Cell:-Pulsar (LHS) : Home Work Design Review Manual Theme: - Design For Assembly

HOME WORK DESIGN REVIEW MANUAL Theme :- Design For Assembly Cell :- Pulsar ( LHS ) Category Sr No Stage No Motion
Loss Applicability Y/N 1.1 Preparatory
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
1 2
LH 1 LH 2
LH 3
LH 4
LH 5
Chassis Loading On Conveyor Rear Axle Rear axle Insertion Battery Band Battery MF Battery Fitment Wet Charged 9 AH CDI Hook Harness :LH Harness Clamp Fitment LH Bolt ( M6 ) LH Engine Hanging plate Engine Insertion Bolts (M8*65 & M8*55)
N DJ151032 DJ161247 N N
DJ201125 DH111064 DJ161132 39168004 DJ161081
N N N N N
39245504
Category Sr No Stage No Motion Loss Applicability Y/N 1.1 Preparatory
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
LH 6
Engine bracket bolt insertion
Bolt Rear LH bracket LH center bracket Allen bolt ( M8)
39241304 DJ161114 DJ161115 39241404
N N N N N
7 8
LH 7
Magneto connection Chain
Engine torque LH 8 checking & chain routine Rear wheel LH 9 alignment
N Fixed clamp to be Separate band required to provided on chassis tie up on chassis for holding itself to route magneto magneto cable cable
Magneto cable band
CPV_08_DR_009
Design _ Proto 2 4.3 _ 8b
Fixed clamp
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Upper & lower chain case Bolts ( M 6 ) 10 LH 10 Chain case fitment washer
52DH0309 DH161283
N N
Required to make s/a of bolt Flange bolt provided & washer for chain case instead of separate bolt fitment & washer
CPV_08_DR_011
Design Basic 4.1 _ 4b
Combine
Gear shift lever Rear cover RR Bolt ( M6 ) 11 LH 11 Gear Shifter Lever Metal ring Fitment
DH101397 DJ101211 39167304
N N N Required to make s/a of metal & rubber rings for fitment To provide metal crimp with rubber ring for fitment
Y Rubber ring M 6 Bolt N
CPV_08_DR_013
Combine
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
LH main step LH main step fitment
DJ161130
N Required to make s/a of spring washer with bolt for main step fitment Precoated bolts provided for LH main step fitment
12 LH 12
M8 Bolts
39231004
CPV_08_DR_014
Pre coated
Spring washer Handle bar fitment Fork Bracket 14 LH 14 Center Bolt Tightening 13 LH 13 Handle bar Center Fork bolts Washer Allen bolts ( M8) Fork cap rubber grommet AC Box clip Carburettor 16 LH 16 Carburettor fitment A C Box clip tightening Accelerator Connection Earthing cable grommet A C Box clip Accelerator Connection 52DH0169
N N N N DG181008 DJ181009 DH121142 DJ101232 N N N N N N N
15 LH 15
LH mud guard fitment
17 LH 17 18 LH 18
19 LH 19
20 LH 20
21 LH 21
22 LH 22
LH side LH Harness harness Connection terminal connection LH side LH seat cowl decal decal pesting PT drain pipe clip Battery Connection LH bellow LH Bellow insertion insertion Case meter connection
DH161310 DH141002
N N N N N
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Petrol Tank Bolt 23 LH 23 Petrol Tank fitment Washer
DJ710122 39155604
N N Required to make s/a of PT bolt with washer Bolt with integrated washer provided Design Basic 4.1 _ 4b
39074011
CPV_08_DR_024
Combine
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
24 LH 24
Grab Handle fitment
Grab handle Bolt Side panel Side lock grommet
DJ161263 52DK5506 33161018
N N N N More preparatory time required for removing nut from panel lock for s/a Thread length to be reduced for reducing panel lock nut tightening time.
25 LH 25
LH side panel fitment
Side panel lock Frame Sub Assly K2 ES UG3
CPV_08_DR_025
Desired thread length
52DJ0182
26 LH 26
Bearing Chassis Number Race Upper Punching Bearing Race lower Barcode sticker PV card
52DH0248 52DH0248 75261601 75118821
N N N N
HOME WORK DESIGN REVIEW MANUAL Theme :- Design For Assembly Cell :- Pulsar ( RHS ) Category Motion Loss Applicability Y/N 1.1 Preparatory
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 1
Rear Wheel Loading
Rear Wheel Rear wheel spacer Rear brake panel
DJ151090 DJ151034 DH151060
N N N Bearing ball is to place on fixture for collecting with the help of tool for fitment on bearing races
RH 2
Rear wheel spacer insertion
Bearing ball
Ball cage provided instead of loose balls
CPV_08_DR_027
Single piece
Grease Fork Bearing Cone Cup Steering Fork Nut Metal & rubber ring Mud guard Brace fender Allen bolts ( M6) Painted set loading 52DH0278 DH161258 DG181008 52DJ0130 DH181025 DH181014
N N N Y
RH 3 Fork fitment stage
a a a
30181018
Y Y N N N N
First to place stearing cup on Lock nut welded with bearing cone & then stearing cup tightening fork with lock nut Required to make s/a of metal & rubber ring for fitment Metal ring with rubber coating
CPV_08_DR_028
Combine
CPV_08_DR_013
Combine
RH 4
Mud guard fitment stage
Category Motion Loss Applicability Y/N 1.1 Preparatory
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 5
Front Number Plate Fitment
Front number plate Bolt Plain washer Spacer Magnet ( Self cancellation ) Front axle with grease application Front wheel Case meter Spacer
52DH0317
N Y Y Y
a a a
Required to make s/a of bolt , washer & spacer
Single piece
CPV_08_DR_029
Combine
DH121130
DJ151041
N DH151062 DS151058 N N Split pin required to fit on front axle Lock nut introduced instead of simple nut Design Basic 4.1 _ 4b
RH 6
Front wheel fitment
Front axle lock nut Front axle washer RH front bracket RH rear bracket Hanging plate nuts ( M8)
59150003
CPV_08_DR_031
Combine
39078111 DH161190 DJ161271 59150005
N N N N
RH 7
Engine bracket fitment stage
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 8
Engine fitment stage Center bracket bolt ( M12 ) Hanging plate nuts ( M8 ) Rear axle nut Fairing Assembly Bolt with locktite application 39245504
RH 9
Center bracket tightening stage
59150005 DH171019
N N N Locktite to apply on bolt before fitment Pre locktite bolt introduced for brake kit fitment Design Basic 4.1 _ 4b
10 RH 10
Fairing Fitment Stage Front brake kit routine stage
11 RH 11
59150003 DH161245 59150005 52DJ0226 39258204
Y N N N N
CPV_08_DR_033
Pre coated
12 RH 12
Lock nuts Engine tightening stage Simple nuts Front wheel tightening stage RH step holder M13 bolts
13 RH 13
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Rod end M8 main step bolt Spring washer 14 RH 14 Brake connection stage Main step RH Adjuster nut Spring Plain washer Brake padel 15 RH 15 Brake padel fitment stage Flange bolt (M12) Torque rod bolt Spring washer - T Rod
15191026 39231004
N N Pre coated bolt to be introduced for main step fitment
Required to make s/a of spring washer with bolt
CPV_08_DR_034
Pre coated
DJ161131 DH191045 30191035 39019811 DH191001 39176904 30151096
N N N N N N N
39078912
Spring washer required to place on bolt before nut tightening
Flange lock nut to be introduced
CPV_08_DR_036
Combine
16 RH 16
Rear wheel tightening stage
Center axle nut (M22) Torque rod nut (M14)
DH171019 39079415
N N
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Starter motor grommet
17 RH 17
Starter motor connection stage Spring washer
Starter motor on engine from engine assembly with spring washer & nut - During connection spring washer & nut has to take out then after keeping terminal connection to be done with placing spring washer & nut
Instead of spring washer , surreted nut in loose condition directly at final assembly stage
CPV_08_DR_037
Combine
Nut 18 RH 18 19 RH 19 Front brake kit tightening stage Upper lever tightening DK7303ZZ
N N N N N N
Seat cowl fitment Seat cowl stage RH Harness 20 RH 20 connection stage RH Harness 21 RH 21 connection stage RH Harness 22 RH 22 connection stage
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Silencer Plain big washer Small washer Lock nuts (M17) Flange bolts Flange nuts Gasket 24 RH 24 Silencer tightening Snap pin stage Flange bolts (M6) Seat cowl tightening stage
DJ101259
N Big plain washer has to place Press fit bush with at rear mounting washer introduced Design Basic 4.1 _ 4b
39242511
CPV_08_DR_038
Combine
23 RH 23
Silencer fitment stage
39024811 DD161071 39185004 59150005 DJ101064 DH151055 39194304
N N N N N N N
25 RH 25
Washers
39178924
Required to make s/a of plastic washer with tightening bolt
Bolt with press fitment plastic washer
CPV_08_DR_040
Combine
26 RH 26
Carburettor clip tightening stage
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
27 RH 27
Clutch connection stage Side panel RH side seat cowl decal
N N N N N N
28 RH 28
Side lock grommet Side panel lock Battery 29 RH 29 Vehicle inspection terminal removal
Side panel sub assembly stage
HOME WORK DESIGN REVIEW MANUAL Theme :- Design For Assembly Cell :- Pulsar ( LHS ) Category 1.1 Preparatory 1.2. Difficult To Assemble 1.3. Difficult To Access Sr No Stage No Motion Loss Applicability Y/N 1.4. Difficult To Identify
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
LH 1
Chassis Loading On Conveyor
N Provide entry chamfer of 1.5 X 45 degree at start of threading portion & 2 X 30 degree at the end of threading portion. Band locking design change from rod type to hook type Entry chamfer of 1.5 X 45 degree at start of threading portion & 2 X 30 degree at the end of threading portion.
LH 2
Rear Axle Insertion
Rear axle
DJ151032
Hard to insert rear axle.
CPV_08_DR_001
Battery Band
DJ161247
Battery band is difficult to insert in chassis bracket ( Rod design )
CPV_08_DR_002
Design _ Proto 1 4.2 _ 8a
Clip type design
LH 3
Battery Fitment
Battery MF Wet Charged 9 AH
DJ201125
CDI Hook Harness :LH
DH111064
N Difficult to identify the correct position harness clamp on chassis Stopper / line mark / embossing on chassis for reference for exact position of hook on chassis
LH 4
LH Harness Clamp Fitment
DJ161132
CPV_08_DR_003
Line mark for reference
LH 5
Bolt ( M6 ) LH Engine Hanging plate Engine Insertion Bolts (M8*65 & M8*55)
39168004 DJ161081
N N
39245504
Category 1.1 Preparatory 1.2. Difficult To Assemble 1.3. Difficult To Access Sr No Stage No Motion Loss Applicability Y/N 1.4. Difficult To Identify
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Bolt
39241304
N Bold embossing with colour filling to be provided on bracket for clear identification
Rear LH bracket Engine bracket bolt insertion LH center bracket
DJ161114
Difficult to identify correct bracket for fitment
CPV_08_DR_004
Bold embossing with colour filled
LH 6
DJ161115
Bold embossing with colour filling to be provided on bracket for clear identification
CPV_08_DR_005
Allen bolt ( M8)
39241404
a
7 LH 7 Magneto connection Y
Difficult to access coupler for magneto connection
Harness length increase for easy access
CPV_08_DR_006
Pre Pilot Production 5_5
50mm more length for every coupler connection.
Bullet type connection Difficult to assemble neutral to be change to coupler coupler due to bullet type type
CPV_08_DR_007
Coupler type design
Engine torque LH 8 checking & chain routine
Chain
Yellow color strip with Difficult to identify correct clear identificaion direction chain while routine provided on chain for clear identification
CPV_08_DR_008
Identification for direction
LH 9
Rear wheel alignment
Magneto cable band
Fixed clamp to be Separate band required to provided on chassis tie up on chassis for holding itself to route magneto magneto cable cable
CPV_08_DR_009
Fixed clamp
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Upper & lower chain case Chain case fitment
52DH0309
Difficult to assemble upper & lower chain case on vehicle due to touching of chain case to swing arm welding gusset.
Relieve provided on upper & lower chain case to avoid touching of chain case to swing arm at welding gusset for easy matching
CPV_08_DR_010
Relieve to avoid fouling
10 LH 10
Bolts ( M 6 )
DH161283
washer
Required to make s/a of bolt Flange bolt provided & washer for chain case instead of separate bolt fitment & washer
CPV_08_DR_011
Combine
Gear shift lever
DH101397
GSL mouting boss to be Difficult to maintain correct modified , instead of position of GSL during surretion it should be fitment square or hexagonal type.
CPV_08_DR_012
Square / Hexagonal design instead of serretion
Rear cover Gear Shifter Lever RR 11 LH 11 Fitment Bolt ( M6 ) Metal ring
DJ101211 39167304
N N Required to make s/a of metal & rubber rings for fitment To provide metal crimp with rubber ring for fitment
Y Rubber ring M 6 Bolt N
CPV_08_DR_013
Combine
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
LH main step LH main step fitment
DJ161130
N Required to make s/a of spring washer with bolt for main step fitment Precoated bolts provided for LH main step fitment
12 LH 12
M8 Bolts
39231004
CPV_08_DR_014
Pre coated
Spring washer Handle bar fitment Fork Bracket 14 LH 14 Center Bolt Tightening 13 LH 13 Handle bar Center Fork bolts Washer 52DH0169
N N N N Mud guard brace fender bolt Mud guard with brace tightening is not easy due to fender mounting mounting from in side provided from out side
Allen bolts ( M8)
DG181008
CPV_08_DR_015
Clamping from out side
15 LH 15
Fork cap rubber grommet
DJ181009
Instead of allen bolt , Hammer & special tool hexagonal bolt to be required for pressing rubber provided to cover cavity cap on fork of fork bracket
CPV_08_DR_016
Combine
AC Box clip
DH121142
Difficult to assemble carburettor clip on carburettor bellow
AC Box clip diameter increased from 50 mm to 52 mm
CPV_08_DR_017
Sufficient clearance
Carburettor 16 LH 16 Carburettor fitment Earthing cable grommet
DJ101232
Difficult to identify correct carburettor for fitment as per model
Model identification sticker pested on carburettor for easier identification
CPV_08_DR_018
Identification
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
17 LH 17
A C Box clip tightening
A C Box clip
Difficult to access carburettor clip due to clip tightening screw head located behind chassis pipe
Provide access for tightening.
CPV_08_DR_019
Sufficient access
18 LH 18
Accelerator Connection
Accelerator Connection LH side harness terminal connection
19 LH 19
LH Harness Connection
Difficult to access LH harness coupler for connection
Harness length increased by 50mm for easy access of harness coupler for connection
CPV_08_DR_020
LH side LH seat cowl decal decal 20 LH 20 pesting PT drain pipe clip 21 LH 21 Battery Connection LH bellow insertion 22 LH 22 LH Bellow insertion Case meter connection
DH161310
Difficult to take out decal rapper for pesting on seat cowl
Cut section provided on decal for easy removal
CPV_08_DR_021
Projection for easy removal
DH141002
N N Hard to insert bellow inside fairing cavity Fairing cavity to be increased Design Basic 4.1 _ 4b
CPV_08_DR_022
Enough space
Hard to insert case meter cable upper grommet in number plate bracket
Number plate bracket should be modified like Discover brake kit
CPV_08_DR_023
Wire type bracket
Petrol Tank Bolt 23 LH 23 Petrol Tank fitment Washer
DJ710122 39155604
N N Required to make s/a of PT bolt with washer Bolt with integrated washer provided Design Basic 4.1 _ 4b
39074011
CPV_08_DR_024
Combine
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
24 LH 24
Grab Handle fitment
Grab handle Bolt Side panel Side lock grommet
DJ161263 52DK5506 33161018
N N N N More preparatory time required for removing nut from panel lock for s/a Thread length to be reduced for reducing panel lock nut tightening time.
25 LH 25
Side panel lock
CPV_08_DR_025
Frame Sub Assly K2 ES UG3 Chassis Number Bearing Punching Race Upper Bearing Race lower Barcode sticker PV card
52DJ0182
Difficult to insert tackle hook in chassis for lifting Tackle modified No space between A C Box & Chassis frame.
CPV_08_DR_026
Access for tackle
26 LH 26
52DH0248 52DH0248 75261601 75118821
N N N N
HOME WORK DESIGN REVIEW MANUAL Theme :- Design For Assembly Cell :- Pulsar ( RHS ) Category 1.2. Difficult To Assemble 1.3. Difficult To Access Motion Loss Applicability Y/N 1.4. Difficult To Identify 1.1 Preparatory
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 1
Rear Wheel Loading
Rear Wheel Rear wheel spacer Rear brake panel
DJ151090 DJ151034 DH151060
N N N Bearing ball is to place on fixture for collecting with the help of tool for fitment on bearing races
RH 2
Bearing ball
Ball cage provided instead of loose balls
CPV_08_DR_027
Single piece
Grease Fork Bearing Cone Cup Steering Fork Nut Metal & rubber ring Mud guard Brace fender Allen bolts ( M6) Painted set loading 52DH0278 52DJ0130 DH181025 DH181014
N N N Y
RH 3 Fork fitment stage
a a a
30181018
Y Y N
First to place stearing cup on Lock nut welded with bearing cone & then stearing cup tightening fork with lock nut Required to make s/a of metal & rubber ring for fitment Metal ring with rubber coating
CPV_08_DR_028
Combine
CPV_08_DR_013
Combine
RH 4
DH161258
Mud guard brace fender bolt tightening is not easy due to mounting from in side
Mud guard with brace fender mounting provided from out side
CPV_08_DR_015
DG181008
N N
Category 1.2. Difficult To Assemble 1.3. Difficult To Access Motion Loss Applicability Y/N 1.4. Difficult To Identify 1.1 Preparatory
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 5
Front Number Plate Fitment
Front number plate Bolt Plain washer Spacer Magnet ( Self cancellation ) Front axle with grease application Front wheel
52DH0317
N Y Y Y
a a a
Required to make s/a of bolt , washer & spacer
Single piece
CPV_08_DR_029
Combine
DH121130
DJ151041
N Difficult to assemble case meter in front due to clip bending Strengthening required to improve for the clip to avoid bending
Case meter Front wheel fitment
DH151062
CPV_08_DR_030
Strong design
RH 6
Spacer Front axle lock nut Front axle washer
DS151058
N Split pin required to fit on front axle Lock nut introduced instead of simple nut Design Basic 4.1 _ 4b
59150003
CPV_08_DR_031
Combine
39078111
N Bold embossing with colour filling to be provided on bracket for clear identification
RH front bracket
DH161190
CPV_08_DR_004
RH 7
RH rear bracket
DJ161271
Bold embossing with colour filling to be provided on bracket for clear identification
CPV_08_DR_005
Hanging plate nuts ( M8)
59150005
Difficult to identify correct nut for fitment
Passivation of nut be change for clear identification
CPV_08_DR_032
Identification
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 8
Engine fitment stage Center bracket bolt ( M12 ) Hanging plate nuts ( M8 ) Rear axle nut Fairing Assembly Bolt with locktite application 39245504
RH 9
59150005 DH171019
N N N Locktite to apply on bolt before fitment Pre locktite bolt introduced for brake kit fitment Design Basic 4.1 _ 4b
10 RH 10
11 RH 11
59150003
CPV_08_DR_033
Pre coated
Lock nuts 12 RH 12 Engine tightening stage Simple nuts
DH161245
Difficult to identify correct nut for fitment ( Lock nut & simple nut )
Passivation of simple nut & lock nut to be change
CPV_08_DR_032
Identification
59150005
Difficult to identify correct nut for fitment ( Lock nut & simple nut )
Passivation of simple nut & lock nut to be change
CPV_08_DR_032
Identification
13 RH 13
Front wheel tightening stage
RH step holder M13 bolts
52DJ0226 39258204
N N
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Rod end M8 main step bolt Spring washer 14 RH 14 Brake connection stage Main step RH Adjuster nut Spring Plain washer
15191026 39231004
N N Pre coated bolt to be introduced for main step fitment
Required to make s/a of spring washer with bolt
CPV_08_DR_034
Pre coated
DJ161131 DH191045 30191035 39019811
N N N Y
a
Difficult to identify correct position of brake padel on vehicle Brake padel mouting boss to be modified , instead of surretion it should be square or hexagonal type. Square / Hexagonal design instead of serretion
Brake padel 15 RH 15 Brake padel fitment stage Flange bolt (M12) Torque rod bolt Spring washer - T Rod
DH191001
CPV_08_DR_035
39176904 30151096
N N
39078912
Spring washer required to place on bolt before nut tightening
Flange lock nut to be introduced
CPV_08_DR_036
Combine
16 RH 16
Rear wheel tightening stage
Center axle nut (M22) Torque rod nut (M14)
DH171019 39079415
N N
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Starter motor grommet
17 RH 17
Starter motor connection stage Spring washer
Starter motor on engine from engine assembly with spring washer & nut - During connection spring washer & nut has to take out then after keeping terminal connection to be done with placing spring washer & nut
Instead of spring washer , surreted nut in loose condition directly at final assembly stage
CPV_08_DR_037
Combine
Nut 18 RH 18 19 RH 19 Front brake kit tightening stage Upper lever tightening DK7303ZZ
N N N Harness length increased by 50mm for easy access of harness coupler for connection Harness length increased by 50mm for easy access of harness coupler for connection Harness length increased by 50mm for easy access of harness coupler for connection
Seat cowl fitment Seat cowl stage
20 RH 20
RH Harness connection stage
Difficult to access required coupler on harness for connection
CPV_08_DR_020
RH Harness 21 RH 21 connection stage
CPV_08_DR_020
RH Harness 22 RH 22 connection stage
CPV_08_DR_020
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Silencer Plain big washer Small washer Lock nuts (M17) Flange bolts Flange nuts Gasket
DJ101259
N Big plain washer has to place Press fit bush with at rear mounting washer introduced Design Basic 4.1 _ 4b
39242511
CPV_08_DR_038
Combine
23 RH 23
39024811 DD161071 39185004 59150005 DJ101064
N N N N N Bend provided on snap pin round area Difficult to insert snap pin on for getting grip to troque rod bolt hole due to thump fingure to sharp bending apply force for insertion on torque rod bolt hole
24 RH 24
Silencer tightening Snap pin stage
DH151055
CPV_08_DR_039
Bend for thumb support
Flange bolts (M6) 25 RH 25 Seat cowl tightening stage
39194304
Washers
39178924
Required to make s/a of plastic washer with tightening bolt
Bolt with press fitment plastic washer
CPV_08_DR_040
Combine
26 RH 26
Carburettor clip tightening stage
Difficult to access clip tightening mounting head due to chassis tube
Provide access for tightening for tightening.
CPV_08_DR_041
Sufficient access
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
27 RH 27
Clutch connection stage Side panel RH side seat cowl decal Side panel sub assembly stage Side lock grommet
N N N N Thread length to be reduced for reducing panel lock nut tightening time.
28 RH 28
Side panel lock
More preparatory time required for removing nut from panel lock for s/a
CPV_08_DR_025
Battery 29 RH 29 Vehicle inspection terminal removal
Difficult to remove battery negative terminal
Negative terminal taken to front side of battery
CPV_08_DR_043
Easy access
HOME WORK DESIGN REVIEW MANUAL Theme :- Defect Loss Cell :- Pulsar ( LHS ) CATEGORY Reverse Missing Loose Not tightened fully Wrong part assembly Mis orientation Not matching Adjustment not good PDI / EFR
Sr No
Stage No
Stage Description
Part Name
Part Number
Defect Loss Applicability Y/N
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
2.2 Missing
Possibility of rear wheel rubber damper missing Possibility of wrong part assembly of sprocket assembly ( K1 & K2 ) Pulsar rear axle can be interchange with JC or JM rear axle
Rubber damper in single piece
CPV_08_DR_044
LH 2
Chassis Loading On Conveyor
Sprocket Assembly Y
2.5 Wrong part assembly
Sprocket passivation to be change for sprocket ( CPV_08_DR_045 Blue for K1 & Golder for K2 ) Passivation to be different for Pulsar & JC rear axle CPV_08_DR_046
LH 3
Rear Axle Insertion
Rear axle
DJ151032
2.5 Wrong Part assembly
Battery Band Battery MF Wet Charged 9 AH
DJ161247
DJ201125
LH 4
Battery Fitment
CDI
DH111064
Possibility of CDI mis match ( K1 & K2 )
Body colour to be change for K1 & K2 CDI CPV_08_DR_047 for identification
CATEGORY Reverse Missing Loose Not tightened fully Wrong part assembly Mis orientation Not matching Adjustment not good PDI / EFR
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
LH 5
Hook Harness :LH Bolt ( M6 ) LH Engine Hanging plate Bolts (M8*65 & M8*55) Bolt Rear LH Bracket
DJ161132 39168004 DJ161081
N N Y
Possibility of LH side hook fitted on RH side & vice a versa
Common design for LH CPV_08_DR_048 & RH side harness hook
Possibility of wrong hanging plate fitment
LH 6
Engine Insertion
Bold embossing with colour fill to be change for hanging plates
CPV_08_DR_004
39245504 39241304 DJ161114
N N Y
Possibility of wrong bracket fitment
Bold embossing with colour fill to be change for hanging plates Bold embossing with colour fill to be change for hanging plates
CPV_08_DR_005
LH 7
LH Center Bracket Allen bolt ( M8 )
DJ161115
Possibility of wrong bracket fitment
CPV_08_DR_006
39241404
N Y
2.5 Loose
LH 8
Magneto Connection
Possibility of loose connection of magneto due to bullet type terminal. Possibility of reverse direction of chain.
Coupler type terminal introduced.
CPV_08_DR_049
LH 9
Engine Torque Checking
Chain Routine
2.1 Reverse
Yellow colour clip added on chain link for CPV_08_DR_008 knowing correct direction chain.
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Y 10 LH 10 Rear Wheel Alignment Magneto cable band Y
2.3 Loose
Possibility of loosening of Fixed clamp to be on magneto cable due to chassis itself to hold cable holding with band magneto cable firmly Possibility of chain adjuster marking adjustment not done correctly Marking provided on both side of chain adjuster for easy and correct adjustment.
CPV_08_DR_009
2.8 Adjustment Not Good
CPV_08_DR_051
11
LH 11
Chain case fitment
Upper and Lower Chain case Bolts (M10) Washer
52DH0309
2.7 Not Matching
Relieve provided on upper & lower chain Possibility of upper & case to avoid touching lower chain case not of chain case to swing matching with each other arm at welding gusset for complete matching Possibility of washer missing Possibility of wrong positioning of gear shift lever
CPV_08_DR_052
DH161283
N Y
2.2 Missing
Gear Shift Lever
DH101397
2.6 Mis orientation
Flange bolt instead of CPV_08_DR_011 washer. GSL mouting boss to be modified , instead of surretion it should be CPV_08_DR_053 square or hexagonal type for correct position.
Rear Cover (RR cover) Bolt ( M 6 ) 12 LH 12 Gear Shifter Lever Fitment Metal Ring
DJ101211 39167304
N N Y N Y
2.2 Missing 2.2 Missing
Possibility of metal ring missing.
To provide metal crimp with rubber ring for fitment
CPV_08_DR_013
Rubber Ring N M6 Bolt N
Possibility of rubber ring missing.
To provide metal crimp with rubber ring for fitment
CPV_08_DR_013
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
LH Main Step Fitment 13 LH 13 LH main step fitment M8 Bolts Spring washer 14 15 Handle bar fitment Fork Bracket LH 15 Center Bolt Tightening LH 14 Handle bar Center Fork bolts Washer Allen Bolts (M8) 16 LH 16 LH Mud guard fitment Fork cap Rubber Grommet AC Box Clip Carburettor 17 LH 17 Carburettor Fitment Earthing Cable Gromet
DJ161130 39231004
N N Y
2.2 Missing
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Possibility of spring washer missing
Precoated bolts
CPV_08_DR_014
52DH0169
N N N
DG181008
2.2 Missing
Possibility of brace fender Bolt mounting from out CPV_08_DR_015 mud guard bolt missing side for clear visibility Possibility of fork cap rubber grommet not pressed fully Possibility of wrong carburettor fitment Instead of allen bolt , hexagonal bolt to be CPV_08_DR_016 provided to cover cavity Model identification sticker on carburettor cap
Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b
DJ181009 DH121142 DJ101232
Y N Y
2.4 Not tightened fully
CPV_08_DR_018
N N
18 19
A C Box Clip Tightening Accelerator LH 19 Connection LH 18 LH 20 LH Harness Connection Battery Connection
20
Accelerator Connection LH side harness terminal connection
N Possibility of loose connection of harness due to incomplete pressing of bullet Coupler type connector provided instead of bullet type connector Design Basic 4.1 _ 4b
2.3 Loose
CPV_08_DR_054
21
LH 21
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
22
LH 22
LH Seat Cowl Decal Pesting
LH Side Decal Petrol Tank Drain Pipe Clip LH bellow insertion Case meter connection Petrol Tank Bolt Washer Grab Handle Bolt Side Panel RH Side Seat Cowl Decal Side Lock Grommet Side panel lock Frame Sub Assly K2 ES UG3 Side stand switch
DH161310 DH141002
N N N Possibility of incomplete insertion of case meter cable upper grommet in number plate bracket Number plate bracket should be modified like Discover brake kit Design Basic 4.1 _ 4b
23
LH 23
LH Bellow Insertion
Y DJ710122 39155604 39074011 DJ161263 N N Y N N 52DK5506 Y N 33161018 N Y
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
2.3 Loose
CPV_08_DR_055
24
LH 24
Petrol Tank Fitment Grab Handle Fitment
2.2 Missing
Possibility of PT washer missing
Bolt with integrated washer
CPV_08_DR_024
25
LH 25
2.3 Loose
26
LH 26
LH Side Panel Fitment
2.3 Loose
Possibility of side panel getting loose due to bracket bend
Provided strengthened bracket for side panel locking.
CPV_08_DR_056
52DJ0182
N Side stand switch mechanism not working due to mud accumulation on actuating button Side stand switch mechanism change CPV_08_DR_057 from mechanical type to electromagnetic type
2.9 PDI / EFR
LH 1
Chassis Number Punching Bearing Race Upper Bearing Race lower Barcode sticker PV card
52DH0248 52DH0248 75261601 75118821
N N N N
DR Point For Review
Combine
Identification
Identification
Identification
DR Point For Review
Commonisation
Coupler type design
Identification for direction
DR Point For Review
Fixed clamp
Both side identification
Relieve to avoid fouling
Combine
Combine
Combine
DR Point For Review
Pre coated
Combine
Identification
Coupler type design
DR Point For Review
Wire type design
Combine
Strong design
Non contact design
HOME WORK DESIGN REVIEW MANUAL Theme :- Defect Loss Cell :- Pulsar ( RHS ) CATEGORY Reverse Missing Loose Not tightened fully Wrong part assembly Mis orientation Not matching Adjustment not good PDI / EFR
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 1
Rear Wheel Loading
Rear Wheel
DJ151090 DJ151034 DH151060
N N N Y
2.2 Missing
Rear Wheel Spacer Rear Brake Rear wheel spacer RH 2 Panel insertion Bearing ball Grease Fork Bearing Cone Cup Steering Fork Nut
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Possibility of bearing ball missing
Ball cage instead of loose balls
CPV_08_DR_027
Single piece
52DJ0130 DH181025 DH181014 30181018
N N N N N Y 2.2 Missing Possibility of metal ring missing. Possibility of rubber ring missing. Rubber ring coating on metal ring. Metal ring with rubber coating. CPV_08_DR_013 Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Combine
RH 3 Fork fitment stage Metal ring
Rubber ring
2.2 Missing
CPV_08_DR_013
Combine
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Mud guard Brace fender 4 RH 4 Mud guard fitment stage Allen Bolts (M6) Painted set loading Front Number plate Bolt Plain washer Spacer Magnet (Self canceling indicator) Front Axle ( With grease application ) Case Meter Spacer Front Axle Nut Front Axle Washer Split pin
52DH0278 DH161258 DG181008
N N Y N 2.2 Missing Possibility of mud guard bolt missing due to mounting from inside Mud guard mounting from out side CPV_08_DR_015 Design Basic 4.1 _ 4b Mounting from out side
52DH0317
N N Y Y
2.2 Missing
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Possibility of number plate plain washer missing Possibility of number plate spacer missing Single piece CPV_08_DR_029
RH 5
Front Number Plate fitment
2.2 Missing
Combine
DH121130
DJ151041 DH151062 DS151058 59150003 39078111
N N N N N Y
2.2 Missing
RH 6
Front wheel fitment
Possibility of front axle split pin missing
Lock nut instead of castle nut & split pin
CPV_08_DR_031
Combine
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
RH 7
Engine Fitment Stage
Engine RH Front bracket
DJ101231 DH161190
N Y
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Possibility of wrong bracket fitment due to identification Possibility of wrong bracket fitment due to identification Possibility of wrong bracket fitment due to identification
RH 8
Engine Bracket Fitment Stage
RH Rear bracket Hanging plate Nuts (M8) Center Bracket Bolt ( M12 )
DJ161271
59150005
Bold embossing with colour filling to be provided on CPV_08_DR_004 bracket for clear identification Bold embossing with colour filling to be provided on CPV_08_DR_005 bracket for clear Different passivation to be provided to the nuts for CPV_08_DR_032 clear identification
Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b
Bold embossing with colour filled Bold embossing with colour filled Identification
39245504
Center Bracket RH 9 Tightening Stage
Plastic washer Hanging Plate Nuts ( M8) Rear Axle Nut Fairing Assembly Bolt ( with loctite application ) 59150005 DH171019
N N N Possibility of loctite application missing on bolt Design Basic 4.1 _ 4b
10
RH 10
Fairing Fitment Stage Front Brake Kit Routing Stage
11
RH 11
59150003
2.2 Missing
Pre loctite bolt
CPV_08_DR_033
Pre coated
Lock Nuts 12 RH 12 Engine Tightening Stage Simple Nuts
DH161245
Passivation of nut to be Possibility of wrong nut change for simple & lock fitment due to identification nuts.
CPV_08_DR_032
Identification
59150005
Passivation of nut to be Possibility of wrong nut change for simple & lock fitment due to identification nuts.
CPV_08_DR_032
Identification
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
13
RH 13
Front Wheel Tightening Stage
RH Step Holder M13 Bolts Rod End M8 Main Step Bolt Spring washer
52DJ0226 39258204 15191026 39231004
N N N N Y
2.2 Missing
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
14
RH 14
Brake Connection Main Step Stage RH Adjuster Nut Spring Plain Washer Brake pedal
Possibility of spring washer missing during main step fitment
Pre coated bolt to be introduced
CPV_08_DR_034
Pre coated
DJ161131 DH191045 30191035 39019811 DH191001 39176904 30151096 39078912 DH171019 39079415
N N N N Y N N Y N N
2.2 Missing
2.6 Mis orientation
15
RH 15
Brake Pedal Fitment Stage
Possibility of brake padel orientation wrong wrt main step
16
RH 16
Rear Wheel Tightening Stage
Flange bolts (M 12) Torque Rod Bolt Spring Washer - T Rod Center Axle Nut (M 22) Torque Rod Nut (M 14)
Brake padel mouting boss to be modified , instead of CPV_08_DR_035 surretion it should be square or hexagonal type.
Possibility of spring washer missing during torque rod bolt fitment
Flange lock nut to be provided instead of spring washer
CPV_08_DR_036
Combine
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
17
RH 17
Starter Motor Connection Stage
Starter Motor Gromet Star Washer
N Y N N DK7303ZZ N Y
2.3 Loose 2.2 Missing
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Possibility of star washer missing
Instead of star washer , surreted nut to be
CPV_08_DR_037
Combine
18 19
Nut Front Brake Kit Upper lever RH 18 tightening Stage tightening Seat Cowl Fitment Seat Cowl RH 19 Stage insertion
Possibility of harness wire connection loose Possibility of blinker bullet connection not pressed fully
Harness length increase by 50mm with introduction of coupler type connection
CPV_08_DR_020
Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b
50mm more length for every coupler connection. Coupler type design
20
RH Harness RH 20 Connection Stage
Coupler type connection introduced instead of bullet CPV_08_DR_020 type.
Possibility of wrong harness Common harness introduce. CPV_08_DR_020 fitment on chassis Possibility of harness wire connection loose Possibility of blinker bullet connection not pressed fully Harness length increase by 50mm with introduction of coupler type connection CPV_08_DR_020
Commonisation 50mm more length for every coupler connection. Coupler type design
Y RH Harness RH 21 Connection Stage
2.3 Loose
21
Possibility of wrong harness Common harness introduce. CPV_08_DR_020 fitment on chassis Harness length increase by 50mm with introduction of coupler type connection instead of bullet type.
Commonisation
Y RH Harness Connection Stage
2.3 Loose
Possibility of harness wire connection loose
CPV_08_DR_020
22
RH 22
Possibility of blinker bullet connection not pressed fully
Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b
Coupler type design
Possibility of wrong harness Common harness introduce. CPV_08_DR_020 fitment on chassis
Commonisation
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
Silencer Plain Big washers Small washers Lock Nuts (M 17) Flange Bolts (M 14) Flange Nuts (M 12) Gasket Snap Pin Flange Bolts (M 6) Washers
DJ101259 39242511 39024811 DD161071 39185004 59150005 DJ101064 DH151055 39194304 39178924
N Y N N N N N Y N Y
2.2 Missing 2.4 Not tightened fully 2.2 Missing
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Possibility of plain washer missing
Press fit bush with washer
CPV_08_DR_038
Combine
23
RH 23
Silencer Fitment Stage
24
RH 24
Silencer Tightening Stage
Possibility of incomplete insertion of snap pin on torque rod bolt due to
Bend provided on snap pin for better contact area on thumb for insertion
CPV_08_DR_039
Pre Pilot Production Bend for thumb support 5_5
25
Seat Cowl RH 25 Tightening Stage
Possibility of plastic washer missing
Bolt with press fit plastic washer
CPV_08_DR_040
Design Basic 4.1 _ 4b Design Basic 4.1 _ 4b
Combine
26
RH 26
Carburetor Clip Tightening Stage
Possibility of carburettor clip Provide access for tightening not tightened fully due to no CPV_08_DR_041 for tightening. access
Sufficient access
Sr No
Stage No
Stage Description
Part Name
Part Number
Activity / Problem
Idea
Kaizen ID No
NPDS Stage
DR Point For Review
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
27
Clutch RH 27 Connection Stage
Possibility of incomplate insertion of clutch cable grommet on cable
Clutch bracket design change for easy insertion of grommet
CPV_08_DR_042
Strong Design
Side Panel RH Side Seat Cowl Decal Side Lock Grommet Side panel lock
DK730822
2.3 Loose
Possibility of side panel lock coming out of chassis bracket
Provided strengthened bracket for side panel locking.
CPV_08_DR_053
Strong Design
28
RH 28
Side Panel Sub Assembly Stage
DH161013 31161018
N N N
HOME WORK DESIGN REVIEW MANUAL Theme :- Cost Reduction Cell :- Pulsar ( LHS ) Category
3.2. Length Reduction
Stage Description
Part Name
Part Number
3.3. Element Deletion
3.1. Material Change
LH 1
2 3
LH 2 LH 3
Frame Sub Assly K2 ES UG3 Side stand switch Chassis Number Bearing Race Upper Punching Bearing Race lower Barcode sticker PV card Chassis Loading Sprocket On Conveyor Assembly Rear Axle Rear axle Insertion Battery Band
52DJ0182
52DH0248 52DH0248 75261601 75118821
DJ151032 DJ161247 Foam required for resting battery on metallic surface from back side AC Box design change for resting battery on AC Box itself AC Box design for accomodating battery.
3.4 Yeild
Sr No
Stage No
Cost Loss Applicability Y/N
Activity / Problem
Idea
Cost saved by ( Rs )
Status
DR Point For Review
Battery foam 4 LH 4 Battery Fitment Battery MF Wet Charged 9 AH CDI DJ201125
Rs / Veh
Impl
AC Box design Separate bracket change for required for battery accomodating fitment battery on AC Box itself
Rs / Veh
Impl
AC Box design for accomodating battery.
DH111064
Category
Stage Description
Part Name
Part Number
LH 5
Hook Harness :- LH Bolt ( M6 ) LH Engine Hanging plate Bolts (M8*65 & M8*55) Bolt Rear LH bracket LH center bracket Allen bolt ( M 8)
DJ161132 Cost involved by using M6 bolt Bolt can be replaced with smalle size Provide harness hook tightening bolt with size
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
39168004
Rs.. / Veh
Plan
DJ161081 39245504 39241304 DJ161114 DJ161115 39241404
LH 6
Engine Insertion
LH 7
LH 8
Magneto connection Chain Magneto cable band Upper & lower chain case 52DH0309 DH161283 Separate bolt & washer required for chain case fitment Flange bolt introduced instead of separate bolt & washer Cost saved by. Use flange bolt of dimension for chain case fitment Y
Engine torque LH 9 checking & chain routine Rear wheel 10 LH 10 alignment 9
Extra material provided on chain case
Chain case width reduced
Cost saved By
Impl
11 LH 11
Chain case fitment
Bolts ( M 6 )
washer
Impl
Category
Stage Description
Part Name
Part Number
Gear shift lever Rear cover RR Gear Shifter Lever 12 LH 12 Bolt ( M6 ) Fitment Metal ring Rubber ring M 6 Bolt LH main step 13 LH 13 LH main step fitment M8 Bolts Spring washer Main key grommet 14 LH 14 Handle bar fitment Handle bar Fork Bracket Center Bolt Tightening Center Fork bolts Washer Allen bolts ( M 8) Fork cap rubber grommet AC Box clip Carburettor 17 LH 17 Carburettor fitment Earthing cable grommet
DH101397 DJ101211 39167304
DJ161130 39231004
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
a a
Rubber grommet used on main key switch
Grommet deleted
Cost saved by Rs .. Cost saved by Rs ..
Impl
Provide main key with out rubber grommet Provide carburettor with choke lever itself
52DH0169
Choke lever Separate cable included in required for choke carburettor body connection itself
Impl
15 LH 15
DG181008 DJ181009 DH121142 DJ101232 Y
16 LH 16
Carburettor Cover change from metallic diaphragm metallic to fybre cover
Cost saved by Rs..
Impl
Provide fyber material cover for diaphragm inplace of metallic cover
Category
Stage Description
Part Name
Part Number
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
18 LH 18
A C Box clip tightening Accelerator Connection LH Harness Connection
A C Box clip
Separate bolt,washer & Step bolt spacer required for introduced AC Box fitment
Cost saved by Rs
Impl
Provide step bolt for AC Box fitment
19 LH 19
20 LH 20
Accelerator Connection LH side harness terminal connection LH side decal PT drain pipe clip DH161310 DH141002 Y
LH seat cowl decal 21 LH 21 pesting Battery Connection LH Bellow insertion
Seat cowl decal with size.
Size reduced to.
Cost saved by Rs.
Impl
Provide seat cowl decal with size
22 LH 22
23 LH 23
LH bellow insertion Case meter connection Petrol Tank PT cap inner screw
DJ710122 Y
a a
24 LH 24
Petrol Tank fitment
Anti theft screw required on inner side of petrol tank cap More length of PT drain pipe
Screw deleted
Cost saved by Rs Cost saved by Rs
Impl
Provide PT cap with out anti theft screw mounting Provide drain pipe with reduced length of ..mm
Drain pipe Bolt Washer 39155604 39074011
Pipe length reduced
Impl
Category
Stage Description
Part Name
Part Number
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
25 LH 25
Grab Handle fitment
Grab handle Bolt
DJ161263
Grab handle of material.
Grab handle material change from.to.
Cost saved by Rs..
Impl
Provide grab handle with material.
26 LH 26
Side panel Side lock grommet Side panel lock
52DK5506 33161018
HOME WORK DESIGN REVIEW MANUAL Theme :- Cost Reduction Cell :- Pulsar ( LHS ) Category
Stage Description
Part Name
Part Number
RH 1
Rear Wheel Loading
Rear Wheel Rear Wheel Spacer Rear wheel damper
DJ151019 DJ151034 Y
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
a a
Rear wheel spacer with yellow passivation 6 groove rear wheel damper
Passivation change from yellow to green. Single piece
Plan
Impl
Provide rear wheel spacer with green passivation Provide 4 groove damper for rear wheel 1] Provide green passivated sprocket 2] Provide green passivated rear brake arm 3] Provide sprocket mounting on 4 bolts Use flange bolt for rear shock lower mounting instead of dome nut , plain washer & spring washer
RH 2
Rear Brake Panel
DH151060
1] Platted sprocket on brake panel 2] Platted rear brake arm 3] Sprocket mounting on 6 bolts
1] Instead of platting , green passivation provided 2] Passivation change 3] Sprocket mounting on 4 bolts
Impl
Rear shock
Separate dome nut , Bracket addd on swing plain washer & arm for mounting spring washer shock lower with flange required for shock bolt lower fitment
Impl
Bearing ball Grease
Category
Stage Description
Part Name
Part Number
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
Fork Friction Plate Fork side bracket 3 RH 3 Fork fitment stage Bearing Cone Cup Steering Fork Nut Metal ring Rubber ring
52DJ0130
Y Y
a a a
More threaded length Thread length reduced Friction plate required Separate bolt & nut required for side bracket fitment Friction plate deleted
Impl Impl
Provide fork with thread length .. Mm
Allen bolt introduced
Impl
DH181025 DH181014 30181018 Y
Black passivation for cup stearing
Passivation change from black to green
Impl
Provide cup stearing with green pasivation
Mud guard
52DH0278
1] Mud guard mounting from inner side - required bolt & washer assembly 2] Rubber grommet on LH side of mud guard
1] Mud guard mounting from outer side with allen bolt 2] Rubber grommet deleted
Impl
1] Provide mud guard mounting from out side with allen bolt
RH 4
Brace fender
DH161258
Separate clamp required to fastened Brace fender with with brace fender for clamp brake kit hose grommet fitment
Impl
Provide clamp welded with brace fender for brake kit hose grommet fitment.
Allen Bolts (M6) Painted set loading
DG181008
Category
Stage Description
Part Name
Part Number
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
Front Number plate Bolt Plain washer Spacer Magnet (Self canceling indicator) Front Axle ( With grease application ) Front wheel
52DH0317
Separate bracket is to fastened with Front number plate number plate for with bracket brake kit hose clamp pipe.
Impl
Provide welded bracket to FNP for brake kit hose.
RH 5
Front Number Plate fitment
DH121130
DJ151041
Case meter Front wheel fitment
DH151062
Case meter cost more due to magnetic type
Case meter design change from gear type to magnetic type
Cost saved By Rs
Impl
Provide case meter with magnetic type
RH 6
Spacer Split pin Front axle lock nut Front axle washer
DS151058 Y 59150003 39078111
Castle nut & split Instead of castle nut & pin required for front split pin - lock nut wheel fitment used
Impl
Provide lock nut of size . For front wheel fitment
Category
Stage Description
Part Name
Part Number
RH 7
RH front bracket RH rear bracket Hanging plate nuts ( M8)
DH161190 DJ161271 59150005
RH 8
Engine fitment stage Center bracket bolt ( M12 ) Plastic washer 39245504
RH 9
Starter relay & OEN relay Hanging plate nuts ( M8 ) Rear axle nut Fairing Assembly Bolt with locktite application 59150005 DH171019
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
Separate starter relay & OEN relay required
Starter relay combined with OEN relay
Cost saved by Rs.
Impl
Provide single piece device to functon for starter & OEN relay
10 RH 10
11 RH 11
59150003 DH161245 59150005
Lock nuts Engine tightening 12 RH 12 Simple stage nuts
Category
Stage Description
Part Name
Part Number
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
13 RH 13
Front wheel tightening stage
RH step holder M13 bolts
52DJ0226 39258204 15191026 39231004
Pillion step fitment on step holder with "O" ring , plain washer & split pin
Pillion step mounting with circlip
Cost saved by Rs
Impl
Provide circlip of size for pillion step fitment
Rod end M8 main step bolt Spring washer Brake connection Main step 14 RH 14 stage RH Adjuster nut Spring Plain washer Brake padel Brake padel Flange bolt 15 RH 15 fitment stage (M12) Torque rod bolt Spring washer - T Rod 16 RH 16 Rear wheel tightening stage Center axle nut (M22) Torque rod nut (M14)
DJ161131 DH191045 30191035 39019811 DH191001 39176904 30151096 39078912
DH171019
39079415
Category
Stage Description
Part Name
Part Number
Starter motor grommet Starter motor 17 RH 17 connection stage Spring washer Nut 18 RH 18 19 RH 19 Front brake kit tightening stage Upper lever tightening DK7303ZZ
Seat cowl fitment Seat cowl stage RH Harness 20 RH 20 connection stage RH Harness 21 RH 21 connection stage RH Harness 22 RH 22 connection stage Silencer Plain big washer Small washer Lock nuts (M17) Flange bolts Flange nuts Gasket 24 RH 24 Silencer tightening stage Snap pin
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
DJ101259 39242511 39024811 DD161071 39185004 59150005 DJ101064 DH151055
Silencer with platting..
Platting change from..to .
Cost saved by Rs.
Impl
Provide silencer with platting.
23 RH 23
Category
Stage Description
Part Name
Part Number
Flange bolts (M6) 25 RH 25 Seat cowl tightening satge DG Screw Washers Carburettor clip tightening stage Clutch connection 27 RH 27 stage 26 RH 26 Side panel RH side seat cowl Side panel sub decal 28 RH 28 assembly stage Side lock grommet Side panel lock Battery 29 RH 29 Vehicle inspection terminal removal
39194304 Y 39178924
3.4 Yeild
Sr No
Stage No
Activity / Problem
Idea
Status
DR Point For Review
DG screw required Bolt introduced for seat for seat cowl fitment cowl fitment
Cost saved by Rs..
Impl
Provide bolt for seat cowl fitment

Cell:-Pulsar (LHS) : Home Work Design Review Manual Theme: - Design For Assembly

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Cell:-Pulsar (LHS) : Home Work Design Review Manual Theme: - Design For Assembly

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HOME WORK DESIGN REVIEW MANUAL Theme :- Design For Assembly Cell :- Pulsar ( LHS ) Category Sr No Stage No Motion

Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

DJ201125 DH111064 DJ161132 39168004 DJ161081

Category Sr No Stage No Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

Engine bracket bolt insertion

Bolt Rear LH bracket LH center bracket Allen bolt ( M8)

39241304 DJ161114 DJ161115 39241404

Magneto connection Chain

Engine torque LH 8 checking & chain routine Rear wheel LH 9 alignment

Magneto cable band

Design _ Proto 2 4.3 _ 8b

Category Sr No Stage No Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

Design Basic 4.1 _ 4b

DH101397 DJ101211 39167304

Y Rubber ring M 6 Bolt N

Design Basic 4.1 _ 4b

Category Sr No Stage No Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

LH main step LH main step fitment

Design Basic 4.1 _ 4b

N N N N DG181008 DJ181009 DH121142 DJ101232 N N N N N N N

LH mud guard fitment

Category Sr No Stage No Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

Petrol Tank Bolt 23 LH 23 Petrol Tank fitment Washer

Category Sr No Stage No Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

Grab Handle fitment

Grab handle Bolt Side panel Side lock grommet

DJ161263 52DK5506 33161018

LH side panel fitment

Side panel lock Frame Sub Assly K2 ES UG3

Design Basic 4.1 _ 4b

Desired thread length

52DH0248 52DH0248 75261601 75118821

DR Point For Review

Rear Wheel Loading

Rear Wheel Rear wheel spacer Rear brake panel

DJ151090 DJ151034 DH151060

Rear wheel spacer insertion

Ball cage provided instead of loose balls

Design Basic 4.1 _ 4b

RH 3 Fork fitment stage

Design Basic 4.1 _ 4b

Design Basic 4.1 _ 4b

Mud guard fitment stage

Category Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

Front Number Plate Fitment

Required to make s/a of bolt , washer & spacer

Design Basic 4.1 _ 4b

Front wheel fitment

39078111 DH161190 DJ161271 59150005

Engine bracket fitment stage

Category Motion Loss Applicability Y/N 1.1 Preparatory

DR Point For Review

Center bracket tightening stage

Fairing Fitment Stage Front brake kit routine stage

59150003 DH161245 59150005 52DJ0226 39258204

Category Motion Loss Applicability Y/N 1.1 Preparatory