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