CUSTOMER COMPLAINTS VERIFICATION CHECK SHEET

DATE OF CATCHABLE
SR.NO PART NO. PART NAME MODEL CUSTOMER DEFECT ROOT CAUSE ANALSIS ACTION TO BE TAKEN Shop PDI AREA STATUS OPEN/CLOSE
OCCURRENCE YES/NO

Occurance :- DIFFERENT MODEL PART CAN BE WELDED IN THE FIXTURE Occurance :- MISTAKE PROOFING ADDED IN WELDING FIXTURE
35 5/1/2013 YP8 NPD STIFFENER NUT M8 POSITION NG IN BKT, BRAKE DUE TO WRONG BKT, BRAKE USED. Outflow :- CHECK POINT ADDED IN EOL BOP NO PRESS PDI closed
Outflow:- NO CHECK POINT
49069m74l51 Pedal Assy Brake

Occurance :- OLD MATERIAL IN STOCK & NEW MATERIAL RUN ON LINE Occurance :- FIFO for the switch will be maintain to avoid rust issue in the part YES
36 7/1/2013 YP8 MSIL RUST OBSERVED INSIDE BRAKE SWITCH WHICH LEADS TO DISCONTINUITY PRESS SHOP (BY DEVIATION) WELD PDI closed
Outflow:- NO VISUAL CHECK POINT FOR RUST IN SWITCH Outflow :- CHECK POINT ADDED
49069m74lr0 Pedal Assy Brake

Occurance :- Spot broken due to blank short in the part Occurance :- Before welding part will be checked for the pressing defects
37 12/1/2013 YL7 Internal BRAKE PEDAL SWITCH SPOT BROKEN BOP NO PLATING closed
Outflow:- INSPECTION WAS DONE ON SAMPLING BASIS Outflow :- 100% INSPECTION STARTED
49069- Pedal Assy Brake

Occurance :- Touch sensor added in the robot to avoid the bead shifting.
Occurance :- BEAD SHIFT
38 12/1/2013 YL7 Internal WELD PENETRATION NG Outflow :- DOUBLE INSPECTION AT WELDING STAGE AS WELL AS ASSEMBLY STAGE IS STARTED FOR BEAD POSITION AND ROBO SHOP YES PLATING closed
Outflow:- ONLY BEAD PRESENCE WAS CHECKED BY THE ISPECTOR PRESENCE
49069- Pedal Assy Brake

Occurance :- SWITCH GOT MOVED FROM ITS POSITION DURING TRANSPORTATION Occurance :- DESIGN OF THE THREADS HAS BEEN MODIFIED BY THE SUPPLIER TO AVOID DAMAGE
39 1/1/2014 YL7 Internal SWITCH GAP SETTING NG Outflow :- SWITCH SETTING INSPECTION STARTED AT MSIL LINE ASSY SHOP NO ASSY closed
Outflow:- HANDLING
49069- Pedal Assy Brake

Occurance :- MIXING OF PARTS Occurance :- Handling of the part improved to avoid mixing
40 1/1/2014 YL7 MSIL BUSH MISS IN CLUTCH PEDAL WELD SHOP NO WELD PDI closed
Outflow:- without EOL inspection dispatched to MSIL Outflow :- 100% adherence of EOL and daily check point added for EOL working with NG sample.
49069- Pedal Assy Brake

Occurance :- Bkt got shifted due to spatter deposition Occurance :- relive provided in the jig to avoid spatter deposition
41 3/1/2014 YP8 Warranty STAY FOULING WITH SWITCH BRACKET DISPATCH NO ASSY closed
Outflow:- NO CHECK POINT Outflow :- check point added in the PDI stage
49069- Pedal Assy Brake

Occurance :- ONE SIDE STOPPER IN FIXTURE FOR PART LOCATION Occurance :- Jig design modified to arrest the position of the Bkt.
42 6/1/2014 OMNI Internal WELDING SHIFTED OF L BKT BOP NO WELD PDI closed
Outflow:- INSPECTION DONE ON SAMPLING BASIS Outflow :- 100%CHECK POINT ADDED
49069- Pedal Assy Brake

Occurance :- difference between YP8 and YL1 was only of felt Occurance :-now in the both models felt pasting introduced
43 7/1/2014 YP8 Internal FELT MISS WELD SHOP YES WELD PDI closed
Outflow:- WRONG PACKING SLIP PLACED ON THE BOX Outflow :-
49069- Pedal Assy Brake

Occurance :- WRONG ARM WELDED AS NO PROVISION IS THERE TO DETECT THE SAME Occurance :-Additional block added in the jig to avoid wrong model part welding
44 8/1/2014 YP8 Inernal WRONG PEDAL ARM WELDED ASSY SHOP YES PLATING closed
Outflow:- NO PROVISION IS THERE IN THE RG Outflow : - PROVISION EXPLORE IN THE RG TO DETECT NG PART
49069- Pedal Assy Brake

Occurance :- PAINT ACCUMULATE INSIDE THREAD,WHICH WAS NOT RETAPPED Occurance :-After Taping marking will be done.
45 8/1/2014 OMNI INTERNAL THREAD TIGHT BOP YES WELD PDI closed
Outflow:- INSPECTION WAS DONE ON SAMPLING BASIS Outflow :- 100% INSPECTION WITH BOLT.
49069- Pedal Assy Brake

Occurance :- MANUAL WELDING MISS IN ARM COMP REACH OF OPERATOR IS NOT OK Occurance :-for low volume models robotic welding will be introduced.
46 11/1/2014 YL1 Internal WELDING MISS BOP NO PLATING closed
Outflow:- INSPECTION WAS DONE ON SAMPLING BASIS Outflow :- Additional check point added
49069- Pedal Assy Brake

Occurance :- SINGLE BOLT IS THERE FOR TIGHTNING OF BKT, WHICH GOT LOOSE DUE TO PIVOT ACTION OF PART DURING HANDLING Occurance :-torqueing done at higher spec. 13±5 (presently done on 18 Nm)
47 11/1/2014 YL7 Inernal BOLT LOOSE Outflow:- HANDLING Outflow :- Additional check point added, cross marking PRESS SHOP NO PLATING closed
49069- Pedal Assy Brake

Occurance :- MANUAL SPOT MISS Occurance :-Manual operation will be converted in the robotic welding
48 2/1/2015 YL8 Internal SPOT MISS Outflow:- ONLY SAMPLING BEING DONE BOP NO PRESS PDI closed
Outflow :- Additional check point added
49069- Pedal Assy Brake

Occurance :- 3 SIDE STOPPER AVAILABLE, 1 SIDE IS OPEN WHICH GOT TILTED DUE TO CYLINDER PRESSURE Occurance :-Additional Block added in the welding jig to prevent part movement in the jig. YES
49 4/1/2015 YL7 Msil PLATE TILTED Outflow:- CHECK POINT NOT AVAILABLE IN GAUGE Outflow :- CHECK POINT ADDED IN THE GAUGE PRESS SHOP (BY DEVIATION) WELD PDI closed

49069- Pedal Assy Brake

Occurance :- REAMING NOT DONE ACROSS THE HOLE Occurance :-OPERATOR TRAINING FOR COMPLETE INSERTION OF REAMER INSIDE THE HOLE
50 7/1/2015 YL1 MSIL TMC HOLE TIGHT IN BRAKE PEDAL Outflow :- PIN DESIGN MODIFIED, AND CHAMFER REMOVED BOP NO PLATING closed
Outflow:- CHAMFER IN PIN OF GAUGE, DUE TO WHICH IT WAS NOT DETECTED.
49069- Pedal Assy Brake

Occurance :- THREAD GOT DAMAGED DURING PROJECTION WELDING OPERATION Occurance :-WELDING PARAMETER REVISED TO AVOID THREAD DAMAGE
51 8/1/2015 YL1 Inernal M6 NUT NO GO QUALIFY ROBO SHOP YES PLATING closed
Outflow:- RETAPPING BEING DONE FOR CORRECTING THE THREAD Outflow :- INSPECTION WITH BOLT STARTED
49069- Pedal Assy Brake

Occurance :-PROGRAMM OF PLC FOR DC TOOL CHANGED. IF TORQUING DONE ON SINGLE NUT TWICE THEN CLAMP WILL NOT
Occurance :- CHANCES OF TORQUE BEING DONE ON SAME NUT WAS HIGH
52 11/1/2015 YRA Msil M10 NUT LOOSE Outflow:-NO CHECK POINT IN EOL OPEN ASSY SHOP NO ASSY closed
Outflow :- ADDITIONAL CHECK POINT OF LIMIT WRENCH CHECK ADDED, EOL PROGRAMMED TO CHECK TORQUE UPTO 16NM
49069- Pedal Assy Brake

Occurance :-PROGRAMMING ERROR REMOVE,ALSO SELECTOR SWITCH HAS BEEN REMOVED,PROGRAMM SLECTION DONE
Occurance :- ERROR IN EOL PROGRAMMING,DUE TO WHICH WRONG STICKER PRINT AND PASTED
53 3/1/2016 Y9T MSIl WRONG STICKER PASTED Outflow:-NO CHECK POINT THROUGH TOUCH PANNEL WELD SHOP NO WELD PDI closed
Outflow :- DATE ON STICKER CHECKING STARTED.
49069- Pedal Assy Brake

Occurance :- MANUAL FITMENT, PROPER INSERTION MAY NOT BE THERE Occurance :-PY ADDED IN EOL FOR CUSHION PRESENCE
54 4/1/2016 Y9T Inernal CUSHION MISS Outflow:-NO CHECK POINT Outflow :- MARKING ON CUSHION AFTER PROPER INSERTION DONE BY INSPECTOR DISPATCH NO ASSY closed

49069- Pedal Assy Brake

Occurance :- Clamping force not proper on fixture. Occurance :- Cyleneder has been changed from small to big.
55 9/10/2016 YJC Internal PAD PLATE TILT Outflow:-NO CHECK point on gauge to detect the problem. Outflow :- fix block has been added to ditect the problem. BOP NO WELD PDI closed

49069- Pedal Assy Brake

1 4/5/2017 29810M79F00 GUTTER YE-3 GURGAON FITMENT ISSUE OBSERVED DUE TO RADIUS NG ( REQ-30 FOUND 36) TOOL WORN OUT DUE TO TOOL LIFE OVER NEW TOOL TO BE MADE BOP NO PRESS PDI closed

YES
2 4/21/2017 67510M797B2 ROOF CTR PILLER RH OMNI GURGAON WRINCKLE MORE CLERANCE BETWEEN DIE AND PUNCH DUE TO TOOL WORN OUT NEW DRAW TOOL TO BE MADE PRESS SHOP (BY DEVIATION) WELD PDI closed

3 4/26/2017 3666165M30 BKT ENG HARN YAD 15 GURGAON FITMENT ISSUE OBSERVED DUE TO 9.5 MM DIM FOUND 8.0MM ) PART SHIFTED DURING FORMING OPERATION BECAUSE NO PROPER LOCATION. P/Y ADDED IN FORMING TOOL BOP NO PLATING closed

4 6/19/2017 36653M62R00 BKT ENG PROTECTOR YJC GURGAON SPATTER ON BKT SPATTERS STICKED DURING WELDING DUE TO PART NOT COVER BY BLOCK LOCATING BLOCK PROVIDED IN JIG TO COVER THE PART ON BOTH SIDE ROBO SHOP YES PLATING closed

5 6/19/2017 49069M84M80 BREAK PEDAL CLUTCH YL-7 MANESAR WRONG ARM FITTED NO PROVISION IN TORQUING FIXTURE TO DETECT THE PART P/Y ADDED IN INSPECTION GAUGE TO DETECT THE WRONG ARM ASSY SHOP NO ASSY closed

6 6/23/2017 63510M70A00 PANEL ROOF FLOOR GYPSY GURGAON SPOT FAIL ELECTRODE FORCE NOT PROPER DUE TO MACHINE EARTIC BEHAVIOR MACHINE AIR CYLINDER MAINTENANCE DONE AND VALVE REPLACED WELD SHOP NO WELD PDI closed

7 7/1/2017 49069M62R01 BREAK PEDAL ASSY YJC GURGAON LEVER REMOVE LEVER REMOVE DURING HANDLING THE PART PART PACKING IMPROVED TO AVOIDE THE SUCH TYPE OF ISSUES DISPATCH NO ASSY closed

8 7/5/2017 49069M62R01 HITCH GYPSY GURGAON STUD THREAD FREE STUD THREAD FREE DUE TO WE USED THE SOFT BOLT AND IT IS NOT POSSIBLE TO TAKE 800 KGF LOAD. NEW STUD FROM USED AT 8.8 GRADE TO KAKE THE 800 KGF LOAD BOP NO WELD PDI closed

9 7/25/2017 59791M60MOO PANEL COWL YL-8 GURGAON NUT MISS (M6) OPERATOR NOT COMPLETED THE CYCLE AND PARTS KEPT IN OK BIN. WORK INSTRUCTION DISPLYED ON LINE TO CONTROL THE ISSUES. WELD SHOP YES WELD PDI closed

10 8/3/2017 83990M68POO DAMPER BACK DOOR YRA MANESAR PLATE GAP NG (DUE TO TORQING NOT DONE ) AFTER ASSY. TORQUING NOT DONE AND WELD THE NUT. TORQUING FIXTURE MADE FOR TORQUING THE PART ASSY SHOP YES PLATING closed

11 8/5/2017 67560M797B2 RENIF CTR PILLER OMNI GURGAON 7/16 NUT THREAD MISS THREAD WASH DUE TO PART FALLEN DOWN IN OK BIN DURING FEEDING THE PART IN TAPPING MACHINE AT SUPPLIER END COVER PROVIDED IN HOOPER THREE SIDE TO CONTROL THE PART FALLEN DOWN. BOP YES WELD PDI closed

12 8/5/2017 36661-66R10 BKT. ENGINE HARN AMT YSD MANESAR BENDING NG PART DAMEGED DURING HANDLING PART PACKING IMPROVED TO AVOIDE THE SUCH TYPE OF ISSUES BOP NO PLATING closed

17 11/9/2017 49079M62R11 BREAK PEDAL CLUTCH YJC GURGAON Same colour switch SWITCH DAMAGED DURING THE HANDLING IN TRANSPORTATION HANDLING IMPROVED ASSY SHOP YES ASSY closed

DURING THE PUNCHING PROCESS TOOL WARN OUT

23 12/4/2017 23910M53M00 GUIDE CLUTCH YE3 GURGAON PUNCHING BURR TOOL HAS BEEN CORRECTED PRESS SHOP YES PLATING closed
AND DUE TO THIS BURR OBSERVED

OPERATOR NOT COMPLETED THE PROCESS YES ASSY closed

24 12/6/2017 49069M79M30 BRAKE PEDAL ASSY YP8 MANESAR BUSH MISS TRAINING GIVEN TO OPERATOR / INSPECTOR ASSY SHOP
AND THAT NG PART MIXED WITH OK PART

29 1/17/2018 33954M76M00 BKT CNG COUNT YL7 MANESAR WRONG SIZE STUD WRONG PART MIXED WITH OK STUD 100% PART CHECKED WITH BOLT WELD SHOP YES PLATING closed

30 2/1/2018 55321-82P00 DUST COVER YAD GURGAON DIM NG BURR GENRATE ON FLANGE DUE TO THIS DIM NG DRAW TOOL HAS BEEN CORRECTED PRESS SHOP NO PLATING closed

BENDING TOOL HAS BEEN CORRECTED AND LOCATING YES PLATING closed
31 2/24/2018 366651-66R10 BKT ENG HARN AMT ` GURGAON DIM FOUND NG PART SHIFTED DURING THE BENDING OPERATION BECOUSE LOCATING GAUGE NOT FULLPROOFING BOP (BY DEVIATION)
GAUGE MODIFIED

32 3/6/2018 49069-79A00 BRAKE PEDAL OMNI GURGAON SPOT FAIL ELCTOROD ALEIMENT NOT AMTCHING DUE TO MACHINE PROBLEM MACHINE MAINTENACE HAS BEEN DONE WELD SHOP NO ASSY closed

33 3/13/2018 24390-53M00 TM COUNT CABLE YE3 GURGAON SPOT FAIL SUNTING ISSUE INSHULATION HAS BEEN DONE ON ARM WELD SHOP NO PLATING closed

34 3/20/2018 24390-65M01 TM COUNT CABLE YRA MANESAR FITMENT ISSUE PART OUT WELDED DURING THE WELDING PROCESS ARM INSULATION WILL BE DONE WELD SHOP NO PLATING closed

15 01.09,2017 59140M78L00 T/M COUNT CABLE YE-3 GURGAON CD OUT DURING ASSY. PART TOUCH WITH TRANSMISSION BODY IN MSIL AND PART CD OUT. WELDING JIG ADJUSTED AND GAP MAINTAINED BETWEEN BODY AND BKT. PRESS SHOP NO PLATING closed

27 10.01.2018 49069M59R30 BRAKE PEDAL ASSY YL8 GURGAON SPOT FAIL CURRENT ERROR PLC SYSTEM MODIFIED ROBO SHOP NO ASSY closed

28 12.01.2018 23910M53M00 GUIDE CLUTCH YE3 GURGAON BKT OUT WELD PART SHIFTED DURING THE WELDING WELDING JIG HAS BEEN MODIFIED WELD SHOP YES PLATING closed

25 14.12.2017 72520M53M50 TRAY BATTERY YE3 D MANESAR FITMNET ISSUE DIM FOUND NG AS PER DRAWING TOOL HAS BEEN CORRECTED BOP NO PLATING closed

16 17.10.2017 65120-82P00 REINF.COMP ROOF FR. INNER YBA GURGAON DIM. NG PART DAMAGED DURING HANDLING DUE TO PART SUPPLY IN NON STANDERD TROLLEY. PART WILL BE DISPATCHED ONLY STANDERD TROLLEY. WELD SHOP NO WELD PDI closed

18 17/11/2017 65129M797E0 VAN PANEL OMNI GURGAON SPOT FAIL DURING WELDING OPERATION, TIP DRESSING NOT DONE BY OPERATOR BECAUSE TIP DRESSING SENSOR NOT WORKING. TIP DRESSING SENSOR CORRECTED AND A NEW LIGHT SYSTEM ALSO INSTALLED. WELD SHOP NO WELD PDI closed

13 19.08.2017 49511-62R00 BKT. ACCELERATOR YJC GURGAON CD OUT PART VARITION COMING IN 1ST PIERCING OPERATION DUE TO NO PROPER LOCATION PROVIDED IN DIE 1st PIERCING DIE MODIFIED (PROFILE LOCATION )TO CONTROL THE VARIATION PRESS SHOP NO PLATING closed

26 20.12.2017 65120M82P00 ROOF FR INNER YBA GURGAON HOLE UNDER SIZE BURR ON HOLE PUNCHING TOOL HAS BEEN CORRECTED PRESS SHOP NO WELD PDI closed

19 20/11/2017 23910M53M00 GUIDE CLUTCH CABLE YE3 GURGAON PUNCHING OUT DURING THE DRAW OPERATION PART GOTED SHIFTED TOOL HAS BEEN CORRECTED PRESS SHOP YES PLATING closed

14 22.08.2017 59140M78L00 BKT.COMP. FUEL TANK Fr. RH ECCO GURGAON WRONG PART WELD WRONG CHILD PART WELD DUE TO PLAY IN WELDING JIG. WELDING JIG CORRECTED AND TIGHT WITH TWO BOLT WELD SHOP YES ASSY closed

YES ASSY closed

20 23/11/2017 49069M59R30 BRAKE PEDAL ASSY YL8 GURGAON OVER WELDING OVER WELDING DONE ON PART DUE TO MORE STRENGTHEN OF WELDING EARLIER SUCH TYPE OF ISSUE NOT REPORTED NOW EXTRA WELDING STOP FOR ALL MODEL ROBO SHOP (BY DEVIATION)

21 27/11/2017 68721-68P00 REAR DOOR OUTER LH YRA MANESAR CRACK OIL NOT APPLIED ON SHEET DURING MANUFACTRING OF COIL BY SUPPLIER WORK INSTRUCTION DISPLYED ON LINE TO CONTROL THE ISSUES. PRESS SHOP YES PRESS PDI closed

22 28/11/2017 49069M79022 BREAK PEDAL ASSY OMNI GURGAON HOLE OVER SIZE DURING PIERCING OPERATION, OPERATOR DONE THE PIERCING TWO TIMES AFTER MOVING THR PART WORK INSTRUCTION DISPLYED ON LINE TO CONTROL THE ISSUES. BOP YES ASSY closed

WELD SHOP YES WELD PDI closed

 SHOP DEFECT
PLATING PDI 15
ASSY PDI 9
WELD PDI 8
PRESS DPI 2

SHOP CATCHABLE DEFECT

PLATING PDI 5
ASSY PDI 4
WELD PDI 4
PRESS DPI 1

SHOP DEFECT
WELD SHOP 10
BOP 8
PRESS SHOP 8
ASSY SHOP 4
DISAPTCH 1 P

PLATING PDI

10
 10

WELD SHOP

MONTH WISE DEFECT DEFECT QTY

APRIL 3
MAY 3
JUNE 3
JULY 5
AUGUST 1
SEPTEMBER 1
OCTOBER 1
NOVEMBER 6
DECEMBER 4
JANUARY 3
FEBRUARY 2
MARCH 3
 PDI WISE DEFECT
2017-2018
15

9
8

PLATING PDI ASSY PDI WELD PDI PRESS DPI

PDI WISE CATCHABLE DEFECT

2017-2018

4 4

PLATING PDI ASSY PDI WELD PDI PRESS DPI

SHOP WISE DEFECT DETAILS

2017-2018
10

8 8

4
 10

8 8

WELD SHOP BOP PRESS SHOP ASSY SHOP DISAPTCH