PART NAME WHAT WHERE HOW MANY WHY HOW TO DO

Head Lamp Foam Bend PDI 10 PACKING NOT GOOD PACKING STANDERD CHANGE
MOLD EJECTOR SPRING NOT
Pipe clamp Bend DEFLASHING 20 WORKING SPRING CHANGED
CHECK POINT NOT AVAILABLE IN CHECK POINT POPROVIDED TO DEFLASING
mouth Cap black Spot PDI 19 DEFLESHING AREA AREA AND SAMPLE DISPLAY
JACK SEET RUBBER BUBBLE PDI 7 LIMIT SAMPLE NOT AVAILABLE LIMIT SAMPLE TO BE PROVIDED
COOLING TIME NOT PROPER AS PER
SEAL BUBBLE Deflashing 34 PROCESS SHEET COOLING TIME AS PER PROCESS SHEET
BARREL HEATER NOT WORKING
JACK SEAT RUBBER 1 Bubble PDI 26 PROPERLY BARREL HEATER TO BE CHANGED
COOLING TIME NOT PROPER AS PER
SEAL BUBLLE Deflashing 24 PROCESS SHEET COOLING TIME AS PER PROCESS SHEET
NOZZLE HEATER NOT WORKING
W CLAMP BURRAN MARK DEFLASHING 280 PROPERLY NOZZLE HEATER TO BE CHANGED
GRAB HANDLE PEG. C D OUT PDI 36 UNSKILLED OPERATOR TRAINING PROVIDED
GRAB HANDLE PEG. C D OUT PDI 18 dim. 160.0 found due to shirinkage EXTERNAL COOLING TO BE PROVIDED
CHECK POINT NOT AVAILABLE IN
GRABE HANDLE C D OUT PDI 7 DEFLESHING AREA CHECK POINT TO BE PROVIDED
COOLING FIXT.NOT PROPER
FITMANT DUE TO UNSKILED
GRAB HANDLE CD OUT PDI 15 OPERATOR MOULDING OPERATOR TRAINING PROVIDED
NO CHECK POINTTO C D OUT
Fog lamp CD OUT PDI 22 DEFELASING AREA CHECK POINT TO ADD.CD OUT
Thermostat Champer over Size PDI 14 SAMPLING BAIS CHECKFOR IQC 100%PART CHECKING IQC
COLOUR MISH MASTER BATCH MIXING QUANTITY
TREE CLIP MATCH Deflashing 3000 NOT DEFINE MASTER BATCH MIXING PERCENTAGE DEFINE
Timing Cover ( 113 ) Crack+ insert flash DEFLASHING 21 AIRVENT NOT PROPER CLEAING AIRVENT PROPER CLEAING
Timing Cover front Cut + Bend PDI 6 SETUP PART RED BIN AND TRAINING PROVIDED
w w handle cut mark PDI 19 LIMIT SAMPLE NOT AVAILABLE LIMIT SAMPLE TO BE PROVIDED
4Speed knob cut mark PDI 14 LIMIT SAMPLE NOT AVAILABLE LIMIT SAMPLE TO BE PROVIDED
W W HANDLE cut mark PDI 29 HANDLING STANDARD NOT GOOD HANDLING STANDARD CHANGED
DEFELESHING MEMBER NOT
SKILLED AND NO CHECKPOINT
W W HANDLE cut mark PDI 37 AVAILABLE TRAINING AND CHECKPOINT PROVIDED
BUMPER SCEROW cut mark PDI 23 HANDLING STANDARD NOT GOOD HANDLING STANDARD CHANGED
W W HANDLE cut mark DEFLASHING 14 Mould ejctor speed high mould ejctor speed as per process sheet
Thermostat cut mark DEFLASHING 50 PACKING NOT GOOD PACKING STANDERD CHANGE
G S L knob 4 speed cut mark PRODUCTION 68 PACKING NOT GOOD PACKING STANDERD CHANGE
MOULD Ejctor speed NOT AS PER
W W KNOB cut mark DEFLASHING 40 PROCESS SHEET mould ejctor speed as per process sheet
DEFELESHING MEMBER NOT
SKILLED AND NO CHECKPOINT
Mounting Rod cut mark PDI 130 AVAILABLE LIMIT SAMPLE DISPLAY TO DEFELASING AREA
CUT MARK SHORT
W W HANDLE ACE MOULD PRODUCTION 155 MOULD CAVITY SCRATCH MOULD CAVITY TO BE POLICED
ECU COVER DAMGE DEFLASHING 5 PART HANDLING PROCESS NOT OK PART HANDLING PROCESS CHANGE
MOULD CAVITY NOT PROPER
piping clip Extra Flash DEFLASHING 480 MATCHING MOULD CAVITY PROPER BLOW MATCHING
BUMPER SCREW Extra Flash DEFLASHING 11 MOLD MATCHING NOT PROPER MOULD CAVITY BLOW MATCHING
CROCODAIL CLAMP EXTRA FLASH Deflashing 30 THERMO COUPLE NOT WORKING THERMO COUPLE CHANGE
MOLD CAVITY MATCHING NOT
NUT PLASTIC EXTRA FLASH Deflashing 400 PROPER BLUE PASTE MATCHING

Timing Cover Front Fitment problem PDI 1 fitmant point not check in deflasing stage fit mant point to be add.in deflasing stage
HEAVY SCRATCH
THERMOSTATE INSIDE Deflashing 30 HANDLING STANDARD NOT GOOD HANDLING STANDARD PROVIDED
Grab handle hole Block DEFLASHING 21 MOULD HOLE PIN U/S MOULD HOLE PIN SIZE INCRISE
OK MATERIAL AND REJECT MATERIAL
THERMOSTATE INSERT DAMAGE PDI 13 OK AND REJECT MATERIAL MIXED LOCATION TO BE DEFINE
CNG FRONT INSERT DAMAGE DEFLASHING 18 REJ.INSERT TOMIXUP REJ.PART &ok part location to discieded
MATRIAL OVER PAICING DUE TO
CNG FRONT INSERT FLASH PRODUCTION 28 UNSKILD OPERATOR MATRIAL PACKING ASPER PROCESS SHEET
CHECK POINT NOT AVAILABLE IN CHECK POINT POPROVIDED TO DEFLASING
Pop up knob line mark PDI 84 DEFLESHING AREA AREA AND SAMPLE DISPLAY
LOCK HEAVY
ECU COVER FLASH Deflashing 10 SETUP PART RED BIN PROVIDED
MOLDING M/C NOT PROPER PROPER CLEANING AND CHECKSHEET
HOUSING LH OIL MARK DEFLASHING 12 CLEANED PROVIDED
T.FRONT 800CC OVER FLASH DEFLASHING 14 MOLD MATCHING NOT PROPER BLUE MATCHING
MOULD CAVITY NOT PROPER
Seat seal mounting OVER FLASH DEFLASHING 25 MATCHING MOULD CAVITY PROPER BLOW MATCHING
Seat seal mounting OVER FLASH DEFLASHING 15 SETUP PART red bin privided trainnig
W W KNOB Pin mark Deflashing 80 EJECTOR PRESSURE INCREASED PRESSURE DECREASE
GSL KNOB BLACK Pin mark PRODUCTION 68 EJECTOR PIN HIGHT O/S EJECTOR PIN HIGHT U/S
W W KNOB Pin mark Deflashing 45 MOLD COOLING PIPE BLOCKED COOLING PIPE TO BE CHANGED
EJECTOR SRING NOT WORKING
FLAT GLASS Pin mark Deflashing 55 PROPERLY SPRING CHANGED
GSL KNOB 1TON Pin mark DEFLASHING 20 EJECTOR PIN HIGHT O/S EJECTOR PIN CHANGED
EJCTOER SPRING NOT PROPER
Timing Cover 113 Pin mark DEFLASHING 16 WORKING EJCTOR SPRING TO BE CHANGED
PIN MARK CUT
GSL KNOB BLACK SCRATCH PDI 15 EJECTOR PIN HIGHT O/S EJECTOR PIN CHANGED
MOULDING CAVITY TO RUNING MOULD CAVITY PROPER POLICING BY
Pop up knob scratch DEFLASHING 23 COUNDITION
CHECK POINTSCRATCH
NOT AVAILABLE IN TOOLROOM
GRIP ACE scratch PDI 10 DEFLESHING AREA CHECK POINT TO BE ADD. DEFELASING AREA

JUNCTION BOX SCRATCH PDI 36 UNSKILLED OPERATOR deflasing man TRAINING PROVIDED and limit sample display
SCRATCH + White
HOUSING LH mark PDI 8 UNSKILLED DEFLASING MAN TRAINING PROVIDED CHECK PROVIDED
SCRATCH PIN
HOUSING RH MARK PDI 80 HANDLING STANDARD NOT GOOD HANDLING STANDARD PROVIDED
 SCRATCH PIN
HOUSING LH MARK PDI 75 HANDLING STANDARD NOT GOOD HANDLING STANDARD PROVIDED
Grommet Glass Clip Short DEFLASHING 7 SETUP PART RED BIN AND TRAINING PROVIDED
APILLAR Short PRODUCTION 34 Moulding operator unskild proper training provided
Bush lower Short PRODUCTION 50 SETUP PART red bin privided trainnig
TREE CLIP ( Ace ) Short DEFLASHING 25 UNSKILLED OPERATOR TRAINING PROVIDED
WW handle ( Ace ) Short DEFLASHING 13 UNSKILLED OPERATOR TRAINING PROVIDED
Pipe Clip Short DEFLASHING 15 UNSKILLED OPERATOR TRAINING PROVIDED
GRAB HANDLE SHORT ,BEND DEFLASHING 10 PROCESS SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
SHORT &LOCK
W W KNOB DAMGE DEFLASHING 14 SETUP PART RED BIN PROVIDED
KNOB M6 Short ( PCS Stick ) PRODUCTION 50 THERMO COUPLE NOT WORKING THERMO COUPLE CHANGE
SHORT + INSERT MOUDL INSERT PIN DAMGE RUNING
GLASS CLIP FLASH DEFLASHING 30 COUNDITION MOUL INSERT PIN CHANGE BY TOOL ROOM
SHORT + INSERT
800 CC FRONT FLASH DEFLASHING 10 MOULD SETUP PART TRAINING PROVIDED RED BIN PROVIDED
CHECK POINT NOT AVAILABLE IN CHECK POINT TO BE PROVIDED AND LIMIT
TIMING COVER BOTTO SHORT +SCRATCH PDI 13 DEFLESHING AREA SAMPLE DISPLAY
w.w.handle Short mold DEFLASHING 18 MOULD SETUP PART TRAINING PROVIDED M/C RED BIN
Crocodile Short mold PRODUCTION 60 SETUP PART MIXUP RED BIN PROVIDED & TRAINING PROVIDED
short mold and cut
G S L cover mark PRODUCTION 5 SETUP PART MIXUP RED BIN PROVIDED & TRAINING PROVIDED
W CLAMP SHORT MOULD Deflashing 5 SETUP PART RED BIN PROVIDED
NUT PLASTIC SHORT MOULD Deflashing 25 SETUP PART RED BIN PROVIDED
NOZZLE HEATER NOT WORKING
COLLER BUSH SHORT MOULD PRODUCTION 100 PROPERLY HEATER TO BE CHANGED
HEATER THERMACOPAL NOT
W W KNOB SHORT MOULD PRODUCTION 35 PROPER WORKING THERMACOPAL CHANG

Glass grommet SHORT MOULD PRODUCTION 77 MOULDING OPERATOR UNSKILLED TRAINING PROVIDED

4 Speed knob SHORT MOULD PRODUCTION 68 MOULDING OPERATOR UNSKILLED TRAINING PROVIDED

outer handle lever SHORT MOULD PRODUCTION 25 MOULDING OPERATOR UNSKILLED TRAINING PROVIDED

Door pull SHORT MOULD PRODUCTION 45 MOULDING OPERATOR UNSKILLED TRAINING PROVIDED
NUT PLASTIC SHORT MOULD Deflashing 18 SETUP PART RED BIN PROVIDED
GLASS GROMET SHORT MOULD PDI 20 UNSKILLED OPERATOR TRAINING PROVIDED
UNSKILLED OPERATOR IN MOLDING
APILLAR SHORT MOULD Deflashing 25 AREA TRAINING PROVIDED & RED BIN PROVIDED
BUTTAN CILP SHORT MOULD Deflashing 25 SET UP PART RED BIN PROVIDED

SHORT MOLD OBSERVED DUURING

FOG LAMP COVER SHORT MOULD PRODUCTION 30 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED

SHORT MOLD OBSERVED DUURING

DUCT LH SHORT MOULD PRODUCTION 73 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED
 SHORT MOLD OBSERVED DUURING
CROCODAIL CLAMP SHORT MOULD PRODUCTION 46 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED

SHORT MOLD OBSERVED DUURING

BUMPER SCROW SHORT MOULD PRODUCTION 10 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED

SHORT MOLD OBSERVED DUURING

SEAT SEAL SHORT MOULD PRODUCTION 70 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED

SHORT MOLD OBSERVED DUURING

APILLAR SHORT MOULD PRODUCTION 20 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED

SHORT MOLD OBSERVED DUURING

ECU COVER SHORT MOULD PRODUCTION 20 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED
INJECTION NOT AS PER PROCESS SETTING PROVIDED AS PER PROCESSV
BUTTAN CILP SHORT MOULD PRODUCTION 100 SHEET SHEET

SHORT MOLD OBSERVED DUURING

SOCKET BUSH SHORT MOULD PRODUCTION 30 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED
W CLAMP SHORT MOULD Deflashing 80 UNSKILLED OPERATOR TRAINING PROVIDED
NOZZLE HEATER NOT WORKING
GSL KNOB BLACK SHORT MOULD PRODUCTION 50 PROPERLY NOZZLE HEATER TO BE CHANGED
NOZZLE HEATER NOT WORKING
DUCT LH SHORT MOULD PRODUCTION 30 PROPERLY NOZZLE HEATER TO BE CHANGED
CUB HOUSING SHORT MOULD PRODUCTION 59 OPERATOR UNSKILLED TRAINING PROVIDED
KNOB M6 SHORT MOULD PRODUCTION 27 SETUP PART RED BIN PROVIDED
TREE CLIP SHORT MOULD Deflashing 160 UNSKILLED OPERATOR TRAINING PROVIDED
BUTTAN CLIP SHORT MOULD Deflashing 110 UNSKILLED OPERATOR TRAINING PROVIDED
RAW MATERIAL NOT MELTING
PROPERLY,HEATER NOT WORKING
MUD FLAP CNG SHORT MOULD PRODUCTION 80 PROPERLY HEATER TO BE CHANGED

SHORT MOLD OBSERVED DUURING

W CLAMP SHORT MOULD DEFLASHING 23 MOLDING DUE TO POWER CUT RED BIN PROVIDED
RAW MATERIAL NOT MELTING
PROPERLY,HEATER NOT WORKING
BUTTON CLIP SHORT MOULD PRODUCTION 162 PROPERLY HEATER TO BE CHANGED
RAW MATERIAL NOT MELTING
PROPERLY,HEATER NOT WORKING
KNOB M6 SHORT MOULD PRODUCTION 33 PROPERLY HEATER TO BE CHANGED
TUBE HOLDER SHORT MOULD DEFLASHING 14 MOULD SETUP PART TRAINING PROVIDED RED BIN PROVIDED
TREE CLIP SHORT MOULD DEFLASHING 10 UNSKILLED OPERATOR TRAINING PROVIDED
W CLAMP SHORT MOULD DEFLASHING 30 UNSKILLED OPERATOR TRAINING PROVIDED
MATRIAL POSTION NOT ASPER
Thermostate SHORT MOULD PRODUCTION 108 PROCESS SHEET MATRIAL POSTION ASPER PROCESS SHEET
BUMPER SCREW SHORT MOULD PRODUCTION 71 THERMO COUPLE NOT WORKING THERMO COUPLE CHANGE
Door pull ace SHORT MOULD PRODUCTION 80 MANPOWER UNSKILD TRAINING PROVED
juction box SHORT MOULD PRODUCTION 35 MOULD SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
BUTTON CLIP SHORT MOULD DEFLASHING 110 PROCESS SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
PIPE CLIP SHORT MOULD DEFLASHING 20 PROCESS SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
MATRIAL NOTPROPER MAILT
WINDO DISEL SHORT MOULD PRODUCTION 94 HEATER NOT WORKING HEATER TO BE CHANGED
CNG REAR SHORT MOULD PRODUCTION 27 PROCESS SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
CHECK POINTS SOP SUPPLIED AND LIMIT
Mounting bracket SHORT MOULD PDI 14 NO CHECK POINT AVAILABLE SAMPLE DISPLAYED
Bush lower SHORT MOULD DEFLASHING 4 SET UP PART RED BIN PROVIDE
Arm Scropio SHORT MOULD PRODUCTION 33 OPERATOR UNSKILLED TRAINING PRVIDED
DASH CAP SHORT MOULD DEFLASHING 50 UNSKILLED OPERATOR TRAINING PROVIDED
RAW MATERIAL NOT MELTING
PROPERLY,HEATER NOT WORKING
MTG COVER SHORT MOULD PRODUCTION 50 PROPERLY HEATER TO BE CHANGED
T COVER 114 SHORT MOULD DEFLASHING 7 SETUP PART RED BIN PROVIDED
W CLAMP SHORT MOULD DEFLASHING 17 MOULD SETUP PART TRAINING PROVIDED RED BIN PROVIDED
ENJCTION SPEED NOT AS PROCESS ENJCTION SPEED AS PROCESS SHHEET
PIPE CLAMP SHORT MOULD DEFLASHING 100 SHHEET FEELAUP TO PLC
MUD FLAP CNG SHORT MOULD PDI 4 SETUP PART RED BIN AND TRAINING PROVIDED
SHORT MOLD OBSERVED DUURING
MOLDING DUE TO POWER CUT AND
THERMOSTATE SHORT MOULD PRODUCTION 80 NOT DETECTED MANPOWER TO TRAINING PROVIDED RED BIN
GRAB HANDLE SHORT MOULD PRODUCTION 8 MOULD SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
SHORT MOULD SHORT MOLD OBSERVED DURING
PIPE CLAMP BEND Deflashing 30 MOLDING DUE TO POWER CUT RED BIN AND TRAINING PROVIDED
SHORT MOULD BARREL HEATER NOT WORKING
W CLAMP BURN MARK Deflashing 150 PROPERLY THERMOCOUPLE TO BE CHANGED
SHORT MOULD
THERMOSTATE INSERT FLASH PRODUCTION 43 INSERT PIN DAMAGED INSERT PIN CHANGED
SHORT MOULD
W W KNOB SHRINKG Deflashing 31 UNSKILLED MACHINE OPERATOR TRAINING PROVIDED
SHORT MOULD BARREL HEATER NOT WORKING
W WHANDLE SILVER PRODUCTION 42 PROPERLY BARREL HEATER TO BE CHANGED
SHORT
MOULD,INSERT REJ.INSERT MIXUP &LOCATION OK MATERIAL AND REJECT MATERIAL
CNG FRONT FLASH PRODUCTION 35 NOT DEFINE AREA LOCATION TO BE DEFINE
knob m6 Short Mould+ Silver PRODUCTION 7 SET UP PART RED BIN PROVIDED
HUSING short moulding Deflashing 10 SETUP PART RED BIN PROVIDED
Timing Cover 113 ShortMould PDI 13 UNSKILLED DEFLASING MAN TRAINING PROVIDED CHECK POINT DISPLAY
MUD FLAP CNG SHRINKAGE DEFLASHING 19 EXTERNAL COOLING BLOCKED EXTRNL COOLING TO BE SUPPLIED
EXTERNAL COOLING NOT PROPER
ww knob SHRINKAGE DEFLASHING 140 WORKING EXTERNAL COOLING PIPPE TO BE CHANGE
NO CHECK POINTTO C D OUT
4Speed Knob SHRINKAGE PDI 28 DEFELASING AREA CHECK POINT TO ADD.OGS
4 Speed knob SHRINKAGE PDI 17 MOULD SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
 SHRINKAGE+ Cut
MB cover mark DEFLASHING 250 WATER COOLING PIPPE TO BLOCK WATER COOLING PIPPE TO BE CHANGED
COVER RH SHRINKEG PDI 300 DEFLESHING MEMBER UNSKILLED TRAINING AND SAMPLE TO BE PROVIDED
WINDO DISEL SHRINKEG PDI 19 DEFLESHING MEMBER UNSKILLED TRAINING AND SAMPLE TO BE PROVIDED
COVER RH SHRINKEG Deflashing 20 SETUP PART RED BIN PROVIDED
BARREL HEATER NOT WORKING
Outer handle patti Silver PRODUCTION 84 PROPERLY HEATER TO BE CHANGED
Door pull ace Silver DEFLASHING 6 SETUP PART MIXUP RED BIN PROVIDED & TRAINING PROVIDED
w clamp Silver DEFLASHING 100 PROCESS SETUP PART MIXUP RED BIN PROVIDED & TRAINING PROVIDED
ww handle Silver DEFLASHING 61 POWER CUT PURGING MATERIAL AFTER POWER CUT
WW handle Silver / Cut mark DEFLASHING 4 SETUP PART MIXUP RED BIN PROVIDED & TRAINING PROVIDED

WW HANDLE SilVER +CUT MARK DEFLASHING 14 UNSKILLED OPERATOR TRAINING PROVIDED

OUTER HANDLE PATTI SILVER MARK PRODUCTION 35 THERMO COUPLE NOT WORKING THERMO COUPLE CHANGE
TEMPERATURE NOT AS PER SETTING PROVIDED AS PER PROCESSV
4SPEED KNOB SILVER MARK PRODUCTION 62 PROCESS SHEET SHEET
Head lamp One Ton SILVER MARK DEFLASHING 50 MOULD SETUP PART MIXUP REDBIN PROVIDED M/C &TRAINING
Door pull ace SILVER MARK DEFLASHING 35 SETUP PART PART MIXUP RED BIN PROVIDED
SILVER SHORT
FRONT 800CC MOULD Deflashing 20 SETUP PART RED BIN PROVIDED & TRAINING PROVIDED
Supplier issue ( information Convey to
Outer handle RH THREAD NG PDI 3 Supplier regarding Issue ) INCOMING SAMPLING % incrise
Outer handle LH THREAD NG PDI 2 incoming sampling % is low INCOMING SAMPLING % incrise
 REJECTION DATA CHART(PP MOULDING)
PROBLEMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 total commulative
Short filling 57 146 225 77 162 64 77 114 137 103 118 41 152 130 21 195 91 168 171 137 192 152 166 137 95 50
air bubble 6 4 5 4 0 0 0 0 0 0 0 0 5 1 0 10 0 0 3 11 0 0 0
flash 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 0 0 0 0 0 0 0 0 0
srinkage 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
catching 44 32 45 87 110 62 22 35 29 44 28 33 14 22 7 30 8 12 26 13 38 28 19 18 12 45
Pin hole 14 12 44 20 23 2 1 6 4 5 15 5 5 0 3 3 0 6 2 21 10 21 9 55
black spot 112 94 98 82 88 150 35 41 131 150 191 100 78 86 12 55 60 47 133 152 157 45 42 89 56 40
voids 41 28 18 48 17 25 18 17 13 43 6 42 75 31 8 25 50 13 8 44 26 46 34 12 26 21

TOTAL REJECTION 274 316 80 435 314 242 303 152 208 316 344 343 221 481 279 53 306 219 253 338 352 418 303 271 277 198 211

TOTAL QUANTITY OK 9400 9589 1226 8984 9612 9490 9408 7123 8964 9454 9808 9893 8183 8098 8436 868 8075 8366 8831 10284 8669 9259 8866 8469 9095 8587 8696

TOTAL PRODUCTION 9674 9905 1306 9419 9926 9732 9711 7275 9172 9770 10152 10236 8404 8579 8715 921 8381 8585 9084 10622 9021 9677 9169 8740 9372 8785 8907

defect ratio PPM % 2.83 3.19 6.13 4.62 3.16 2.48 3.12 2.19 2.27 3.23 3.38 3.51 2.63 5.6 3.2 5.75 3.65 2.55 2.78 3.18 3.9 4.32 3.3 3.1 2.96 2.25 2.36

rejection data pp molding(%)

7

6 6.13
5.6 5.75
5
4.62
4 4.32
3.9
3.51 3.65
3 3.19 3.16 3.12 3.23 3.38 3.2 3.18 3.3
3.1
2.83 2.78 2.96
2.48 2.63 2.55
2 2.19 2.27 2.25 2.36

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
 pp moulding oct. rejection
PROBLEMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Short filling
air bubble
flash
srinkage
catching
Pin hole
black spot
voids

TOTAL REJECTION
TOTAL QUANTITY OK
TOTAL PRODUCTION

defect ratio PPM %

ct. rejection data(%)
21 22 23 24 25 26 27 28 29 30 31 total commulative
 AUG.REJECTION DATA PP MOULDING
PROBLEMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 TOTAL COMMULATIVE
Short filling 198 255 217 284 200 189 121 194 242 233 143 203 162 139 178 173 343 241 302 144 166 188 200 166 127 5008 5008
air bubble 52 70 6 103 15 4 8 111 149 109 135 6 10 50 63 8 25 7 931 5939
srinkage 24 79 16 8 13 12 9 26 19 27 11 33 11 5 11 35 27 17 16 399 6338
Flash 16 4 40 2 5 8 7 4 8 8 102 6440
catching 125 177 119 141 126 81 167 110 70 141 66 51 138 125 164 110 113 144 205 136 126 118 91 66 65 2975 9415
Pin hole 12 7 89 77 55 82 55 37 22 21 12 469 9884
Black spot 65 69 83 61 93 47 55 66 47 20 24 57 63 26 55 54 31 30 198 234 191 106 80 171 1926 11810
voids 85 74 110 53 65 35 24 14 52 44 18 31 37 34 32 48 56 82 42 67 25 34 40 53 34 1189 12999
TOTAL REJECTION 565 724 555 599 411 0 0 513 370 419 461 507 0 351 0 419 516 515 520 0 564 599 525 708 690 614 593 466 386 409 12999
TOTAL QUANTITY 8043 7572 6733 5614 6181 0 0 8204 7453 8793 8720 10348 0 8142 0 8830 8225 8231 8103 0 7398 7219 7937 8303 8987 8450 0 8970 9147 8887 9115

TOTAL PRODUCTION 8608 8296 7288 6213 6592 0 0 8717 7823 9212 9181 10855 0 8493 0 9249 8741 8746 8623 0 7962 7818 8462 9011 9677 9064 9563 9613 9273 9524

defect ratio PPM 7.02 9.56 8.24 10.67 6.65 6.25 4.96 4.77 5.29 4.90 4.31 4.75 6.27 6.26 6.42 7.62 8.30 6.61 8.53 7.68 7.27 6.61 5.09 4.34 4.49

12.00
6000
REJECTION DATA AUG.-2017 92.53788752981
100
99.215324255712
96.1458573736441
100
85.3757981383183
10.67
5008 90
10.00 9.56 5000 76.2289406877452
80

8.30 8.53 61.4124163397185 70

8.24 4000
8.00 7.62 7.68 60
7.02 7.27
6.65 6.61 6.61 2975
6.25 6.27 6.26 6.42 3000 38.5260404646511 50
6.00 40
5.29 5.09 1926
4.96 4.77 4.90 4.75 2000
4.34 4.49 30
4.31
1189
4.00 931 20
1000
469 399 10
102
2.00 0 0
Short Filling Catching Black Spot Void Air bubble Pin hole Shrinkage Flash

0.00 NUMBER OF PARTS CUMMULATIVE (%)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 (QTY)
 JUNE REJECTION DATA PP MOULDING
PROBLEMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 TOTAL COMMULATIVE
Short filling 206 224 365 306 284 242 218 306 215 319 229 375 227 350 210 245 309 218 343 317 324 306 273 289 327 289 7316 7316
srinkage 158 48 76 144 86 67 89 56 63 166 59 38 56 156 34 45 87 34 86 97 102 49 38 46 53 64 1997 9313
Flash 58 46 14 45 40 46 47 35 43 47 34 49 46 34 39 42 23 48 65 43 42 37 58 49 53 56 1139 10452
catching 98 48 27 54 51 70 34 71 76 54 54 66 87 51 87 46 23 46 23 56 99 53 65 86 64 43 1532 11984
Black spot 89 45 31 34 24 24 39 45 78 48 63 59 42 65 41 26 75 38 43 31 39 46 56 39 77 54 1251 13235
voids 74 89 43 56 38 26 35 24 77 34 34 46 41 56 37 85 34 52 35 36 32 43 34 42 34 78 1215 14450
TOTAL REJECTION
683 500 556 639 523 475 462 537 552 668 473 633 499 712 448 489 551 436 595 580 638 534 524 551 608 584 14450
8903 8069 7030 9217 7063 8794 8100 7049 9106 7894 6583 9219 6957 7830 8077 9783 9107 9085 7928 9078 6620 8989 8039 9131 10034 9272
TOTAL QUANTITY
9586 8569 7586 9856 7586 9269 8562 7586 9658 8562 7056 9852 7456 8542 8525 10272 9658 9521 8523 9658 7258 9523 8563 9682 10642 9856
TOTAL PRODUCTION

defect ratio% 7.12 5.83 7.33 6.48 6.89 5.12 5.40 7.08 5.72 7.80 6.70 6.43 6.69 8.34 5.26 4.76 5.71 4.58 6.98 6.01 8.79 5.61 6.12 5.69 5.71 5.93

june rejection data

june rejection data 95.4244357212954 98.1476938174681 100
8000 87.5368007850834 100
10.00 7316
77.2693817468106 90
7000
9.00
80
8.00 6000
59.0775269872424 70
7.00 5000
60
6.00 4000 50
5.00 40
3000
4.00 1997 30
2000 1532
3.00 1251 1215 1139 20
1000
2.00 10

1.00 0 0
Short Filling Shrinkage Catching Black Spot Void Flash
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 NUMBER OF PARTS CUMMULATIVE (%)
(QTY)
 JULY REJECTION DATA PP MOULDING
PROBLEMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 TOTAL commulative
Short filling 198 122 184 226 195 205 289 215 172 189 121 230 260 233 246 218 187 198 245 200 195 224 227 185 156 5120 5120
srinkage 67 56 126 54 87 54 58 105 98 127 42 74 102 85 45 104 103 89 105 116 75 123 96 86 92 2169 7289
Flash 43 106 67 85 49 89 89 85 89 74 65 94 86 89 58 98 98 84 65 98 89 102 85 85 75 2047 9336
catching 54 87 94 59 75 128 79 94 10 154 52 86 98 138 126 110 45 86 85 58 86 89 63 85 106 2147 11483
Black spot 34 73 56 107 99 106 128 84 94 96 104 96 98 96 85 96 143 85 126 98 85 56 101 117 78 2341 13824
voids 76 34 87 16 12 63 86 18 96 34 10 18 28 17 34 16 44 72 43 23 85 23 24 34 85 1078 14902
TOTAL REJECTION
472 0 478 614 547 517 645 729 0 601 559 674 394 598 672 0 658 594 642 620 614 669 0 593 615 617 596 592 592 14902
7349 7732 7321 8367 7934 7611 7516 8855 8987 9089 8170 6983 8786 7811 6970 6944 7944 8972 8863 7969 9250 7239 6860 7977 7977
TOTAL QUANTITY
7821 8210 7935 8914 8451 8256 8245 9456 9546 9763 8564 7581 9458 8469 7564 7586 8564 9586 9532 8562 9865 7856 7456 8569 8569
TOTAL PRODUCTION

defect ratio % 6.04 5.82 7.74 6.14 6.12 7.81 8.84 6.36 5.86 6.90 4.60 7.89 7.11 7.77 7.85 8.46 7.24 6.41 7.02 6.93 6.23 7.85 7.99 6.91 6.91

REJECTION JULY 2017 july rejection data 100

6000 92.7660716682325 100
10.00
5120 79.029660448262 90
9.00 5000
64.6221983626359 80
8.00 70
4000
7.00 50.0671050865656 60

6.00 3000 50
34.3578043215676
2341
2169 2147 2047 40
5.00 2000
30
4.00 1078 20
1000
3.00 10
2.00 0 0
Short Filling Black Spot Shrinkage Catching Flash Void
1.00

0.00 NUMBER OF PARTS CUMMULATIVE (%)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 (QTY)