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8/13/2019 dis6w2h
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COUNTERMEASURE IMMEDIATE ACTION
Horn cable cut
At Engine
upper bkt
tightening
Stage
DiscoverHorn cable pinchedin between engine
upper bkt. & Engine
Horn cable length
reduced by 40mm &
position of cable shift
away.
Take care while fitment
of Engine upper bkt.
DHOOTTRANSMISS
ION
March.08
Gear shifter
lever bolt head
damaged
Gear shifter
lever fitment
stage
Discover
Axis not match due
to gun foul to
engine base plate
Gear shifter lever bolt
tightening socket
length increased.
Bolt tight by ring
spanner
VEHICLE
ASSEMBLYJune.07
Chain cover
bolt threading
& bkt. nut
threading
damaged
Chain cover
fitment stageDiscover
Axis not match due
to gun faul to swing
arm (New design)
Chain cover bolt
tightening with special
steped socket.
Bolt tight by T' spannerVEHICLE
ASSEMBLYDec.08
Speedo meter
glass scratches
Fairing S/A
stagePulsar Handling ignorance
Scratch guard(Plastic
film) introduced on
glass.
Take care while
assembling
VARROC
&
PRICOL
April.07
Fuel pipe
leakage
Carborrator
fitment stagePulsar
Fuel Pipe pinched
while carb. fitment
Carborrator tubeangle changed for fuel
pipe fitment .
Take care whileassembling of
carborrator on AC box
UCAL
MIKUNIPlan
Fairing
scratches
Fairing
fitment stagePulsar
Brakekit touching to
other fairing on
trolley
Trolley modification.
Fairing s/a locate one by
one on trolley to mainten
distance between two
s/a
VEHICLE
ASSEMBLYJuly.07
6 W 2 HWHO WHEN
HOW TO DOWHAT WHERE WHICH WHY
8/13/2019 dis6w2h
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U/IMPL
IMPL
IMPL
IMPL
U/IMPL
IMPL
STATUS
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(A) (B) (C) (D) (E)
InspectionPoka
Ava
ilableinspectionnotadequate
Acce
ptancestandardsnotcom
mon
No
inspectionatsuppliersE
ND
ProcessPokaYokefailed
1] Accelerator
stickyDiscover 1]
1] Carburettor
2] Reed switch bkt
3] Acceln cable
E100% 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
jamDiscover 3]
1]Rear wheel
2]Rear wheel brake
pannel
3]
A100% inspection at kit
bin loading
Rear brake
pannel
fitment
Brake shoe liner
machining incomplete
100 % inspection at
vendor end for OD
3] Front wheel
axle insertion not
possible
Discover 3]1] Front wheel
2]Fr.wh. axle
3]Fr. Wh. SpacerC 100% inspection at kit
bin loadingFront wheelfitment stage
Front wheel axle O/Doversize
100 % inspection of
front wheel axle OD
at vendor end
4]Front & Rear
wheel paint
uncover
Discover 2]1]Front wheel
2]Rear wheelC
100% inspection at
Front wheel fitment
stage
Front wheel
fitment stageIncomplete painting
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. SpacerA
100 % inspection at kit
bin loading stage
Front wheel
fitment stage
Front wheel spacer ID
u/s
100 % inspection of
spacer ID at vendor
end
Defect
generated at
which stage
/ cell
Root causeCorrective action
initiated
INTERNAL CUSTOMER COMPLAINT ANALYSIS ( QSR )
Immediate counter
action
( Inspection side )
PROCESS SIDE ACTION
PROBLEM
DESCRIPTIONMODEL
1] FUNCTION
2] AESTHETIC
3] FITMENT
QTY IN %CONTRIBUTING
PARTS
y e ec ve
parts reached on
8/13/2019 dis6w2h
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6]LH side panel
lock operation
hard.
Discover 3]1] Chassis
2]Side lockA
100% inspection at
chassis shop before
chassis loading
Side pannel
fitment
Side panel bracket
position shifted
Welding fixture
corrected to
maintain exact
bracket position.
8/13/2019 dis6w2h
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Control Points
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8/13/2019 dis6w2h
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(A) (B) (C) (D) (E)
InspectionPoka
A
vailableinspectionnotade
quate
Acceptancestandardsnotco
mmon
Noinspectionatsuppliers
END
ProcessPokaYokefaile
d
1] Head lamp not
workPulsar 1]
1] Head lamp
2] RH switch base
3] RR unit
4]BCU
B
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
startPulsar 1]
1]CDI unit
2]Magneto
3]H. T Coil
4] Spark plug
A100% 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]Seat100% 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
bracket broken
Pulsar 3]
1]Chassis
Clutch cable
routingbracket
C
100% inspection at
chassis shop before
chassis loading
Clutch cable
connection
stage
Bracket strength
weak
Bracket modify with
stronger design.
1] FUNCTION
2] AESTHETIC
3] FITMENT
QTY IN %CONTRIBUTING
PARTS
y e ec ve
parts reached on
line
Defect
generated at
which stage
/ cell
Root causeCorrective action
initiated
INTERNAL CUSTOMER COMPLAINT ANALYSIS ( QSR )
Immediate counter
action
( Inspection side )
PROCESS SIDE ACTION
PROBLEM
DESCRIPTIONMODEL
8/13/2019 dis6w2h
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(A) (B) (C) (D) (E)
InspectionPoka
Availableinspectionnotad
equate
Acceptancestandardsnotc
ommon
NoinspectionatsuppliersEND
ProcessPokaYokefailed
1] FUNCTION
2] AESTHETIC
3] FITMENT
QTY IN %CONTRIBUTING
PARTS
y e ec ve
parts reached on
Defect
generated at
which stage
/ cell
Root causeCorrective action
initiated
INTERNAL CUSTOMER COMPLAINT ANALYSIS ( QSR )
Immediate counter
action
( Inspection side )
PROCESS SIDE ACTION
PROBLEM
DESCRIPTIONMODEL
5] Neutral
connection not
possible
Pulsar 3] 1]Harness
100% inspection at
chassis shop before
chassis loading
Magneto
connection
stage
Bullet coupler
damaged in handling
Single pole coupler
provided
6] Silencer
mettalic / spatter
noise
Pulsar 1] 1]Silencer D100 % inspection on
stage
PV
inspection
stage
Welding spatter
falling inside
resonator box
New welding fixture
installed to keep
resonator box
position horizontal
during welding.
8/13/2019 dis6w2h
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Control Points
8/13/2019 dis6w2h
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Chain
cover
middle
mtg. bkt.
Nut
damged
Chain
cover
fitment
Discover Bolt t
0
NOV
.
03JUN
E
JUL
L
YAUG
.
WHAT WHERE WHICH WHY
8/13/2019 dis6w2h
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COUNTERM
EASURE
IMMEDIAT
E ACTION
39 86 0
CDI Mtg.
Bkt
Angle
change .
CDI
Mtg.Bkt.
bending
started
previous
PT
fitment
stage
AUTO
COMP
IMPL
HOW TO DO
WHO WHEN STATUS
SEPT.
JAN
.0
6APR
I
L.06
TAR
G
ET
8/13/2019 dis6w2h
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COUNTERMEASUR
EIMMEDIATE ACTION
WHAT WHERE WHICH WHY STATUSWHO WHEN
HOW TO DO
8/13/2019 dis6w2h
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BM TRG COUNTERMEASURE IMMEDIATE ACTION
DiscoverHorn cable
cut
At Engine
upper bkt
tightening
Stage
Horn cable pinchedin between engine
upper bkt. & Engine
8 0
Horn cable length
reduced by 40mm &
position of cable shift
away.
Take care while fitment
of Engine upper bkt.
DHOOTTRANSMISS
ION
March.08 U/IMPL
Discover
Gear shifter
lever bolt
head
damaged
Gear shifter
lever fitment
stage
Axis not match due
to gun foul to
engine base plate
15 0
Gear shifter lever bolt
tightening socket
length increased.
Bolt tight by ring
spanner
VEHICLE
ASSEMBLYJune.07 IMPL
Discover
Chain cover
bolt threading
& bkt. nut
threading
damaged
Chain cover
fitment stage
Axis not match due
to gun faul to swing
arm (New design)
34 0
Chain cover bolt
tightening with special
steped socket.
Bolt tight by T' spannerVEHICLE
ASSEMBLYDec.08 IMPL
Pulsar
Speedo meter
glass
scratches
Fairing S/A
stageHandling ignorance 6 0
Scratch guard(Plastic
film) introduced on
glass.
Take care while
assembling
VARROC
&
PRICOL
April.07 IMPL
PulsarFuel pipe
leakage
Carborrator
fitment stage
Fuel Pipe pinched
while carb. fitment29 0
Carborrator tube
angle changed for fuel
pipe fitment .
Take care while
assembling of
carborrator on AC box
UCAL
MIKUNIPlan U/IMPL
PulsarFairing
scratches
Fairing
fitment stage
Brakekit touching toother fairing on
trolley
12 0 Trolley modification.Fairing s/a locate oneby one on trolley to
mainten distance
between two s/a
VEHICLE
ASSEMBLYJuly.07 IMPL
WHAT WHEREWHICH WHYHOW MANY
STATUSWHO WHENHOW TO DO
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