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Root cause from vendor indicates there is an attached thread on the product.It is possible that the "falling apart" problem may happen because that the sewing of the sponge was not solid enough or that when the workers try to trim the thread, they wrongly cut the key fix thread, and cause the sponge to fall apart.Corrective action: supplier corrective action request (scar) was completed ((b)(6) 2021) by supplier ( (b)(4) ltd.) to advise workers to check sponges to find whose sewing is not meeting standard.Then instruct the correct sewing method to them and tighten the quality inspection on the products made by them.Sewing of the sponge shall strictly follow the steps in the product diagram.If any attached threads need to be trimmed subsequently, carefully cut the redundant threads avoiding the key fix threads to prevent the sponge falling apart problem.If any loose sponges are found during the inspection and packaging process, scrap them immediately to ensure no nonconforming products escaped.Preventive action: as per vendor ( (b)(4) , ltd.) is instruct the intended purpose of the products to the workers to enhance their quality awareness.Notify the complaint content to all workers and paste the complaint picture in the workshop for early warning purpose.Investigation: no manufacturing issue has been found.Process records could not be reviewed because there was no lot number had been indicated by the customer.However inventory check has been performed, evaluation of 6 cases have been randomly inspected and no loose ends have been found.A total of (b)(4) packs of product for the part under complaint have been sold from (b)(6) 2019 through (b)(6) 2021.Three similar issues related to the performance of the product have been reported during the same period of time.The percentage of issues equals to (b)(4) of complaints as compared to selling unit of measure.The investigation is complete at this time.If new and critical information is received, this report will be updated.
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