CAPA Thread Out

ROHTAS FASTENERS PVT. LTD.
SUPPLIER / IN-PLANT QUALITY PROBLEM ANALYSIS AND COUNTERMEASURE SHEET (5
VENDOR / DEPTT : PART NAME :
PROBLEM PART NO. :
ACTUAL CONTENTS ACTUAL INVESTIGATION (PRODN.

PLACE OF RANK Man
MODEL: Machine
OCCURRENCE
SAFETY /
REJ. QTY.:
PERFORMANCE/
OTHERS:
DETAIL OF PROBLEM (DATA/SKETCH)
Method Material
ROOT CAUSE : COUNTERMEASURE DETAIL

CONTAINMENT ACTION :
(SKETCH/DATA/DETAIL)
CORRECTIVE ACTION :
PREVENTIVE ACTION :
WHY-WHY ANALYSIS : MONITORING SHEET (REOCCURAN

PROBLEM I II III IV V May'17 June'17 III MONTH IV MONTH
Occurrence
FMT NO.: F/QA/08-A
VT. LTD. REV.NO.: 01
UNTERMEASURE SHEET (5-RULE) EFF.DT.: 20/04/18
APPROVED
PROBLEM NO. PREPARED BY CHECKED BY DATE:
BY
ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)

PROCESS FLOW RESULT ANALYSIS
RESP. IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)

FEED BACK TO OTHER (HORIZONTALLY
ONITORING SHEET (REOCCURANCE OF DEFECT ) (QTY./GRAPH) DEPLOYMENT)
V MONTH VI MONTH REMARKS PROCESS ( IF SAME TYPE
PROBLEM)
SUPPLIER / IN-PLANT QUALITY PROBLEM ANALYSIS AND COUNTERMEASURE SH
VENDOR / DEPTT : Inhouse Analysis PART NAME : Boot Collar
PROBLEM Thread out PART NO. : 009-M85-044
ACTUAL CONTENTS ACTUAL INVESTIGATION (

PLACE OF RANK
MODEL: : MACHINE
OCCURRENCE MEN
SAFETY /
REJ. QTY.:
PERFORMANCE/ Play in machine undersize
Inhouse Analysis transfer fingure punch Allocation of
used operator &
FIT FUNCTION inspectors
OTHERS:
Clamping not ok
Improper lubrication on tool
DETAIL OF PROBLEM (DATA/SKETCH) and die (collent flow shift)
Neglegence
of inspector
SOP not
followed Poor material
forgability
Drill Out
Thread Out in Boot Collar Poor handling
of setting parts
Work instruction not
available
Method MATERIAL
ROOT CAUSE : COUNTERMEASURE DETAIL

CORRECTIVE ACTION :
(SKETCH/DATA/DETAIL) 1) Quality alert made and displayed in all relevent locations.
2) More than 100 sample will be checked for tapping parameter by

Inprocess inspection engineer before release the material for Tappin
1) Quality alert made and displayed in all relevent locations.
2) More than 100 sample will be checked for tapping parameter by

preventive action to be for next three supplied lot.
PREVENTIVE ACTION :
Drill out during Drilling operation as clamping area was less for holding 1. Drilling process removed and through hole done in forging itself
part in fixture.
2. Forging drawing revised and conc. Added
3. Defect awareness training given to operators
4. 2) More than 100 sample will be checked for tapping parameter b

preventive action to be for next three supplied lot.
WHY-WHY ANALYSIS : MONITORING SHEET (REOC

PROBLEM I II III IV V I MONTH II MONTH III MONTH
During drilling drill out
part loose due to less

direction due to hole
Tapping out during
Tapping process
Tap guided in tilt
clamping area in
clamping fixture
Occurrence
out.
FMT NO.: F/QA/08-A
PVT. LTD. REV.NO.: 01
COUNTERMEASURE SHEET (5-RULE) EFF.DT.: 20/04/18
APPROVED
Boot Collar PROBLEM NO. PREPARED BY CHECKED BY
BY
DATE:
009-M85-044
ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)

PROCESS FLOW RESULT ANALYSIS
MEN
OK
RM Incoming
un-skilled inspector
OK
RM Inspection
OK
Forging
Neglegence Not OK
of inspector Thread Drilling
Out in OK
Boot CNC it is analysed that Drill out during Drilling
Collar operation as clamping area was less for holding
Thread Tapping part in fixture.
Poor material OK
forgability
Plating
OK
OK
F. Inspection
Other grade OK
material used Packing &
Despatch
MATERIAL
RESP. IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)
n all relevent locations.

Vikas '-------
cked for tapping parameter by
e release the material for Tapping , this
Vikas '-------
QA Inspector Next Forging
ugh hole done in forging itself

P. Sharma
. Added
P. Sharma
o operators Vikas Kumar 27.02.2018
hecked for tapping parameter by
e release the material for Tapping , this QA Inspector
e supplied lot.
FEED BACK TO OTHER (HORIZONTALLY

MONITORING SHEET (REOCCURANCE OF DEFECT ) (QTY./GRAPH) DEPLOYMENT)
IV MONTH V MONTH VI MONTH REMARKS PROCESS ( IF SAME TYPE
PROBLEM)
NA
Objective Evidenc
Before Afte
As shown in above picture coolant nozzle with soft material during coolant Now soft material coolant nozzle replaced w
pressure their position shift from actual position nozzle position on tools then coolant flow o
Evidence
After
ial coolant nozzle replaced with metal nozzle, When we fix the
on tools then coolant flow on same position.
Objective Evidenc
Before Afte
80
Drilling operation was there. During Drilling operation drill out problem due to Drilling operation removed and conc. Can b
less clamping area.
Evidence
After
on removed and conc. Can be achieved up to 0.08 mm

Evidence
Sr. No. Action Taken
Before After
01 PQCT Revised
02 Process Forging Drawing Revised

BOOT COLLER BEFORE Model.pdf BOOT COLOR AFTER Model (1).pdf
03
Pages 18 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3
CORE TEAM: GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C

C
S L
PROCESS POTENTIAL
PC ID./ DESC. POTENTIAL EFFECT(S) OF FAILURE E A
REQUIREMENTS FAILURE MODE
V S
S
This will leads to problem During Forging,

Over Size Coil will not enter into die,Hence Reject 6 M
the material.
Diameter
(9.35 ~ 9.40)
This will cause difficulty to control size

Under size 5 M
during forging, Hence Reject the material
Pages 19 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
This will cause cracks in product,Hence

Crack Crack found in R/M Reject the material & send back to 7 C
supplier.
Mechanical Properties/ Forgability

Chemical
Not OK properties will be effected,Hence Reject 7 C
Composition
the material.
Pages 20 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Mechanical Properties will be effected,

Decarb More 7 C
Hence Reject the material.
10. RAW
MATERIAL
INSPECTION
Not as per IS 11169 Mechanical Properties will be

Inclusion Rating 6 M
part-1-1984 effected.,Hence Reject the material.
Pages 21 OF 80
ROHTAS
ITEM : Boot Color
ITEM10.
CODE:
RAW 009-M85-044-3
MATERIAL
INSPECTION
C
S L
PROCESS POTENTIAL
V S
S
Not as per IS 11169 Hardenability Properties will be

Grain Size 6 M
part-1-1984 effected,Hence Reject the material.
More than Leads to poor forgability, adverse effect

Tensile Strength 4 m
specification on the tool life,Hence Reject the material.
INSPECTION
Pages 22 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Hardness in Soft Leads to poor forgability, adverse effect

More than
Condition on the tool life, Hence Reject the 4 m
specification
(HRB) material.
As Quenched Less than Mechanical Properties will be

7 C
Hardness specification effected.Hence Rejct the material.
Pages 23 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Fitment problem may arise during

Over Size 6 M
Assembly , Leads to Rework
1. Total Length
(9.35 ~ 9.65)
Under Size 6 M
Assembly , Leads to Rejection

Over Size 6 M
2. Length
(5.35 ~ 5.65)
Under size 6 M
Pages 24 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S

Over Size 6 M
3. Length
Under size 6 M

Over Size 6 M
4. Collar Dia.
Under size 6 M
Pages 25 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Over Size Spanner will not insert ,Leads to Rework 6 M

5. Across Flat
Spanner will become Loose , Leads to
Under size 6 M
Rejection
20. FORGING NP: Problem During Tapping

C1:Fitment Problem
Over Size 7 M
OEM:Performance not OK
EU:None
Drill Dia
Pages 26 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
20. FORGING S L
PROCESS POTENTIAL
V S
S
Drill Dia
NP: Problem During Tapping
C1:Fitment Problem
Under Size 6 M
OEM:Performance not OK
EU:None

Over Size 6 M
7. Counter Dia.
(8.10 ~ 8.25)
Under Size 6 M
8. Chamfer
Not OK Not much significant effect. 8 C
(0.50 x 45°)
20. FORGING
Pages 27 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
9. Counter Angle
(30°)
10. Collar Angle

(30° Max.)
11. Hex Angle

(31° ~ 36°)
Burr,Dent,Chip,Unfil
ling,Cracks,Without May Leads to rejection & hence
12. Appearance 6 M
Operation Pcs etc. Customer Dissatisfaction
Are not allowed
Pages 28 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Go Thread Plug May cause fitment problem , Leads to

7 C
Gauge tight rework
1. Threads
(M8 x 1.25 - 6g)
No Go Thread Plug May cause fitment problem , Leads to

7 C
Gauge Qualifies rework
30. TAPPING
Pages 29 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
REQUIREMENTS
30. TAPPING FAILURE MODE
V S
S
Burr,Dents,Chips in
Threads, Reverse
Threads , Inclined May Leads to rejection & hence
2. Appearance 6 M
Threads ,Without Customer Dissatisfaction
Operation Pcs etc.
Are not allowed
May cause fitment problem,

Over Size 7 M
Leads to rework
1. U-Cut Dia.
(9.90 ~ 10.10)
May Cause Fitment problem,
Under size 7 M
Leads to Rejection
Pages 30 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S

Over Size 7 M
Leads to rework
2. U-Cut Width
(2.40 ~ 2.60)
Under size 7 M
Leads to Rejection
40. MACHINING
Over Size 7 M
Leads to rework
3. Length
(1.90 ~ 2.10)
Under size 7 M
Leads to Rejection
Pages 31 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

40. MACHINING
C
S L
PROCESS POTENTIAL
V S
S
Burr,Dent,Chip,Tool
Marks, Without May Leads to rejection & hence
4. Appearance 7 M
Operation Pcs etc. Customer Dissatisfaction
Are not allowed
Pages 32 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Go Thread Plug May cause fitment problem , Leads to

7 M
Gauge tight rework
1. Threads
(M8 x 1.25 - 6h)
No Go Thread Plug May cause fitment problem , Leads to

7 M
Gauge Qualifies rework
Pages 33 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
2. Plating
Trivalent Zn. White
Not OK Product Becomes Rusty Very Soon 7 M
(Hexavalent
50. SURFACE Chromium Free)
TREATMENT
(M/S SK
Enterprises)
3. Plating Thickness Less than
Product Becomes Rusty Very Soon 7 M
(8 Microns Min.) specification
Pages 34 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

50. SURFACE
TREATMENT
CORE TEAM:
(M/S SK
GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C
Enterprises) C
S L
PROCESS POTENTIAL
V S
S
4. SST Life
(For White Rust
Less than
72 Hrs. Min. Product Becomes Rusty Very Soon 7 M
specification
For Red Rust
240 Hrs. Min.)
Rusty,Black & White

Spots ,Dents,Plating May Leads to rejection & hence
5. Apperance 6 M
Peel Off etc. are not Customer Dissatisfaction
allowed
Pages 35 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
Parameters (Length,
Parameters
Dia, Outness etc.) 1. Leads to rejection during Assembly
60. FINAL (Length,Dia.,Angle,
checked as per 2. Chances 7 M
INSPECTION Appearance etc.)
Sampling plan / of field failure
Not ok
Product Drawing/ CP
Pages 36 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
a) Improper Qty.
1. Customer will not meet his set target
B) Part
a) Qty. as per 2. Damage part is
70. PACKING Damage due to
specified unusable 3. 7 M
Improper Packing
b) Standard Packing Mixing leads to Rejection
c) Mixing
of Diff. Parts
Pages 37 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
1. Due to Improper Stacking

i) More space covered for limited
a) Improper parts ii) More time consume
stacking during parts take out from Rack
a) Proper Stacking
b) Damage during iii) Part may be
80. STORAGE b)Safe handling 5 M
Handling damage 2. Damage part
c) Maintain FIFO
c) FIFO not is unusable 3.If FIFO not
followed followed i)
Material becomes unusable due to Rusty
etc.
Pages 38 OF 80
ROHTAS
ITEM : Boot Color
ITEM CODE: 009-M85-044-3

C
S L
PROCESS POTENTIAL
V S
S
a) Part should be
90. DISPATCH Part Damage during
damage free during Damage Part is unusable 5 M
Transit
Transport
Rev. No. Rev. Date

01 26.07.2016 Drawing revied as per Customer Inspection standard
02 27.02.2018 ID 6.90/6.80 Thru hole added in forging was 6.85/6.75 blind
Pages 39 OF 80
PROCESS FAILURE MODE AND EFFECT ANALYSIS

PROCESS RESPONSIBILITY: Mgr. (Q.A) PFMEA No. :
FMEA DATE (ORG)
PREPARED BY: Q.A FMEA DATE (APPL
FMEA LATEST REV
APPROVED BY: GM (Operations) FMEA LATEST REV
O D
POTENTIAL CAUSE C E R
CURRENT PROCESS CONTROL CURRENT PROCESS
MECHANISM(S) OF C T P
PREVENTION CONTROL DETECTION
FAILURE U E N
R C
Raw Material Fault (Drawing Regular audit at supplier end as per Checking Each Coil /Raw
2 3 36
die not OK/ Worn out) audit plan Material Test Report
Raw Material Fault (Drawing Regular audit at supplier end as per Checking Each Coil /Raw
2 3 30
Die Not Ok) audit plan Material Test Report
Pages 40 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Doing Upsetting of one piece

Regular audit at supplier end as per
Raw Material Fault 2 from each Coil/ Raw Material 3 42
audit plan
Test Report
Cross checking by Doing

Regular audit at supplier end as per spectro analysis from out
Raw Material Fault 2 3 42
audit plan side lab/ Raw Material Test
Report
Pages 41 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Doing microscopic checking

Raw Material Fault (Improper Regular audit at supplier end as per
2 of one piece from each Coil/ 3 42
Annealing) audit plan
Raw Material Test Report

Raw Material Fault 2 of one piece from each Coil/ 3 36
audit plan
Pages 42 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C

Raw Material Fault 2 of one piece from each Coil/ 3 36
audit plan
Doing Tensile testing of one

Regular audit at supplier end as per piece from the Coil having
Raw Material Fault 2 3 24
audit plan HRB higher than specified/
Pages 43 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Doing hardness checking of

Raw Material Fault (Improper Regular audit at supplier end as per
2 one piece from each Coil/ 3 24
Reduction) audit plan
Doing hardness checking of

Raw Material Fault 2 one piece from each Coil/ 3 42
audit plan
Pages 44 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Inspection at the time of
Tool not ok / Tool / Die inspection report /
3 Setting / Tooling Change & 3 54
Setting not ok Setting approval slip.
/ 2Hr.
/ 2Hr.
/ 2Hr.
/ 2Hr.
Pages 45 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
/ 2Hr.
/ 2Hr.
/ 2Hr.
/ 2Hr.
Pages 46 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
/ 2Hr.
/ 2Hr.
Wrong setting in machine./
M/c parameter setting as per PCS./ Inspection at the time of
Die/Punch misalignment /
3 Tool History Card / initial setting Setting / Tooling Change & 5 105
Approval / Training To operator. / 2Hr.
Punch size over /
Pages 47 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Wrong setting in machine./
M/c parameter setting as per PCS./ Inspection at the time of
Die/Punch misalignment /
3 Tool History Card / initial setting Setting / Tooling Change & 5 90
Approval / Training To setter. / 2Hr.
Punch size Under /

/ 2Hr.
/ 2Hr.
Tool not ok / Tool/Die inspection report/ Inspection at the time of

3 3 72
Setting not ok Setting approval slip. Setting & Tooling Change
Pages 48 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C

3 3 72

3 3 72

3 3 72

Raw Material Problem OR Raw Material Incoming Records/
Forging Problem Setting Approval Slip
/Hr.
Pages 49 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C

Setting Not OK 3 Setting Approvel Slip Setting / Tooling Change & 3 63
/Hr.

/Hr.
Pages 50 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C

/Hr.

/2Hr.
/2Hr.
Pages 51 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
/2Hr.
/2Hr.
/2Hr.
/2Hr.
Pages 52 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C

/Hr.
Pages 53 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Process parameter Regular audit at supplier end as per Incoming Inspection Report /
3 3 63
not followed. audit plan Vendor PDIR
3 3 63
Pages 54 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
3 3 63
3 3 63
Pages 55 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
3 3 63
3 3 54
Pages 56 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Setting Slip / Patrol/Procss Inspection Final Inspection report/

In-Process fault 3 Report / Process Drawing/Process Customer Drawing/Control 3 63
Control Plan Plan
Pages 57 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Check Points followed during

Check Points during Packing Awareness by Training provide to Packing regarding
3 3 63
not followed concerned Qty./Wt./Poly Bag Size/Box
Size/Labelling etc.
Pages 58 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Check Point followed during

Check Points during Storage
Awareness by Training provide to FG Storage regarding
in FG Store 3 3 45
concerned FIFO/Damage Free
not followed
Handling/Stacking etc.
Pages 59 OF 80

FMEA DATE (ORG)
FMEA LATEST REV
O D
FAILURE U E N
R C
Material loading under

Awareness by Training provide to
Improper Material Loading 3 supervision of PPC 3 45
concerned
Supervisor
Rev. Detail
Pages 60 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
FMEA DATE (ORG): 30.07.15
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
FMEA LATEST REV. No. 02 REV NO/ REVISION
APP.
FMEA LATEST REV. DT. 27.02.2018 DATE: DETAILS
ACTION RESULTS
RESPONSIBILI
RECOMMENDATION TY & TARGET S O D R
ACTION(S) COMPLETION ACTION
E C E P
DATE TAKEN
V C T N
Rej. the Material & Ask

Supplier for action Plan
DO
Pages 61 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
DO
DO
Pages 62 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
DO
DO
Pages 63 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
DO
DO
Pages 64 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
DO
DO
Pages 65 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
--
--
Pages 66 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
--
--
Pages 67 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
--
Pages 68 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
--
--
Pages 69 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
--
--
Pages 70 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
Pages 71 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
--
Pages 72 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
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Pages 73 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
Pages 74 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
Pages 75 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
Pages 76 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
--
--
Pages 77 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
Follow Cantrol Plan

During Inspection
Pages 78 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
Do Periodical Internal
Audit
Pages 79 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
Do Periodical Internal
Audit
Pages 80 OF 80
FMT No.:- F/PD/04
Rev. No.:- 00
Eff. Date :- 01.09.11
8
01
ID 6.90/6.80 Thru
PFMEA-SA-0102
.2
hole added in
02
forging was
7.
6.85/6.75 blind
/2
FMEA DATE (APPL):
02
30.07.15
APP.
ACTION RESULTS
RESPONSIBILI
E C E P
DATE TAKEN
V C T N
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ROHTAS FASTENERS PVT. LTD.

SUPPLIER / IN-PLANT QUALITY PROBLEM ANALYSIS AND COUNTERMEASURE SHEET (5

VENDOR / DEPTT : PART NAME :

PROBLEM PART NO. :

ACTUAL CONTENTS ACTUAL INVESTIGATION (PRODN.

DETAIL OF PROBLEM (DATA/SKETCH)

ROOT CAUSE : COUNTERMEASURE DETAIL

WHY-WHY ANALYSIS : MONITORING SHEET (REOCCURAN

VT. LTD. REV.NO.: 01

UNTERMEASURE SHEET (5-RULE) EFF.DT.: 20/04/18

ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)

RESP. IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)

VENDOR / DEPTT : Inhouse Analysis PART NAME : Boot Collar

PROBLEM Thread out PART NO. : 009-M85-044

ACTUAL CONTENTS ACTUAL INVESTIGATION (

ROOT CAUSE : COUNTERMEASURE DETAIL

2) More than 100 sample will be checked for tapping parameter by

2) More than 100 sample will be checked for tapping parameter by

3. Defect awareness training given to operators

4. 2) More than 100 sample will be checked for tapping parameter b

WHY-WHY ANALYSIS : MONITORING SHEET (REOC

part loose due to less

Tap guided in tilt

PVT. LTD. REV.NO.: 01

COUNTERMEASURE SHEET (5-RULE) EFF.DT.: 20/04/18

ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)

RESP. IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)

n all relevent locations.

QA Inspector Next Forging

ugh hole done in forging itself

FEED BACK TO OTHER (HORIZONTALLY

on removed and conc. Can be achieved up to 0.08 mm

02 Process Forging Drawing Revised

ITEM : Boot Color

ITEM CODE: 009-M85-044-3

CORE TEAM: GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C

This will leads to problem During Forging,

This will cause difficulty to control size

ITEM : Boot Color

ITEM CODE: 009-M85-044-3

CORE TEAM: GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C

This will cause cracks in product,Hence

Mechanical Properties/ Forgability

ITEM : Boot Color

ITEM CODE: 009-M85-044-3

CORE TEAM: GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C

Mechanical Properties will be effected,

Not as per IS 11169 Mechanical Properties will be

ITEM : Boot Color

Not as per IS 11169 Hardenability Properties will be

More than Leads to poor forgability, adverse effect

ITEM : Boot Color

ITEM CODE: 009-M85-044-3

CORE TEAM: GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C

Hardness in Soft Leads to poor forgability, adverse effect

As Quenched Less than Mechanical Properties will be

ITEM : Boot Color

ITEM CODE: 009-M85-044-3

CORE TEAM: GM (Operations), Engg. I/C,Prod I/C,Q.A. I/C

Fitment problem may arise during

Fitment problem may arise during

ITEM : Boot Color

ITEM CODE: 009-M85-044-3