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Learning Sheet (Past defect History)

Part Name :- Tank Oil Catch


Part Name:- Tank Oil Catch Data :- 12/11/2015
Part No. :- 24813-56R00 Model :- YL1 - MC
Verification During NPD

Defect
Reported
Sr. Problem Reported C/m Impl Applic Action for new
Part Name Model FromNPD/ Root Cause Countermeasure Taken
No. Description Month MSIL/Internal/ date able model ________
Warranty

STUD STUD THREAD FREE DUE TO WE USED NEW STUD FROM USED
1 HITCH GYPSY THREAD 7/5/2015 MSIL THE SOFT BOLT AND IT IS NOT POSSIBLE AT 8.8 GRADE TO KAKE 12/5/2015
FREE TO TAKE 800 KGF LOAD. THE 800 KGF LOAD

MACHINE AIR CYLINDER


PANEL ROOF ELECTRODE FORCE NOT PROPER DUE TO
2 GYPSY SPOT FAIL 26//4/2015 MSIL MAINTENANCE DONE 28//4/2015
FLOOR MACHINE EARTIC BEHAVIOR AND VALVE REPLACED

WORK INSTRUCTION
DURING PIERCING OPERATION,
3 BREAK PEDAL HOLE OVER 2/19/2015 Inernal DISPLYED ON LINE TO 2/19/2015
OMNI OPERATOR DONE THE PIERCING TWO
ASSY SIZE CONTROL THE
TIMES AFTER MOVING THR PART
ISSUES.

4 DUST COVER OMNI HOLE BURR 8/5/2014 Inernal DIE PUNCH CLEARNCE NG TOLL IMMPROVED 10/5/2014

WORK INSTRUCTION
5 NUT MISS 19.08.2014 MSIL OPERATOR NOT COMPLETED THE CYCLE DISPLYED ON LINE TO 22.08.2014
PANEL COWL YL-8 (M6) AND PARTS KEPT IN OK BIN. CONTROL THE ISSUES.

DURING WELDING OPERATION, TIP DRESSING


TIP DRESSING NOT DONE BY SENSOR
6 VAN PANEL OMNI SPOT FAIL 01.09,2015 MSIL OPERATOR BECAUSE TIP CORRECTED AND A 07.09,2015
DRESSING SENSOR NOT NEW LIGHT SYSTEM
WORKING. ALSO INSTALLED.
PLATE
GAP NG TORQUING FIXTURE
7 DAMPER BACK (DUE TO 17.10.2013 Inernal AFTER ASSY. TORQUING NOT MADE FOR 17.10.2013
YRA
DOOR TORQING DONE AND WELD THE NUT. TORQUING THE
NOT DONE PART
)

8 DIM NG 20/05/2015 MSIL BURR GENRATE ON FLANGE DUE DRAW TOOL HAS BEEN 25/05/2015
DUST COVER YAD CORRECTED
TO THIS DIM NG

WELDING JIG
DURING ASSY. PART TOUCH WITH ADJUSTED AND GAP
9 T/M COUNT 27/11/2014 MSIL 3/12/2014
YE-3 CD OUT TRANSMISSION BODY IN MSIL MAINTAINED
CABLE
AND PART CD OUT. BETWEEN BODY
AND BKT.

HOLE PUNCHING TOOL


10 ROOF FR YBA UNDER 12/4/2015 Inernal BURR ON HOLE HAS BEEN 18/4/2015
INNER
SIZE CORRECTED

WORK
OIL NOT APPLIED ON SHEET INSTRUCTION
11 REAR DOOR YRA CRACK 14.12.2013 Inernal DURING MANUFACTRING OF COIL DISPLYED ON LINE 15.12.2013
OUTER LH
BY SUPPLIER TO CONTROL THE
ISSUES.

GUIDE
12 CLUTCH PUNCHIN 20.02.2015 MSIL DURING THE DRAW OPERATION TOOL HAS BEEN 28.02.2015
YE3
G OUT PART GOTED SHIFTED CORRECTED
CABLE

100% PART
13 BKT CNG YL7
WRONG 2/1/2013 Inernal WRONG PART MIXED WITH OK
CHECKED WITH 5/1/2013
COUNT SIZE STUD STUD
BOLT

MORE CLERANCE BETWEEN DIE


14 ROOF CTR OMNI
WRINCKL 24/2/2015 Inernal AND PUNCH DUE TO TOOL RUN
NEW DRAW TOOL 10/3/2015
PILLER RH E TO BE MADE
OUT
Learning Sheet (Past defect History)
Part Name :- Tank Oil Catch
SR.NO DATE OF PART NAME MODEL PLACE DEFECT ROOT CAUSE ANALSIS ACTION TO BE TAKEN Shop APPLICABLE Action for new model
OCCURRENCE ________

STIFFENER NUT M8 POSITION NG IN Occurance :- DIFFERENT MODEL PART CAN Occurance :- MISTAKE PROOFING ADDED
1 5/1/2013 Pedal Assy Brake YP8 NPD BKT, BRAKE DUE TO WRONG BKT, BE WELDED IN THE FIXTURE IN WELDING FIXTURE
BOP
BRAKE USED. Outflow :- CHECK POINT ADDED IN EOL
Outflow:- NO CHECK POINT

Occurance :- OLD MATERIAL IN STOCK & Occurance :- FIFO for the switch will be
RUST OBSERVED INSIDE BRAKE NEW MATERIAL RUN ON LINE maintain to avoid rust issue in the part
7/1/2013 Pedal Assy Brake YP8 MSIL SWITCH WHICH LEADS TO PRESS
2
DISCONTINUITY Outflow:- NO VISUAL CHECK POINT FOR SHOP
Outflow :- CHECK POINT ADDED
RUST IN SWITCH

Occurance :- Spot broken due to blank


short in the part Occurance :- Before welding part will be
checked for the pressing defects
3 12/1/2013 Pedal Assy Brake YL7 Internal BRAKE PEDAL SWITCH SPOT BROKEN BOP
Outflow:- INSPECTION WAS DONE ON
SAMPLING BASIS Outflow :- 100% INSPECTION STARTED

Occurance :- Touch sensor added in the


Occurance :- BEAD SHIFT robot to avoid the bead shifting.

4 12/1/2013 Pedal Assy Brake YL7 Internal WELD PENETRATION NG Outflow:- ONLY BEAD PRESENCE WAS Outflow :- DOUBLE INSPECTION AT ROBO SHOP
CHECKED BY THE ISPECTOR WELDING STAGE AS WELL AS ASSEMBLY
STAGE IS STARTED FOR BEAD POSITION
AND PRESENCE

Occurance :- DESIGN OF THE THREADS HAS


Occurance :- SWITCH GOT MOVED FROM BEEN MODIFIED BY THE SUPPLIER TO
1/1/2014 Pedal Assy Brake YL7 Internal SWITCH GAP SETTING NG ITS POSITION DURING TRANSPORTATION AVOID DAMAGE
5 ASSY SHOP
Outflow :- SWITCH SETTING INSPECTION
Outflow:- HANDLING STARTED AT MSIL LINE

Occurance :- Handling of the part


Occurance :- MIXING OF PARTS improved to avoid mixing
6 1/1/2014 Pedal Assy Brake YL7 MSIL BUSH MISS IN CLUTCH PEDAL Outflow:- without EOL inspection Outflow :- 100% adherence of EOL and WELD SHOP
dispatched to MSIL daily check point added for EOL working
with NG sample.

Occurance :- Bkt got shifted due to spatter Occurance :- relive provided in the jig to
STAY FOULING WITH SWITCH deposition avoid spatter deposition
7 3/1/2014 Pedal Assy Brake YP8 Warranty BRACKET DISPATCH
Outflow :- check point added in the PDI
Outflow:- NO CHECK POINT stage

Occurance :- ONE SIDE STOPPER IN


FIXTURE FOR PART LOCATION Occurance :- Jig design modified to arrest
the position of the Bkt.
8 6/1/2014 Pedal Assy Brake OMNI Internal WELDING SHIFTED OF L BKT BOP
Outflow:- INSPECTION DONE ON
SAMPLING BASIS Outflow :- 100%CHECK POINT ADDED

Occurance :- difference between YP8 and Occurance :-now in the both models felt
YL1 was only of felt pasting introduced
9 7/1/2014 Pedal Assy Brake YP8 Internal FELT MISS WELD SHOP
Outflow:- WRONG PACKING SLIP PLACED Outflow :-
ON THE BOX

Occurance :- WRONG ARM WELDED AS NO Occurance :-Additional block added in the


PROVISION IS THERE TO DETECT THE SAME jig to avoid wrong model part welding
10 8/1/2014 Pedal Assy Brake YP8 Inernal WRONG PEDAL ARM WELDED ASSY SHOP
Outflow:- NO PROVISION IS THERE IN THE Outflow : - PROVISION EXPLORE IN THE RG
RG TO DETECT NG PART

Occurance :- PAINT ACCUMULATE INSIDE Occurance :-After Taping marking will be


THREAD,WHICH WAS NOT RETAPPED done.
11 8/1/2014 Pedal Assy Brake OMNI INTERNAL THREAD TIGHT BOP
Outflow:- INSPECTION WAS DONE ON Outflow :- 100% INSPECTION WITH BOLT.
SAMPLING BASIS

Occurance :- MANUAL WELDING MISS IN


ARM COMP REACH OF OPERATOR IS NOT Occurance :-for low volume models robotic
11/1/2014 Pedal Assy Brake YL1 Internal WELDING MISS OK welding will be introduced.
12 BOP
Outflow:- INSPECTION WAS DONE ON Outflow :- Additional check point added
SAMPLING BASIS

Occurance :- SINGLE BOLT IS THERE FOR


TIGHTNING OF BKT, WHICH GOT LOOSE Occurance :-torqueing done at higher
DUE TO PIVOT ACTION OF PART DURING spec. 13±5 (presently done on 18 Nm) PRESS
13 11/1/2014 Pedal Assy Brake YL7 Inernal BOLT LOOSE Outflow :- Additional check point added,
HANDLING SHOP
cross marking
Outflow:- HANDLING

Occurance :-Manual operation will be


Occurance :- MANUAL SPOT MISS converted in the robotic welding
14 2/1/2015 Pedal Assy Brake YL8 Internal SPOT MISS Outflow:- ONLY SAMPLING BEING DONE BOP
Outflow :- Additional check point added

Occurance :- 3 SIDE STOPPER AVAILABLE, 1 Occurance :-Additional Block added in the


SIDE IS OPEN WHICH GOT TILTED DUE TO welding jig to prevent part movement in
4/1/2015 Pedal Assy Brake YL7 Msil PLATE TILTED CYLINDER PRESSURE the jig. PRESS
15
Outflow:- CHECK POINT NOT AVAILABLE IN Outflow :- CHECK POINT ADDED IN THE SHOP
GAUGE GAUGE

Occurance :- REAMING NOT DONE ACROSS Occurance :-OPERATOR TRAINING FOR


THE HOLE COMPLETE INSERTION OF REAMER INSIDE
16 7/1/2015 Pedal Assy Brake YL1 MSIL TMC HOLE TIGHT IN BRAKE PEDAL THE HOLE BOP
Outflow:- CHAMFER IN PIN OF GAUGE, Outflow :- PIN DESIGN MODIFIED, AND
DUE TO WHICH IT WAS NOT DETECTED. CHAMFER REMOVED

Occurance :- THREAD GOT DAMAGED Occurance :-WELDING PARAMETER


DURING PROJECTION WELDING REVISED TO AVOID THREAD DAMAGE
8/1/2015 Pedal Assy Brake YL1 Inernal M6 NUT NO GO QUALIFY OPERATION
17 ROBO SHOP
Outflow :- INSPECTION WITH BOLT
Outflow:- RETAPPING BEING DONE FOR STARTED
CORRECTING THE THREAD