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    Dis 6 W 2 H

    Uploaded by

    Balachandar Sathananthan
    The document provides information on issues identified during vehicle assembly stages, root cause analysis, and corrective actions taken. It lists issues such as horn cable damage during engine bracket fitting, damaged gear shifter lever bolts due to misalignment, scratched speedometer glass, and pinched fuel pipes. For each issue, it identifies the defect location, contributing parts, root cause analysis showing the stage where the defect was generated, and corrective actions initiated such as process changes, improved inspection steps, and design modifications. The status of the corrective actions is also provided.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd

    Dis 6 W 2 H

    Uploaded by

    Balachandar Sathananthan
    137 views14 pages
    The document provides information on issues identified during vehicle assembly stages, root cause analysis, and corrective actions taken. It lists issues such as horn cable damage during engine bracket fitting, damaged gear shifter lever bolts due to misalignment, scratched speedometer glass, and pinched fuel pipes. For each issue, it identifies the defect location, contributing parts, root cause analysis showing the stage where the defect was generated, and corrective actions initiated such as process changes, improved inspection steps, and design modifications. The status of the corrective actions is also provided.

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    dis6w2h

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    The document provides information on issues identified during vehicle assembly stages, root cause analysis, and corrective actions taken. It lists issues such as horn cable damage during engine bracket fitting, damaged gear shifter lever bolts due to misalignment, scratched speedometer glass, and pinched fuel pipes. For each issue, it identifies the defect location, contributing parts, root cause analysis showing the stage where the defect was generated, and corrective actions initiated such as process changes, improved inspection steps, and design modifications. The status of the corrective actions is also provided.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    137 views14 pages

    Dis 6 W 2 H

    Uploaded by

    Balachandar Sathananthan
    The document provides information on issues identified during vehicle assembly stages, root cause analysis, and corrective actions taken. It lists issues such as horn cable damage during engine bracket fitting, damaged gear shifter lever bolts due to misalignment, scratched speedometer glass, and pinched fuel pipes. For each issue, it identifies the defect location, contributing parts, root cause analysis showing the stage where the defect was generated, and corrective actions initiated such as process changes, improved inspection steps, and design modifications. The status of the corrective actions is also provided.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 14

    6W2H

    WHAT WHERE WHICH WHY HOW TO DO COUNTERMEASURE IMMEDIATE ACTION WHO WHEN At Engine upper bkt tightening Stage Horn cable length Horn cable pinched reduced by 40mm & Discover in between engine position of cable shift upper bkt. & Engine away. DHOOT TRANSMISS March.08 ION

    Horn cable cut

    Take care while fitment of Engine upper bkt.

    Gear shifter Gear shifter lever bolt head lever fitment damaged stage

    Axis not match due Discover to gun foul to engine base plate

    Gear shifter lever bolt tightening socket length increased.

    Bolt tight by ring spanner

    VEHICLE ASSEMBLY

    June.07

    Chain cover bolt threading & bkt. nut threading damaged Speedo meter glass scratches Fuel pipe leakage

    Chain cover fitment stage

    Axis not match due Chain cover bolt Discover to gun faul to swing tightening with special Bolt tight by T' spanner arm (New design) steped socket. Scratch guard(Plastic film) introduced on glass. Carborrator tube angle changed for fuel pipe fitment .

    VEHICLE ASSEMBLY

    Dec.08

    Fairing S/A stage Carborrator fitment stage

    Pulsar

    Handling ignorance

    Take care while assembling Take care while assembling of carborrator on AC box

    VARROC & PRICOL UCAL MIKUNI

    April.07

    Pulsar

    Fuel Pipe pinched while carb. fitment

    Plan

    Fairing scratches

    Fairing fitment stage

    Pulsar

    Brakekit touching to other fairing on Trolley modification. trolley

    Fairing s/a locate one by one on trolley to mainten VEHICLE distance between two ASSEMBLY s/a

    July.07

    STATUS

    U/IMPL

    IMPL

    IMPL

    IMPL

    U/IMPL

    IMPL

    INTERNAL CUSTOMER COMPLAINT ANALYSIS ( QSR )


    Why defective parts reached on line (A) (B) (C) (D) (E) Acceptance standards not common Available inspection not adequate No inspection at suppliers END

    PROCESS SIDE ACTION

    Process Poka Yoke failed

    PROBLEM DESCRIPTION

    Inspection Poka

    MODEL

    1] FUNCTION 2] AESTHETIC 3] FITMENT

    QTY IN %

    CONTRIBUTING PARTS

    Immediate counter action ( Inspection side )

    Defect generated at which stage / cell

    Root cause

    Corrective action initiated

    1] Accelerator sticky

    Discover

    1]

    1] Carburettor 2] Reed switch bkt 3] Acceln cable

    100% inspection at carbuerttor s/a

    Accelerator connection

    Reed switch bracket angle distortion

    Previous pin mounting arrangement changed to sliding lock type arrange Provision made in final relation gauge for bkt position checking

    2] Rear Wheel jam

    Discover

    3]

    1]Rear wheel 2]Rear wheel brake pannel 3]

    100% inspection at kit bin loading

    Rear brake pannel fitment

    Brake shoe liner 100 % inspection at machining incomplete vendor end for OD

    3] Front wheel axle insertion not Discover possible

    3]

    1] Front wheel 2]Fr.wh. axle 3]Fr. Wh. Spacer

    100% inspection at kit bin loading

    100 % inspection of Front wheel Front wheel axle O/D front wheel axle OD fitment stage oversize at vendor end

    4]Front & Rear wheel paint uncover

    Discover

    2]

    1]Front wheel 2]Rear wheel

    100% inspection at Front wheel fitment stage

    Front wheel Incomplete painting fitment stage

    100 % inspection of wheel at vendor end.

    5] Front wheel axle insertion hard

    Discover

    3]

    1] Front wheel 2]Fr.wh. axle 3]Fr. Wh. Spacer

    100 % inspection at kit bin loading stage

    100 % inspection of Front wheel Front wheel spacer ID spacer ID at vendor fitment stage u/s end

    6]LH side panel lock operation hard.

    Discover

    3]

    1] Chassis 2]Side lock

    100% inspection at chassis shop before chassis loading

    Side pannel fitment

    Side panel bracket position shifted

    Welding fixture corrected to maintain exact bracket position.

    ON

    Control Points

    INTERNAL CUSTOMER COMPLAINT ANALYSIS ( QSR )


    Why defective parts reached on line (A) (B) (C) (D) (E) Acceptance standards not common Available inspection not adequate No inspection at suppliers END

    PROCESS SIDE ACTION

    Process Poka Yoke failed

    PROBLEM DESCRIPTION

    Inspection Poka

    MODEL

    1] FUNCTION 2] AESTHETIC 3] FITMENT

    QTY IN %

    CONTRIBUTING PARTS

    Immediate counter action ( Inspection side )

    Defect generated at which stage / cell

    Root cause

    Corrective action initiated

    1] Head lamp not Pulsar work

    1]

    1] Head lamp 2] RH switch base 3] RR unit 4]BCU

    PV inspection stage

    BCU regulator /spic voltage controller failure due to dry soldering at tranzop

    100 % wave form ( spic voltage inspection on ocsilloscop with magneto test bench started from 18 10 07

    2] Vehicle no start

    Pulsar

    1]

    1]CDI unit 2]Magneto 3]H. T Coil 4] Spark plug

    100% inspection at Engine assly.

    PV inspection stage

    Star Engg make. Wiring harness connecting wire( ht coil input ) found pinched & shorted

    pFMEA study for the supply chain for handling of Electrical parts started to eliminate each possibility of damage in handling

    3] Seat torn

    Pulsar

    2]

    1]Seat

    100% inspection before fit

    PV inspection stage

    Seat torn in transit.

    Polythene bag introduced with modification in trolley to avoid transit damages.

    4]Chassis Clutch cable routing Pulsar bracket broken

    3]

    1]Chassis Clutch cable routing bracket

    100% inspection at chassis shop before chassis loading

    Clutch cable Bracket strength connection weak stage

    Bracket modify with stronger design.

    INTERNAL CUSTOMER COMPLAINT ANALYSIS ( QSR )


    Why defective parts reached on line (A) (B) (C) (D) (E) Acceptance standards not common Available inspection not adequate No inspection at suppliers END

    PROCESS SIDE ACTION

    Process Poka Yoke failed

    PROBLEM DESCRIPTION

    Inspection Poka

    MODEL

    1] FUNCTION 2] AESTHETIC 3] FITMENT

    QTY IN %

    CONTRIBUTING PARTS

    Immediate counter action ( Inspection side )

    Defect generated at which stage / cell

    Root cause

    Corrective action initiated

    5] Neutral connection not possible

    Pulsar

    3]

    1]Harness

    100% inspection at chassis shop before chassis loading

    Magneto connection stage

    Bullet coupler Single pole coupler damaged in handling provided

    6] Silencer mettalic / spatter Pulsar noise

    1]

    1]Silencer

    100 % inspection on stage

    PV inspection stage

    Welding spatter falling inside resonator box

    New welding fixture installed to keep resonator box position horizontal during welding.

    ON

    Control Points

    ON

    Control Points

    JUNE

    JULL Y

    WHAT

    WHERE

    WHICH

    WHY

    Chain Chain cover cover middle fitment mtg. bkt. Nut damged

    Discover Bolt t

    AUG.

    NOV. 03

    TARG ET

    SEPT.

    JAN.0 6

    APRI L.06

    HOW TO DO
    COUNTERM IMMEDIAT EASURE E ACTION

    WHO AUTO COMP

    WHEN

    STATUS

    CDI Mtg. Bkt Angle change . 39 86 0

    CDI Mtg.Bkt. bending started previous PT fitment stage

    IMPL

    WHAT

    WHERE

    WHICH

    WHY

    HOW TO DO
    COUNTERMEASUR IMMEDIATE ACTION E

    WHO

    WHEN

    STATUS

    WHICH

    WHAT

    WHERE

    WHY

    HOW MANY BM TRG

    HOW TO DO COUNTERMEASURE IMMEDIATE ACTION Horn cable length reduced by 40mm & position of cable shift away.

    WHO

    WHEN

    STATUS

    Discover

    Horn cable cut

    At Engine upper bkt tightening Stage

    Horn cable pinched in between engine upper bkt. & Engine

    DHOOT Take care while fitment TRANSMISS March.08 of Engine upper bkt. ION

    U/IMPL

    Gear shifter lever bolt Discover head damaged

    Gear shifter lever fitment stage

    Axis not match due to gun foul to engine base plate

    15

    Gear shifter lever bolt tightening socket length increased.

    Bolt tight by ring spanner

    VEHICLE ASSEMBLY

    June.07

    IMPL

    Chain cover bolt threading Chain cover Discover & bkt. nut fitment stage threading damaged

    Axis not match due to gun faul to swing 34 arm (New design)

    Chain cover bolt tightening with special Bolt tight by T' spanner steped socket.

    VEHICLE ASSEMBLY

    Dec.08

    IMPL

    Pulsar

    Speedo meter glass scratches Fuel pipe leakage

    Fairing S/A stage Carborrator fitment stage

    Handling ignorance

    Scratch guard(Plastic film) introduced on glass.

    Take care while assembling

    VARROC & PRICOL UCAL MIKUNI

    April.07

    IMPL

    Pulsar

    Fuel Pipe pinched while carb. fitment

    29

    Carborrator tube Take care while angle changed for fuel assembling of pipe fitment . carborrator on AC box Fairing s/a locate one by one on trolley to mainten distance between two s/a

    Plan

    U/IMPL

    Pulsar

    Fairing scratches

    Brakekit touching to Fairing other fairing on fitment stage trolley

    12

    Trolley modification.

    VEHICLE ASSEMBLY

    July.07

    IMPL

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