Traceability

DEFINE

MM : 53535435
Product Name : BTL DETTOL ID 250ML DT 3092UV
Customer : Reckitt Benckiser Indenesia
Problem : OOS Wall Thinckness
Problem Occur : Line Customer
Reported By : Imam & Fais
Batch : 23213214
Complaint Date : 22/01/2024
SNCR No : RN-23324-43453
Status : Complaint

DETAIL DEFECT

OOS Wall Thickness

TRACEABILITY

Production History :

BTL DETTOL ID FHW 250ML DT 3095596 UVI Batch 16071955

Produced at Machine ASB 12

Production Date : 03-10.01.2024
Total Production : 80.640 pcs
Stock : 40,320
Detail Delivery :
Delivery Order DO Date Quantity(Pcs)
26193938 11/01/2024 40.320
Total Quantity 40.320

Investigation

INVESTIGATION

1. Investigation based on production report

In the production log book there was a report of thin wall thickness variable on cavity 5 on 6/1/2024, shift 2.

2. Investigation based on retain sample

With information of OOS area was around bottom, DP checked wall thickness from retain sample using wall thickness gauge with ball gauge sized 2.5mm on the bottom corner area.

The retain sample shows that the wall thickness was still in-spec.

3. Investigation by GEMBA

GEMBA on production area found that there was a broken bolt that holds the injection core plate, making the injection core is off-centered. Due to the machine movement, the off center can happen in various cavity numbers with cav 5 being the most susceptible due to its position.

Further checking on the machine found that the valve membrane and primary blow regulator is broken which causing unstable blow pressure.

Root Cause Analysis

ANALYSIS ROOT CAUSE

Corrective Action and Improvement

CORRECTTIVE ACTION

  1. Do GEMBA on machine and production report (done: 19/1/2024, PIC: PROD)
  2. Check wall thickness of retain sample and stock (done, 19/1/2024, PIC: QA)
  3. Block and 100% sorting remaining stock on DP WH (done, 18/1/2024)
  4. Replace valve membrane (done, 20/1/2024, PIC: PROD)

PREVENTIVE ACTION

  1. Replace regulator (indent part, due date: March 2024)
  2. Disassemble and replace broken bolt (due date: W4 Jan 2024)
  3. Block and 100% sorting remaining stock on DP WH (done, 18/1/2024)
  4. Tightening Wall Thickness checking from every 8 hours to every 4 hours (next PO, PIC: QA)

REVIEWED

Evaluated By : Yudi, Saroyo, Diara, Andri, Fais

PIC : Production, QA
Due Date : ASAP
STATUS : OPEN