8D Corrective Action Form (CAR)

Middle East Fiber Cable Manufacturing CoSaudi Arabia

Customer Complain Number -001

Creation Date :-

13 Apr 13

FRP Rod 2.0mm

Status

8D in Process

Product Reference :-

D1 : Team Members
Name

Title

Role

Munesh Chandra

Plant Manager

Process Leader

Rakesh Kumar

Quality Head

Process Associate

Hari Ram Soda

Quality Control Engineer

Process Member

Pawan Gupta

Production Mfg-FRP

Process Member

D2 : Problem Discription
Initial Problem Definition (Per Customer)
One Spool of central strength member FRP 2.0mm found break at 42 Km

Detail Problem Definition

In drum No AE-8659 (50 km Spool) of FRP 2.0mm , Customer found break of FRP after 4.55 Km(from Top of the drum) during production of Cable
& Lost production of cable of 4.55 Km .

D3 : Identify and Verify Containment Actions

Material Containment
Action

Qty Impacted

Responsibile

Due Date

Closed Date

Our Marketing Head visited

at Customer ( MEFC) site
and found that FRP may be
break due to curing
probelm and he is agreed
to replacement of one
spool of same length

50Km

Prashant Agrawal

17 Apr 13

17 Apr 13

Type

At Customer site

Immdiate action plan to reduce occurence or increased detection

Action

Maintenance engineer will be check all heating

control panel and to be calibrated all
temperature zone if required .

Responsible

Due Date

Completion Date

Ramesh Saini

25 Apr 13

23 Apr 13

D4 : Root Cause
Root Cause Definition - Occurrence and Detection (Why did the problem occur and why was it not detected ?)
We do'nt have facility of jointing process . Raw joint is not possible in our process
Breaking of FRP may be temperature variation on Machine No -1 so that FRP could not cured properly .
Breaking of FRP may occurs due to variation in line speed causes improper curing of FRP Rod
Sometimes higer Tex of E-glass roving not get mixed with the resin in proper ratio that may be causes of damage FRP Rod

Verified By

Rakesh Kumar

Root Cause Definition - Internal Use Only (Not included in Customer 8D)

Tools used in Root Cause Analysis

Tracebility

Fishbone

Lot History

5 Why

Other

D5 : Identify and Verify Permanent Corrective Actions

Occurence Assignments
Action

Responsibile

Due Date

Closed Date

Verified By

Calibration of die heater & Post Heater by

Thermometer

Ramesh Saini

20 Apr 13

18 Apr 13

Munesh Chandra

Measured line speed by speedometer and

fixed size wise

Pawan Gupta

20 Apr 13

20 Apr 13

Rakesh Kumar

Our Quality Control team will measure

Glass content with resin of each machine
per day .

Hari Ram Soda

16 Apr 13

16 Apr 13

Rakesh Kumar

Detection Assignments
Action

Responsibile

Due Date

Closed Date

Verified By

Inline process quality control audit by QC in

every shift

Hari Ram Soda

22 Apr 13

20 Apr 13

Rakesh Kumar

D6 : Implementation of Permanent Corrective Actions

Occurence Assignments
Action

Responsibile

Due Date

Closed Date

Verified By

Temperature calibration done in other

machine also.

Ramesh Saini

22 Apr 13

21 Apr 13

Rakesh Kumar

Modified SOP of incoming E-Glass roving

inspection and added for checking tex
variation in each pallet

Hari Ram Soda

20 Apr 13

21 Apr 13

Rakesh Kumar

Detection Assignments
Action

Responsibile

Due Date

Closed Date

Verified By

Inline process quality control audit by QC in

every shift

Hari Ram Soda

22 Apr 13

22 Apr 13

Rakesh Kumar

D7 : Prevent Recurrence Across System

Document

Summary of Changes

Due Date

Completed Date

Verified By

Manufacturing Work Instruction

Process Temperatue define AOL/PROD/WI/001 Rev001

23 Apr 13

22 Apr 13

Rakesh Kumar

IPQC Audit

Add process temp AOL/QAD/FM/011

Rev-001

22 Apr 13

20 Apr 13

Rakesh Kumar

D8 : Complaint Evaluation
Munesh Chandra accepted the request for 8D Complaint Evaluation on 11 / 04/ 2013