Analysis - Calibration Report of Test Equipments

No. of Test Equipt. 35 Calibration Calibration Planned Achieved 35 35

40 35 30 25 20 15 10 5 0 No. of Test Equipt. Calibration Planned Analysis - Calibration Report of Test Equipments 35 35

st Equipments
35

Series1

ation Planned

Calibration Achieved

Report of Test Equipments

Analysis - Incoming Inspection (PVC + Copper+M

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

Total No. of Times Received Materials.

44 38 85 68

90 80 70 60 50 40 30 20 10 0 Jul-12 Aug-12 2 2 44 38

g Inspection (PVC + Copper+MB)

Total Rejection
2 2 1 1

1stOct-15th Oct.

85 68 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) 2 Aug-12 1 Sep-12 1 Oct-12

PVC Cable Production- Inprocess Rejection

Months
Jul-12 Aug-12 Sep-12 Oct-12 Total

Total Prd In ''Mtr''

739,798 646052 657056 285650 2328556

Total Rejection in Mtrs.

23 1015 556 0 1594

ppm

685

Nyvin Cable Production -Inprocess Rejection

Months
Jul-12 Aug-12 Sep-12 Oct-12 Total

Total Prd In ''Mtr''

84,688 89,732 156201 56,358 386979

Total Rejection in Mtrs.

0 45 25 5 75

ppm

193.8

800,000 700,000 600,000 500,000 400,000 300,000 200,000 100,000

739,798 646052 657056

Total Prd In ''Mtr'' 285650 Total Rejection in Mtrs.

23 0 Jul-12

1015 Aug-12

556 Sep-12

0 Oct-12

180,000 160,000 140,000 120,000 100,000 80,000 60,000 40,000 20,000 0 0 Jul-12 Aug-12 Sep-12 Oct-12 45 25 5 56,358 84,688 89,732 Total Prd In ''Mtr'' Total Rejection in Mtrs. 156201

PVC Cable Production- Final Rejection

Months
Jul-12 Aug-12 Sep-12 Oct-12 Total

Total Prd In ''Mtr''

739,798 646052 657056 285650 2328556

Total Rejection in Mtrs.

23 0 0 0 23

ppm

10

Nyvin Cable Production - Final Rejection

Months
Jul-12 Aug-12 Sep-12 Oct-12 Total

Total Prd In ''Mtr''

84,688 89,732 156201 56,358 386979

Total Rejection in Mtrs.

0 0 0 0 0

ppm

800,000 700,000 600,000 500,000 400,000 300,000 200,000 100,000 0

739,798 646052 657056

Total Prd In ''Mtr'' 285650 Total Rejection in Mtrs.

23 Jul-12

1015 Aug-12

556 Sep-12

0 Oct-12

180,000 160,000 140,000 120,000 100,000 80,000 60,000 40,000 20,000 0 0 Jul-12 Aug-12 Sep-12 Oct-12 45 25 5 56,358 84,688 89,732 Total Prd In ''Mtr'' Total Rejection in Mtrs. 156201

No.Of Breakdown / Error Analysis - Test Equipments

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

No.of Breakdowns
0 0 2 0

Rectified
0 0 0 0

2.5 2 2 1.5 1 1 0.5 0 0 Jul-12 Aug-12 Sep-12 Oct-12 0 0 0 0 0 0 0 0 0

sis - Test Equipments

Un Rectified
0 0 1 0

No.Of Breakdown / Error Analysis - Test Equipments No.of Breakdowns No.Of Breakdown / Error Analysis - Test Equipments Rectified No.Of Breakdown / Error Analysis - Test Equipments Un Rectified

CUSTOMER COMPLAINT REGISTER

PRR.NO. DATE CUSTOMER PART NO. 22 AWG BC X 1 CORE UL-1007 WIRE. BLACK COLOUR REP. STATUS

CCN-1

1.10.12

HI-COOL

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 1 CORE PVC INS. WIRE GREY -300 Mtrs. & 2.50 SQ MM BC X 1 CORE GREY 200 MTRS.

CCN-4

6.11.12

BSA

CCN-5

6.11.12

BSA

0.50 SQMM BC X 2 CORE (Inner Yellow, Brown) FLRY B SHIELDED CABLE Outer BLACK-500 Mtrs. 0.75 SQ MM BC X 1 CORE FLRY B WIRE WHITE COLOUR -1200 Mtrs. AT AMBERNATH PLANT

ISTER
CUSTOMER COMPLAINT ROOT CAUSE IMMEDIATE ACTION PLAN

NO PRINTING ON 4 N0s OF COILS & COILING NOT PROPER PRINTER NOT SET PROPERLY
0.189,0.188,0.190MM SIZE BC COPPER FOUND They required +_ 0.002 mm Tolerance only.

Visited at HI-COOL

INSTEAD OF 0.20 MM BC , USED 0.193MM BC COPPER

On daviation basis this time customer accepted the material.

REPLACEMENT GIVEN Without inspection of QC TO CUSTOMER By Mr. BLACK COPPER ISSUE IN Person materials were Rajendra on Dtd. BOTH SIZE OF WIRES. dispatched 22.10.2012

FRESH LOT PRODUCTION OUTER SHEATH THICKNESS TAKEN & SENT THE OUTER SHEATHING OPEN ISSUE NOT MAINTAINED PROPERLY. MATERIAL TO CUSTOMER.

Diameter Variation 1.90 MM TO NOT SETTING DIAMETER 2.30 MM PROPERLY ON EXTR. M/C

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 BEFORE TAKING BUNCHING PROCESS IT IS INSTRUCTED TO BUNCHING M/C OPERATOR , TO SELECT ONLY BRIGHT ANNEALED COPPER & ALSO BEFORE DESPATCH ALL MATERIALS SHOULD BE FINALLY CHECKED BY QC PERSON.

17.10.12

CLOSED

22.10.12

CLOSED

INSTRUCTION GIVEN TO OPERATOR FOR PROPER MAINTAINING OF OUTER SHEATH THICKNESS

7.11.12

CLOSED

7.11.12

OPEN

DOC. ENCLOSED

NC REGISTER QC & PROD.

Sr. No. Date Description of Non-Conformity

May-12

Wrong production taken , BSA 16awg Green colour 10000Mtr. ANNA

May-12

Without Drain wire Tape Shielded 200Mtr Reliance0.5sqmmx 4Pair Manish-Taping m/c.

Emerson export 28core x 1.0sqmm 2nd lay stranding defect ( core damage) due to wrong selection of Die _ Jun-12 Yogesh reworked -100Mtr

On Reliance item FRLS not printed on cable as per customer requirement, QTY : 3000M-black -MulticoreJun-12 cable, 1.50sqmm x 3 core BC - Vinod -operator

2CORE not printed on multi core 0.75 sqmm BC cable 5

Jun-12 HIREL-grey cable -1700Mtr, Reworked Kumar -operator

Wrong production taken , 50/42swg ATC White Jun-12 5000Mtr instead of White/Red. Anna/Rajendra Bobst items- 22 AWG BC X 11core 1st lay wrong Jun-12 stranding -100mtr, Reworked - Kamlesh

Jun-12 ESSEL 1.50 sqmm x 4core wrong stranding 50 Mtrs.

Kamlesh

THYSEN 0.75sqmm x 3core Flat cable Wrong outer PVC sheathed instead of HOFR pvc sheathing pvc used.Jun-12 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

13

Sept. 2012

Quality Automation 1.00 sqmm x 2 core BC .400 Mtrs. Sambhajeet / Patil/Anna/Rajendra/Kumar

14

Sept. 2012

Quality Automation 1.00 sqmm x 2 core BC .400 Mtrs. Sambhajeet / Patil/Anna/Rajendra/Kumar

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.

Reason for Non- Conformity

Corrective Action Taken

Green colour cable sent to Store for Wrong colour Job sheet prepared as another customers future requirements per Customer P.O. mentioned short and New production taken as per description like GR instead of GREY customer colour requirement GR means GREY colour.

Under training person is on taping m/c. so this incident happened.

Re-worked 200 mtrs

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 Reprinted as per requirement

By over view & wrong setting of printing matter

Removed the existing printing and Reprinted as per requirement

1. Due to wrong preparation of job sheet. Not carefully study of p.o.

White colour is sent to store for other costomers future requirements and New production is taken as per the costomers requirement.

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

Even mentioned in job sheet for using HOFR PVC . By over looking mistake happened by Operator & No proper communication Sent to store for costomers between Production Head & future requirements. And Operator. Taken the new production

By over looking

Removed the Existing printing & reThis mistake was happened printing done as per BY OPERATOR costomer requirement

Instead of RED Colour , BLACK Colour production taken. Wrong job sheet preparation

Black colour sent to store for future requirements of customers And new production taken..

Wrong Aluminium Mylar taping .

Removed the existing tape .And Re-taping properly. Also removing of outer sheathing

Wrong Aluminium Mylar

Taping.

Removed the existing tape .And Re-taping properly.

Wrong Aluminium Mylar taping .

Removed the existing tape .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.

Preventive Action Taken

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.

Method of Disposition / Rectification (If Applicable)

NC closed: 27.5.2012

Trained person is look out the taping m/c.

NC closed:Date: 04.06.12

Instructed to stranding m/c operator to carefully select the Die sizes before running the items. Instruction is given to operator regarding proper selection of printing matter as per the job sheet.

NC closed: Date : 30.5.2012

NC closed: Date : 30.6.2012 Instruction is given to operator regarding proper selection of printing matter as per the job sheet NC : Closed: Date : 14.06.2012

Before preparation of job sheets carefully study the p.o. and than prepare the job sheet.

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

Instructed the Operator to Carefully study the job sheet before run the Extr. M/c. Instructed to operator before running any item,proper care should be taking while selecting the printing matter. and than run the extruder m/c. Also check the printing matter in starting length.

NC : Closed : Date : 19.06.2012

NC: Closed :Date :22.07.2012

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

NC: Closed :Date:18.09.2012 Instructed to taping m/c operator to follow the carefully time to time changes & instructions from production head

Instructed to taping m/c operator to follow the carefully time to time changes & instructions from production head NC: Closed :Date :18.09.2012

Instructed to taping m/c operator to follow the carefully time to time changes & instructions from production head NC: Closed :18.09.2012

Instruction given to operator to NC: Closed : Date : 22.09.2012 check the surface of wire during the Nylon coating time.

NC: Closed : Date : 8.11.2012

Instructed to OPERRATOR Before start the production set the proper Temp. of Extruder M/c.