Vii Sem

Body and paint shop Body Trimming

Chassis axle & engine assembly

Body, fenders assembly & roll down

Test cell

Conveyer Stores

AXLE

Transmission

Engine

FAI

Office Office

Road test CAI

RFI, Yard check and dispatch

 

 

   

Going to RFI every evening and observing all the defects If a similar manual error observed in multiple vehicles immediately cautioning the worker responsible and informing the cell officer. For vendor part error informing the SQA official Mr. Amol Desai and convincing him that it is a vendor defect. Observing all defects carefully and discussing it with the line officers to decide whether it’s a manual /vendor/process/design error . Making RFI data according to the discussion Assigning module to each defect. Giving feedback at morning standing meeting to the PU manager. Recording the action plan decided by PU manager and follow up of closed concerns at morning meeting.

Making cause and effect diagrams and why-why analysis to confirm the root cause  Disadvantage : Analysis done by a single person or a single dept. Team  Agreement issues while signing off the concerns  Lack of co-ordination 

Phase I

Conformity Analysis (L0) Yes

Concern Resolved NO

Phase II

QC Story initiated/Level 1(L1) analysis

Concern Resolved NO

Phase III

Design related concerns escalated to PVT Concern Closed

Yes

P

PLA N

A

1234-

Select the subject (theme/issue) Justify the choice Understand the current situation Select targets

ACT

D DO

P 9- Summarize and plan future action 8- Standardize

A

D C

7- Confirm the effects

CHECK

5- Analyze 6- Implement corrective measures

C

Fuel tank

Eye end of fuel main pipe

Copper washers

Banjo bolt Fuel main pipe

Brake fluid reservoir

Sensor

BRAKE BOOSTER

Terminal backout

Leaking joint

Clutch fluid reservoir

Clutch Bundy tube Clutch fluid filter

Before

After

AFTER

BEFORE

Mechanical torque wrench

Torque sensing device and Alarm

Mechanical cum Electronic torque wrench

Wheel sensor

 A break in the surface of a thing made by scratching, or by rubbing with anything pointed or rough; a slight wound, mark, furrow, or incision is identified as a scratch. EFFECTS ON CUSTOMER:  Scratches play an important role in body aesthetics of the vehicle.  Decreases the strength of the effected part and make it prone to rusting.  Customer dissatisfaction.  w, or incision is identified as a scratch.

200

0 PVT / 171

PROCESS

DEFECTS

110

OTHER PU/ 34

99

PROBLEM

SHORTAGE

97

DEFECTS

92

RELATED

DESIGN

565

VENDOR

600

DEFECTS

800

MANUAL

1000

DEFECTS

1200

SCRATCHES

1400

1171 120

100

66 80

538

400 100

80

60

40

20

0

 PFC  PFMEA  CP

FORMATS