of

printing matter.

Removed the existing printing and Re-

printed as per requirement

By over view & wrong setting of

printing matter

Removed the existing printing and Re-

printed as per requirement

1. Due to wrong preparation of job

sheet.

White colour is sent to store for other

costomers future requirements and

New production is taken as per the

costomers requirement.

Not carefully study of p.o.

Due to wrong selection of gear.

Removed the cores and Re-stranding

done.

Missing of one core . Only 3 core

stranding instead of 4 CORE

STRANDING.

Removed the cores and Re-stranding

done

Wrong colour Job sheet prepared as

per Customer P.O. mentioned short

description like GR instead of GREY

Green colour cable sent to Store foranother customers future requirements

and New production taken as per

customer colour requirement GR

means GREY colour.

Under training person is on taping

m/c. so this incident happened.Re-worked 200 mtrs


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Even mentioned in job sheet

for using HOFR PVC . By

over looking mistakehappened by Operator & No

proper communication

between Production Head &

Operator.

Sent to store for costomers

future requirements. And

Taken the new production

By over looking Removed the

This mistake was happened

BY OPERATOR

Existing printing & re-

printing done as per

costomer requirement

Instead of RED Colour ,

BLACK Colour production

taken.

Black colour sent to store for

future requirements of

customers And new

production taken..

Wrong job sheet preparation

Wrong Aluminium Mylar

taping .

Removed the existing tape

.And Re-taping properly.Also removing of outer

sheathing


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.And Re-taping properly.

Taping.


taping .


.And Re-taping properly.

Rough surface & Bubbles on

surface of wire Disposal of wire.

Rough surface & Bubbles on

surface of wire Due to

Improper setting of Extruder

M/c Temp.

Removed the Outer sheathing of said

cable & Set the proper Temp. of

Extruder & Start the production.


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Preventive Action Taken

Method of Disposition / Rectification (If

Applicable)

1) Inform to Marketing dept. While

receiving the Orders from Customers,colour of wire/ cable to be mention clearly

in their P.O.s.

2 ) During preparation of Internal Job

Sheet , production Head to be check

description of Colour completely.

Instructed to stranding m/c operator to

carefully select the Die sizes before running

the items. NC closed: Date : 30.5.2012

Instruction is given to operator regarding

proper selection of printing matter as per the

job sheet.

NC closed: Date : 30.6.2012

Instruction is given to operator regarding

proper selection of printing matter as per the

job sheet

Before preparation of job sheets carefully

study the p.o. and than prepare the job sheet.

NC : Closed: Date : 14.06.2012

Instructed to stranding m/c Operrator for

proper selection of gear. NC : Closed : Date: 08.06.2012

Instructed to stranding m/c Operrator for

proper care should be taking. NC : Closed : Date : 16.06.2012

NC closed: 27.5.2012

Trained person is look out the taping m/c. NC closed:Date: 04.06.12


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Instructed the Operator to

Carefully study the job sheet

before run the Extr. M/c. NC : Closed : Date : 19.06.2012

Instructed to operator before

running any item,proper care

should be taking while selecting

the printing matter. NC: Closed :Date :22.07.2012

and than run the extruder m/c.

Also check the printing matter in

starting length.

Instructed to Production Head ,

before preparation of job sheets

carefully study the P.O. And than

prepare the job sheet. NC : Closed :Date:30.08.2012

Instructed to taping m/c operator

to follow the carefully time to timechanges & instructions from

production head

NC: Closed :Date:18.09.2012


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to follow the carefully time to time

changes & instructions from

production head

NC: Closed :Date :18.09.2012


to follow the carefully time to time

changes & instructions from

production head NC: Closed :18.09.2012

Instruction given to operator to

check the surface of wire during

the Nylon coating time.

NC: Closed : Date : 22.09.2012

Instructed to OPERRATOR Before start the

production set the proper Temp. of Extruder

M/c.

NC: Closed : Date : 8.11.2012

Presentation Qc Department

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