G8D Report

Title Date Opened Last Updated

True position of ref: 402 is out of specification
January 8th, 2015 January 8th, 2015
Product/Process Information Organization Information
Cylinder Head 4.4L LH hand Land Rover
CCN Number: CCN080110 CHDiesel 4.4 Barreno FP
Dø Symptom(s)

On Jan, 8th 2015, Nemak Mty reported 48 Cyl Heads LH 4.4L Land Rover found at Ford Chep with true position of Ref: 402
out of specification.
TP of reference 402 out
spec.

Dø Emergency Response Action(s) % Effective Date Implemented

At ILSA:

Certifying all material ready to be shipped. LH and RH 4.4 L.

- Zero stock of PT at ILSA
100% January 8th , 2015
- ILSA place the failure Notice on the Final Control Station
See Failure Notice, please.

D:AF TP FUERA DE
ESPEC.xls

D1 Team (Name, Dept., Phone) D2 Problem

Problem Statement.
Fabian Gonzalez Superviser (ILSA) (01) 8717492700
Melchor Martínez QE (ILSA) (01) 8717492700 - Cyl Head 4.4 L LH Land Rover with True position of
ref: 402 is out specification.
Ivon Gargeda QE (ILSA) (01) 717492700
Vicente Salazar CMM Room (ILSA) (01) 8717492700
- Parts Machined:
Alfredo Mauricio Process Engineer (01) 8717492700
Mario Monares Nemak´s Rep. at ILSA (01) 8717492700
- Traceability:
Leobardo Guajardo Quality (Nemak) (52-81)87485200
PPAP Phase 2 parts
X 5519
D3 Interim Containment Action(s)

At ILSA/Nemak:
– ILSA started to certify Cyl Head 4.4 L LH stock
100% January 8th, 2015
- ILSA place the failure Notice on the Final Control Station
See Failure Notice, please.
100% January 8th, 2015

D:AF TP FUERA DE
ESPEC.xls
January 8th, 2015
ID for dunnages with parts OK certified with a tag. 100%

D:\\material
certificado.JPG

D4 Root Cause(s) % Contribution

1.- CNC Program sequence does not adapted to machine this feature (Drill pilot, Reamer C'Bore, Drill gallery)
2.- The Go-Nogo gage is not adapted to the control (to see the defect)
3.- CMM Program does not control TP of DIAM: 8 mm 100%
4.- The visual control was not made by operator.

D:\\Ishikawa TP REF
402 OUT POSITION.XLS

D5 Chosen Permanent Corrective Action(s) Effective

1.- CNC Program sequence change to machine this feature (Drill pilot, Drill gallery, Reamer C'Bore) 100%
2.- Control the C'Bore with Bore gage (we will use the Go-Nogo gage only for depth)
3. - Update CMM Program in order to control TP of diam. 8mm.
4. - Training the operator on visual control criteria.

D6 Implemented Permanent Corrective Action(s) Date Implemented

1.- CNC Program sequence change to machine this feature (Drill pilot, Drill gallery, Reamer C'Bore) Jan 8ht 2015
2.- Control the C'Bore with Bore gage (we will use the Go-Nogo gage only for depth) 1st Step Jan 22 2015
2d. Step Mar 19 2015
3. - Update CMM Program in order to control TP of diam. 8mm. Jan 15th, 2015
4. - Training the operator on visual control criteria. March 8 2015 (Next run)

D7 Preventive Actions Date Implemented

1. – Visual Inspection training in all the process. March 8 2015 (Next run)

D7 Systemic Prevent Recommendations Responsibility

1. - Apply the Process & Product Change Procedure (SREA) for any change. Immediate (Next Change)
2.- Modify of the PFD, PFMEA, PCP with the Corrective Actions Jan 22 2015
3. – Modify the Standard Job & Inspection Instructions. Jan 26 2015

D8 Team and Individual Recognition Date Closed Reported By:

M. Martinez
Quality Eng.