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Sl.No. Description of Complaint Damage of thread in M12x115 Cut Length Bolt and M12x90 Hex head bolt. The cut length bolt and Hex head bolt are assembled instead of stud. (Qty : 25 nos) Complaint Issued by Maruthi Sharma, WIPRO Mode of Complaint Complaint Received on Qty Rejected Root Cause Corrective Action
25.08.09
Ring Gear ID found over size upto 225 +0.05 +0.2 against 225 +0.046
Dantal
12.12.09
1. The bends / ovaulty after Teeth cutting / Tuffriding to be measured and removed.2. Plug gauge / Snap gauge to be introduced to measure the ID
In G 600 V2 PTO, mounting of pump is difficult. Before mounting filing is being done
Hyva, Bangaluru
Direct
12.12.09
WIPRO
Phone
10.01.10
This is because of PTO is engaged before the gear box stops. This is operator's mistake.
PTO operating instruction leaflet to be prepared and supplied along with every PTO
Mahindra
Phone
12.01.10
Shifting shoe material is Brass which not a good wear resistance material
Shifting shoe material changed to Phospher bronze, because it has higher wear resistance
WIPRO
Phone
20.01.10
Hyva
E mail
04.03.10
This is because of PTO is engaged before the gear box stops. This is operators mistake.
We sent our service person to Delhi to attend this problem. PTO operating instruction leaflet to be prepared and supplied along with every PTO
Mahindra
E mail
05.06.10
This is due to damage of O Ring in the input shaft. When the input shaft along with O ring is inserted into housing hole during assembling, the sharp edge in the hole damages the O ring.
WIPRO
E mail
14.06.10
Microstructure is tested and found OK.The Hardness of the drive gear is tested and found OK. The case depth is checked and found 2.5 instead of 0.6 - 0.8. This is the reason for the breakage.
This is discussed with M/s Sri Heat treatment and M/s Best heat Treatment. 1 sample tested in ASTER from Sri Heat treatment and found 0.8. SOP for Heat treatment process to be made. Supplieaudit to be conducted.
10
Hyva
17.11.2010
11
Palfinger
27.11.2010
This is due to Hardening of U cup where the PTO was operated without oil.
The PTO is designed to use only in tipping purpose and the failure is happened in crane application which is not suitable for our PTO
12
Hyva
25.11.2010
This is due to O ring damage. Damage may happened because of sharp corners.
1. Before assembling it is to be ensured no sharp edges.2. Damaged O rings are to be replaced by VITON O ring. 1. In future VITON O rings only to be used 2. Piston O Ring subassembly is to be redesigned.
13
ZF 9S 1C oil leakage
WIPRO
E mail
07.12.2010
Nitrile O rings fitted on PTOs were replaced with Viton O rings. The O Failure of O Ring caused by hardening of rubber leading to ring material to be changed to a compound which is resistant to water, premature wear. heat and air.
14
Hyva
E mail
20.12.2010
This is due to Blow holes in the nylon dummy. During inward inspection 10 nos of dummy to be broken to find any blow holes present.
Material to be changed
1.Studs to be fitted on the PTO instead of sending separately. 2.Mounting the PTO using M12x100 stud is difficult and instead of the stud Hexagonal head bolt to be used. 3.Pump cannot be fitted with the PTO because the length of the M12 x 115 stud is not sufficient. M12 x 130 mm stud to be used. AD Engineers visited WIPRO and found that this is due to burrs in pump shaft & the pump shaft is not made by Alpha Drives
15
AMW
E mail
10.02.2011
NA
16
WIPRO
E mail
26.04.2011
NA
17
MNAL
E mail
20.06.2011
This might happened while assembling the bearing in inclined position. This might also happened by improper method of disassembling of bearing. Rubbing mark is due to contact of face of grinding wheel during cylindrical grinding. This might happened by improper method of disassembling of adaptor. Bearing failure.
To avoid these 1.Bearings are fitted into the housing using hydraulic press to ensure proper alighnment. 2.Face out 0.05 max is permissible.3. Intially JSK Brand were used and now we are using INA Brand which is a higher quality.
17
AMW
E mail
29.07.2011
Thread length in M12 stud is less and so it could not be tightened enough to prevent oil leakage. This is because Thread length in M12 stud is less and so it could not be tightened enough to prevent oil leakage. To avoid this Instead of M12x115 mm stud M12 x 130 mm stud are supplied.BOM to be modified This may be due to mix up of pump gear which has been sent separately along with each PTO. This will be ensured only by verifying the defective PTO after receiving. The defective PTO is replaced as an interim action.
Instead of M12x115 mm stud M12 x 130 mm stud are supplied. BOM to be modified
18
AMW
E mail
29.07.2011
Instead of M12x115 mm stud M12 x 130 mm stud are supplied. BOM to be modified
18A
WIPRO / KVUL
E mail
13.08.2011
28 teeth Drive Gear and 23 teeth Pump Gear sets to be stored in different place and clearly identified.
19
WIPRO / KVUL
E mail
13.08.2011
This may be due to mix up of 22 and 23 teeth pump gear which has been sent separately along with each PTO.
This will be ensured only verifying the defective PTO after receiving.
20
WIPRO / KVUL
E mail
13.08.2011
The PTO and the flange are assembled together before despatch. During assembling the PTO is disassembled by the customer and again fitted in the vehicle gear box. During disassembling the holes may be shifted.
21
PTO Pump fitment becoming hectic job and time consuming job
WIPRO / KVUL
E mail
13.08.2011
At body building stage before fitment they are Inserting one mounting bolt and washer before assembling the PTO dismantling the PTO to put one mounting bolt and fitment flange and PTO so that PTO can be directly fitted on the gear box. Time done on gear box in three separate parts. Which is killing and energy can be saved at Body builder and original fitment will not to min half hour time for every vehicle and it is hectic job. be disturbed.
22
Receiving two different PTO gear sets with different gear ratios. Gear mismatching and fitment problem
WIPRO / KVUL
E mail
13.08.2011
All the Drive Gears at customer end having 28 teeths to be replaced by This may be due to mix up of 28 teeth Drive Gear and 23 29 teeth Drive Gear and all the Pump Gears having 23 teeths to be teeth Pump Gear set, because earlier 28 teeth Drive Gear replaced by 22 teeth Pump Gear. 1. Only 29 teeth Drive Gear and 22 and 23 teeth Pump Gear set was used in GBS 40 PA PTO. Teeth Pump Gear Combination set to be used for WIPRO. 2. 28 teeth For the past 18 months 29 teeth Drive Gear and 22 Teeth Drive Gear and 23 teeth Pump Gear sets to be stored in different place Pump Gear Combination set is being used. and clearly identified.
23
WIPRO / KVUL
E mail
13.08.2011
1.New Counter shaft is bought from M/s ABT TATA Motors and the shaft smoothly enters into the spline of Drive Gear.2. Gauge used for inspection and the Counter Shaft dimensions are same. 3. Design and Manufacturer parameters are found OK.
24
Spline end bore depth is 16.5 instead of 14.5 in 6209 Quill Shaft
AMW
E mail
26.11.2011
1. Spacer thickness under size. (Measured 11.4 - 11.6 against 11.4 -0.05 in store stock). 2. Bore depth over size. (Measured 26.0 - 26.2 against 26.0 0.05 in store stock).3. Mix up of old model quill shafts. These quill shafts are having excessive step length. The bore is 2 mm deeper than current quill shafts.1.
25
EATON 6209 Oil leakage from stud hole due to blow holes in the hole
AMW
E mail
30.11.2011
This is due to blow hole in 13 mm hole. This is due to slippage of spline shaft into the coupling. Slippage may be due to : 1. Spline shaft outer diameter under size.1. We have checked the spline shaft outer diameter in our stock and found OK.CAPA can be given only after inspecting the failed PTO
1.Vacum Impregnation to be done on all housings. 2. 100 % Visual Inspection to be done on all housings before assembly.
26
AMW
E mail
18.01.2012
27
TAL
Direct
28.03.2012
28
MGB Motors
E mail
20.04.2012
29
WIPRO
E mail
22.04.2012
30
Leakage between Oil seal bore and Adaptor shaft in MLK V1 PTO
Mahindra
E mail
22.04.2012
This is because 1. Oil seal bore over size. 2. Oil seal damage
Oil seals are checked for any damages in Alpha Drives Stock and no damaged oil seals. Assembling operators are instructed to sepatrate the damaged oil seals if any during assembling of PTOs.
31
WIPRO
Direct
01.06.2012
Francis visted WIPRO and segregated the lot and found Pump Gear missing in 6 PTOs. 6 nos of Pump Gear sent to WIPRO
32
WIPRO
Direct
14.06.2012
This is supplied on 8th month of 2011. This is due to blow holes in Nylon Dummy. The material is changed to HDPE(High Density Poyethelene).
33
Mahindra
Direct
20.06.2012
34
WIPRO
E mail
12.08.2012
36
WIPRO
E mail
21.09.2012
Mr.Venakatesh of Alpha Drives visited PRERANA Motors on 24.09.2012 and replaced the damaged Drive Gear. Before engaging PTO, driver has This is because of Drive Gear damage. Damage occurred to press clutch pedal properly and wait for 5 seconds which failing will while PTO is continuously tried to engage before the gear finally damage the drive gear spline and counter shaft. The root cause box stops and preventive action is discussed with Mr.Jagadish of Prerana Motors by Mr.Venkatesh of Alpha Drives
37
WIPRO
E mail
21.09.2012
Problem identified by Prerana Motors, Mysore. Outer milling operation is missed in this Housing
PTO replaced. An attachement is fitted on Test rig so that Housing that missed outer milling cannot be tested. Casting to be modified so that outer milling can be eliminated.
38
WIPRO
E mail
20.10.2012
Not Rejected
No stock of name plate with printed PTO name. Stores issued empty name plate and assembly missed to punch PTO name
39
WIPRO
E mail
20.10.2012
Not Rejected
This is discussed with Francis. This is due to enough time is not given to him for assembling and packing.
100 % verification to be done by packing person and sampling inspection to be done by quality inspector.
40
G 750 PTO cannot be assembled with P408 pump using M12 x 50 mm stud because the non threaded portion length of the stud is high.
WIPRO
E mail
20.10.2012
Not Rejected
Same stud is used for all WIPRO PTOs for last two years and there is no such problem reported. The problem is only with G750 V2 PTO. Customer might have changed their pump's flange thickness.
Stud design to be modified to meet customer requirement and this modified stud can be used for all other PTOs
41
WIPRO
E mail
03.11.2012
1 no
100 % visual inspection to be carried out in inward inspection. Machining and assembly operators are instructed to separate and identify if defective castings found.
42
WIPRO
E mail
03.11.2012
1 no
This is old design PTO. Design was changed 2 years ago and there is no drills on flange are in our existing design.
43
Instead of 4 nos of M12 nut, only 3 nos are packed and sent to WIPRO in 2 nos G600 MPH
WIPRO
E mail
26.11.2012
Not Rejected
This is packed by new operator and he is not properly trained to do this job.
Packing instruction to be prepared and displayed. Understanding training to be given to ensure the operator is capable of packing . Effectivness to be monitored.
44
Bafna
E mail
02.12.2012
1 no
44
WIPRO
E mail
14.12.2012
10 nos
These PTOs were supplied on Dec 2010 and kept ideal for 2 years before using. The rubber parts are damaged which leads to leakage
45
TAL
E mail
28.12.2012
20 nos
46
WIPRO
E mail
29.12.2012
1 no
47
Schenck
E mail
29.12.2012
1 no
48
WIPRO
30.12.2012
1 no
Need to request a pump from WIPRO. As per this pump we have to make a gauge.
49
MNAL
09.01.2013
1 no
50
TATA
25.01.2013
1 no
Suspected due to non availability of circlip,shaft has continuously pressed bearing while working
51
Abnormal sound coming from Transmission gear box. PTO Name : G600 V2
Hyva
04.02.2013
1 no
This is due to mounitng G600 V2 PTO in GB 750 Gear Box instead of GB 600 Gear Box
52
MNAL
14.02.2013
2 nos
53
Hyva
11.03.2013
1 no
1. Internal spline damage. 2. Internal spline width o/s or u/s. 3. Major dia u/s. 4.Uneven Shrinkage during Heat treatment
54
Drive Gear Damage & Leakage in GBS 40 PA PTO from Dummy side.
WIPRO
26.03.2013
In this PTO the flange is old type i.e without slot. During fitment of the PTO in vehicle Gear box the screw might be pressed the dummy into the bore
NA
55
WIPRO
10.04.2013
30
56
Hyva
22.04.2013
Sliding gear internal spline to be checked after Heat treatment 100 % using a gauge
57
BAFNA
25.072013
Sticking of aluminium particles in M8 tap due to poor circulation or mixture of coolant. Missed to fit the part during assembly
Coolant to be checked periodically 1. PTO to be checked for engagement & disengagement before despatch. Test rig to be made. 2. Assembly instruction to be made.
58
BAFNA
25.072013
59
BAFNA
25.072013
1 This is due to bearing breakage. Damaged bearing is not received. During functioning any metal chips inside PTO might damaged bearing. It is not ZF Alpha PTO. It is ZF 9S 2W with quill shaft. It is not our regular supply to WIPRO, it was given for sample purpose. The quill shaft might not fitted properly in vehicle gear box. The PTO works properly. This is due to O ring damage in piston sub assy
60
Hyva
E mail
03.08.2013
Replacement given.
61
PTO continuously in engaged position even air not supplied in ZF Alpha PTO
WIPRO
E mail
14.08.2013
NA
62
WIPRO
E mail
14.08.2013
63
WIPRO
E mail
14.08.2013
Improper engagement of gear box counter shaft into PTO Drive Gear. After some time the drive gear will damage. Engaging Gear box counter shaft in rotating condtion into PTO Drive Gear
Before engaging the PTO, vehicle driver has to apply clutch fully and wait for 20 seconds to stop the Gear Box counter shaft and try to engage counter shaft into the PTO
64
Key Slipped off from pump shaft into pump shaft bore in Dantal 13 HP Gear box
Dantal
E mail
19.08.2013
65
G 750 V2 PTO damage, Cylinder damage & scratches on PTO body Bearaing coming out & air leakage found in the piston in G 750 MPH (Sl.No.: 38263)
Hyva
E mail
10.10.2013
Due to improper handling the packing damaged and finally parts damaged Rejected PTO checked in Alpha Drives and the PTO is in good condition. No air leakage & no bearing loose & this is communicated to WIPRO Rejected PTO checked in Alpha Drives and the PTO is in good condition. No engagement / disengagement problem & this is communicated to WIPRO
Packing method to be improved by introducing special packing iside the cartoon box
66
WIPRO
E mail
10.10.2013
67
Eaton 6306 A PTO with quill shaft always in engaged postion even air not supplied
WIPRO
E mail
10.10.2013