dis6w2h

8/13/2019 dis6w2h

1/14

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

2/14

U/IMPL

IMPL

IMPL

IMPL

U/IMPL

IMPL

STATUS

8/13/2019 dis6w2h

3/14

(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

4/14

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

5/14

Control Points

8/13/2019 dis6w2h

6/14

8/13/2019 dis6w2h

7/14

(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


PARTS

y e ec ve

parts reached on

line

Defect

generated at

which stage

/ cell


initiated


Immediate counter

action

( Inspection side )

PROCESS SIDE ACTION

PROBLEM

DESCRIPTIONMODEL

8/13/2019 dis6w2h

8/14

(A) (B) (C) (D) (E)

InspectionPoka

Availableinspectionnotad

equate

Acceptancestandardsnotc

ommon

NoinspectionatsuppliersEND

ProcessPokaYokefailed

1] FUNCTION

2] AESTHETIC

3] FITMENT


PARTS

y e ec ve

parts reached on

Defect

generated at

which stage

/ cell


initiated


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

9/14

Control Points

8/13/2019 dis6w2h

10/14

8/13/2019 dis6w2h

11/14

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

12/14

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

13/14

COUNTERMEASUR

EIMMEDIATE ACTION

WHAT WHERE WHICH WHY STATUSWHO WHEN

HOW TO DO

8/13/2019 dis6w2h

14/14

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

Documents

dis6w2h