STA 8D Example JLR

Title:L999 Standard Windshield Distortion In Centre of WSDate Opened:Last Updated:2011.09.142011.09.19Product/Process Information:L999 Standard WindshieldOrganisation Information:Joe Bloggs EnterpriseDØ Symptom(s):DØ Emergency Response Action(s):Percentage DateL999 WinshieldEffective:Implemented:2011.09.142011.09.152011.09.15Verification / Validation:100%2011.09.14100%2011.09.15100%2011.09.15100%2011.09.18D1 Team (Name, Dept., Phone)Name Department PhoneChampion:QA.Core Team:FQA.PD.PD.CommercialTeam Leader:QARecorder: QA Facilitator: Factory D2 Problem No.QR No.Date Problem Statement:/2011.09.15Problem Description:Customer Plant:Occur Place:Occur Date:Feedback Date:Production Date/Lot No.:Quantity:Detected by:D3 Interim Containment Action(s):Percentage Date Effective:Implemented:100%2011.09.14100%2011.09.15100%2011.09.15100%2011.09.18D4 Root Cause(s) and Escape Point(s):2011.09.14L999 Heated Windscreen Distortion In Centre of WSremarkSend the defective glass back to JBEfor further analysis.HALEWOOD Assembly Line HALEWOOD The standard windshield was distorted.2011.09.14JLR HALEWOOD Engineer2011.071 pieceCause-effect1)Recheck all the stock at Halewood by Mr XX . -----on going4)Recheck all the stocks by Mr DD in FJB Enterprise Chinese plant(Total:960 pcs) -----no similar defect found 2)Recheck all the stocks in the JB Enterprise Europe Warehouse(Total: 3627 pcs) by Mr BB .3)Recheck all the new arrival products at JB Enterprise Europe Warehouse(Total : 3472 pcs) by Mr CC .Packaging Process2)100% check the stocks in the JB Enterprise European Warehouse and mark the stillages with “100% checked for Distortion”, -----Mr BB2)Recheck all the stocks in the JB Enterprise EuropeanWarehouse(Total: 3627 pcs) by Mr BB .-----on going1) Check the online products at Halewood: 100% visual check stock ----Mr XX4) Breakpoint Date: Sep. 15th , 2011Part No.1234567893)100% check the stocks in JB Enterprise Chinese plant and mark the case with " distortion checked " -----Mr CC 1)Recheck all the stock at Halewood by Mr XX . -----on going1) JLR complaint shows that there is a distortion in a small area on the standard WS ,When vieweing the glass threw the drivers position there is a distorted view.3)Recheck all the new arrival products at JB Enterprise European Warehouse(Total : 3472 pcs) by Mr CC .-----on going4)Recheck all the stocks by Mr DD in JB Enterprise Chinese plant(Total:960 pcs) -----no similar defect found breakpoint markTrimming & Washing NGOKOptics inspectionOKNGInspectionScrapAccessory installationInspectionInspectionpackingInspectionScrapOKNG OKNG Optical distortionManMeasureMethod MachineMaterialScratch part buffering re-workThe buffering re-workflow The scratch degree that can be re-workedMark the re-work partsMark after bufferingre-workMark after optical inspection Whether the optical inspector changedOperators' qualification and skillsOptical inspection facilityOptical inspectionInspection conditionInspection method andfrequencyOptical inspection afterbuffering repairScratch buffering Re-work influence WI is not clearN/AN/AScratch part buffering re-workEscape Point:Verification:Percentage Contribution:DateImplemented:NO 100%2011.9.16NO 100%2011.9.16NOYES 100%2011.9.16NO NO 100%2011.9.16Active:1 Why2Why3Why5WhySpecific rootcause Optical distortionTo Much Buffering duringRepair Scratched glass requiresbuffering Detection rootcause Missed InspectionThe rack of buffered repaired parts was identified, risk of missing individual parts.The operator did not mark every piece of the buffering re-work glass - Operatorerror.Systemic rootcauseThe repair WI is not clearD5 Chosen Permanent Corrective Action(s):ResponsibilityPercentage Effective:100%100%100%100%Verification:100%D6 Implemented Permanent Corrective Action(s):ResponsibilityDateImplemented:2011.09.162011.09.162011.09.162011.09.19D7 Prevent Actions (Systemic Prevent Recommendations:):DateImplemented:2011.09.19D8 Team and Individual Recognition:Date Closed:Reported by:Responsibility1.Define the degree which can be buffering repaired , make limit sample on site and train the operators .3.Improve the mark mangment of the scratch buffering re-work partsA. Mark the " Buffering repaired " label on every buffering repaired part (see picture A) , see attached 1- The special label for the buffering repairB. Mark the red card on whole shelf of the repaired parts . (see picture B)C.Optical inspection . (see picture C)D.Stick the green qualified label on every piece of qualified part . (see picture D)E.stick the red NG label on every unqualified part . (see picture E)Update the buffering re-work WI , See Attached 2- Buffering re-work WI4.Update the WI4Why 5)Environment: N/A 5Why analysis1)Man: 1.Check the optical inspectors and the buffering re-work operators , the operator has not changed 2.Check the operators' qualification and the skills , all the operators are qualified 3.Improve the mark mangment of the scratch buffering re-work partsA. Mark the " Buffering repaired " label on every buffering repaired part (see picture A) , see attached 1- The special label for the buffering repairB. Mark the red card on whole shelf of the repaired parts . (see picture B)C.Optical inspection . (see picture C)D.Stick the green qualified label on every piece of qualified part . (see picture D)E.stick the red NG label on every unqualified part . (see picture E)2.Do 100% inspection the optical after buffering repair , and stick the green qualified label on the top right conner of each good glass . After the IPQC spot check and confirm , the parts can be moved .1.Define the scratch degree which can be buffering repaired , make limit sample on site and train the operators .2) Machine: Check the optical inspection facility , the facility is normally .3) Material: N/A6)Measure: N/A4)Method:4.1.Optical inspection4.1.1.Inspection condition : The inspection condition of the optical inspection room meet the standard .4.1.2.Inspection method and frequency : the inspection method on site is right and the frequency is 100% .4.2.Scratch buffering Re-work influence4.2.1.The scratch degree that can be re-worked : The operators compare the boundary sample to judge whether the scratch part is can be re-worked or not .4.2.2.The buffering re-work flow : The flow is qualified , and the operating method on the site is right .4.3.Optical inspection after buffering : The operator do 100% check the optical on the site , and stick the green qualified label on the right corner of every qualified part .4.4. Identification of the repaired parts4.4.1.Identification after buffering re-work : The operator identified the whole rack of repaired parts , but did not identify every piece of the buffering re-worked glass .4.4.2.Identify after optical inspection : Inspect the optical of all the buffering re-worked parts , and stick the qualified green label on the top right conner of every good glass .4.Update the WI 2.Do 100% inspection the optical after buffering repair , and stick the green qualified label on the top right conner of every good glass . After the IPQC spot check and confirm , the parts can be moved .During Sep 15th to 17th ,We check 50 pcs buffering repaired parts and did not find similar defect .Problem anyanlys:mark the whole shelf of the repaired partsmark after bufferingrepairedmark qualified afterinspectionoptical inspection OKmark disqualified partsand segregatedNGPicture APicture BPicture CPicture DPicture E。