final pulsar

HOME WORK

DESIGN REVIEW MANUALTheme :- Design For AssemblyCell :- Pulsar ( LHS )

Stage Description Part Name Part Number

Category

Activity / Problem Idea Kaizen ID No NPDS Stage DR Point For Review

1 LH 1 N

2 LH 2 Rear axle DJ151032 N

3 LH 3 Battery Fitment

DJ161247 N

DJ201125 N

CDI DH111064 N

4 LH 4DJ161132 N

Bolt ( M6 ) 39168004 N

5 LH 5 Engine Insertion

DJ161081 N

39245504 N

Sr No

Stage No

Motion Loss Applicability

Y / N 1.1

P

rep

ara

tory

Chassis Loading On Conveyor

Rear Axle Insertion

Battery Band

Battery MF Wet Charged 9 AH

LH Harness Clamp Fitment

Hook - Harness :- LH

LH Engine Hanging plate

Bolts (M8*65 & M8*55)


Category

Activity / Problem Idea Kaizen ID No NPDS Stage DR Point For ReviewSr No

Stage No


Y / N 1.1

P

rep

ara

tory

6 LH 6

Bolt 39241304 N

DJ161114 N

DJ161115 N

39241404 N

7 LH 7 N

8 LH 8 Chain N

9 LH 9 Y a CPV_08_DR_009 Fixed clamp

Engine bracket bolt insertion

Rear LH bracket

LH center bracket

Allen bolt ( M 8 )

Magneto connection

Engine torque checking & chain routine

Rear wheel alignment

Magneto cable band

Separate band required to tie up on chassis for holding magneto cable

Fixed clamp to be provided on chassis itself to route magneto cable

Design _ Proto 24.3 _ 8b


Category


Stage No


Y / N 1.1

P

rep

ara

tory

10 LH 10

52DH0309 N

Bolts ( M 6 ) DH161283 N

washer Y a CPV_08_DR_011 Combine

11 LH 11

DH101397 N

DJ101211 N

Bolt ( M6 ) 39167304 N

Metal ring

Y a CPV_08_DR_013 Combine

Rubber ring

M 6 Bolt N

Chain case fitment

Upper & lower chain case

Required to make s/a of bolt & washer for chain case fitment

Flange bolt provided instead of separate bolt & washer

Design Basic4.1 _ 4b

Gear Shifter Lever Fitment

Gear shift lever

Rear cover RR

Required to make s/a of metal & rubber rings for fitment

To provide metal crimp with rubber ring for fitment



Category


Stage No


Y / N 1.1

P

rep

ara

tory

12 LH 12

DJ161130 N

M8 Bolts 39231004 Y a CPV_08_DR_014 Pre coated

N

13 LH 13 Handle bar 52DH0169 N

14 LH 14N

Washer N

15 LH 15

DG181008 N

DJ181009 N

AC Box clip DH121142 N

16 LH 16

Carburettor DJ101232 N

N

17 LH 17 A C Box clip N

18 LH 18 N

19 LH 19 N

20 LH 20DH161310 N

DH141002 N

21 LH 21 N

22 LH 22N

LH main step fitment

LH main step

Required to make s/a of spring washer with bolt for main step fitment

Precoated bolts provided for LH main step fitment


Spring washer

Handle bar fitment

Fork Bracket Center Bolt Tightening

Center Fork bolts

LH mud guard fitment

Allen bolts ( M 8 )

Fork cap rubber grommet

Carburettor fitment Earthing

cable grommet

A C Box clip tightening

Accelerator Connection


LH Harness Connection

LH side harness terminal connection

LH seat cowl decal pesting

LH side decal

PT drain pipe clip

Battery Connection

LH Bellow insertion

LH bellow insertion


Category


Stage No


Y / N 1.1

P

rep

ara

tory

22 LH 22N

23 LH 23

Petrol Tank DJ710122 N

Bolt 39155604 N

Washer 39074011 Y a CPV_08_DR_024 Combine

LH Bellow insertion Case meter

connection

Petrol Tank fitment

Required to make s/a of PT bolt with washer

Bolt with integrated washer provided



Category


Stage No


Y / N 1.1

P

rep

ara

tory

24 LH 24Grab handle DJ161263 N

Bolt N

25 LH 25

Side panel 52DK5506 N

33161018 N

Y a CPV_08_DR_025 Desired thread length

26 LH 26

52DJ0182 N

52DH0248 N

52DH0248 N

75261601 N

PV card 75118821 N

Grab Handle fitment

LH side panel fitment

Side lock grommet

Side panel lock

More preparatory time required for removing nut from panel lock for s/a

Thread length to be reduced for reducing panel lock nut tightening time.


Chassis Number Punching

Frame Sub Assly K2 ES UG3

Bearing Race Upper

Bearing Race lower

Barcode sticker

HOME WORK

DESIGN REVIEW MANUALTheme :- Design For AssemblyCell :- Pulsar ( RHS )


Category


1 RH 1 Rear Wheel DJ151090 N

2 RH 2

DJ151034 N

DH151060 N

Bearing ball Y a CPV_08_DR_027 Single piece

Grease N

3 RH 3

Fork 52DJ0130 N

DH181025 N

DH181014 Y aCPV_08_DR_028 Combine

Fork Nut 30181018 Y a

Y aCPV_08_DR_013 Combine

4 RH 4

Mud guard 52DH0278 N

DH161258 N

DG181008 N

N

Sr No

Stage No


Y / N

1.1

Pre

para

tory

Rear Wheel Loading

Rear wheel spacer insertion

Rear wheel spacer

Rear brake panel

Bearing ball is to place on fixture for collecting with the help of tool for fitment on bearing races

Ball cage provided instead of loose balls


Fork fitment stage

Bearing Cone

Cup Steering First to place stearing cup on

bearing cone & then tightening fork with lock nut

Lock nut welded with stearing cup


Metal & rubber ring

Required to make s/a of metal & rubber ring for fitment

Metal ring with rubber coating


Mud guard fitment stage

Brace fender

Allen bolts ( M 6 )

Painted set loading


Category


Stage No


Y / N

1.1

Pre

para

tory

5 RH 5

52DH0317 N

Bolt Y a

Single piece CPV_08_DR_029 CombineY a

Spacer Y a

DH121130 N

DJ151041 N

6 RH 6

Front wheel N

Case meter DH151062 N

Spacer DS151058 N

59150003 Y a CPV_08_DR_031 Combine

39078111 N

7 RH 7

DH161190 N

DJ161271 N

59150005 N

Front Number Plate Fitment

Front number plate

Required to make s/a of bolt , washer & spacer


Plain washer

Magnet ( Self cancellation )

Front axle with grease application

Front wheel fitment Front axle

lock nutSplit pin required to fit on front axle

Lock nut introduced instead of simple nut


Front axle washer

Engine bracket fitment stage

RH front bracket

RH rear bracket

Hanging plate nuts ( M 8 )


Category


Stage No


Y / N

1.1

Pre

para

tory

8 RH 8 N

9 RH 9

39245504 N

59150005 N

DH171019 N

10 RH 10 N

11 RH 11 59150003 Y a CPV_08_DR_033 Pre coated

12 RH 12Lock nuts DH161245 N

Simple nuts 59150005 N

13 RH 1352DJ0226 N

M13 bolts 39258204 N

Engine fitment stage

Center bracket tightening stage

Center bracket bolt ( M12 )

Hanging plate nuts ( M8 )

Rear axle nut

Fairing Fitment Stage

Fairing Assembly

Front brake kit routine stage

Bolt with locktite application

Locktite to apply on bolt before fitment

Pre locktite bolt introduced for brake kit fitment


Engine tightening stage

Front wheel tightening stage

RH step holder


Category


Stage No


Y / N

1.1

Pre

para

tory

14 RH 14

Rod end 15191026 N

39231004 N

Y a CPV_08_DR_034 Pre coated

DJ161131 N

Adjuster nut DH191045 N

Spring 30191035 N

39019811 N

15 RH 15

Brake padel DH191001 N

39176904 N

30151096 N

16 RH 16


DH171019 N

39079415 N

Brake connection stage

M8 main step bolt

Spring washer

Required to make s/a of spring washer with bolt

Pre coated bolt to be introduced for main step fitment


Main step RH

Plain washer

Brake padel fitment stage

Flange bolt (M12)

Torque rod bolt

Rear wheel tightening stage

Spring washer - T Rod

Spring washer required to place on bolt before nut tightening

Flange lock nut to be introduced


Center axle nut (M22)

Torque rod nut (M14)


Category


Stage No


Y / N

1.1

Pre

para

tory

17 RH 17

N


Nut N

18 RH 18 N

19 RH 19 Seat cowl DK7303ZZ N

20 RH 20 N

21 RH 21 N

22 RH 22 N

Starter motor connection stage

Starter motor grommet

Spring washer

Starter motor on engine from engine assembly with spring washer & nut - During connection spring washer & nut has to take out then after keeping terminal connection to be done with placing spring washer & nut

Instead of spring washer , surreted nut in loose condition directly at final assembly stage


Front brake kit tightening stage

Upper lever tightening

Seat cowl fitment stage

RH Harness connection stage




Category


Stage No


Y / N

1.1

Pre

para

tory

23 RH 23

Silencer DJ101259 N


39024811 N

DD161071 N

Flange bolts 39185004 N

Flange nuts 59150005 N

Gasket DJ101064 N

24 RH 24 Snap pin DH151055 N

25 RH 25

39194304 N

Washers 39178924 Y a CPV_08_DR_040 Combine

26 RH 26 N

Silencer fitment stage

Plain big washer

Big plain washer has to place at rear mounting

Press fit bush with washer introduced


Small washer

Lock nuts (M17)

Silencer tightening stage

Seat cowl tightening stage

Flange bolts (M6)

Required to make s/a of plastic washer with tightening bolt

Bolt with press fitment plastic washer


Carburettor clip tightening stage


Category


Stage No


Y / N

1.1

Pre

para

tory

27 RH 27 N

28 RH 28

Side panel N

N

N

N

29 RH 29 Vehicle inspection N

Clutch connection stage

Side panel sub assembly stage

RH side seat cowl decal

Side lock grommet

Side panel lock

Battery terminal removal

HOME WORK

DESIGN REVIEW MANUALTheme :- Design For AssemblyCell :- Pulsar ( LHS )


Category


1 LH 1 N

2 LH 2 Rear axle DJ151032 Y a Hard to insert rear axle. CPV_08_DR_001


DJ161247 Y a CPV_08_DR_002 Clip type design

DJ201125 N

CDI DH111064 N

4 LH 4DJ161132 Y a CPV_08_DR_003 Line mark for reference

Bolt ( M6 ) 39168004 N


DJ161081 N

39245504 N

Sr No

Stage No


Y / N 1.1

P

rep

ara

tory

1.2

. D

ifficu

lt

To A

ssem

ble

1.3

. D

ifficu

lt

To A

ccess

1.4

. D

ifficu

lt

To I

den

tify


Rear Axle Insertion

Provide entry chamfer of 1.5 X 45 degree at start of threading portion & 2 X 30 degree at the end of threading portion.


Entry chamfer of 1.5 X 45 degree at start of threading portion & 2 X 30 degree at the end of threading portion.

Battery Band

Battery band is difficult to insert in chassis bracket ( Rod design )

Band locking design change from rod type to hook type

Design _ Proto 14.2 _ 8a




Difficult to identify the correct position harness clamp on chassis

Stopper / line mark / embossing on chassis for reference for exact position of hook on chassis



Bolts (M8*65 & M8*55)


Category


Stage No


Y / N 1.1

P

rep

ara

tory

1.2

. D

ifficu

lt

To A

ssem

ble

1.3

. D

ifficu

lt

To A

ccess

1.4

. D

ifficu

lt

To I

den

tify

6 LH 6

Bolt 39241304 N

DJ161114 Y a CPV_08_DR_004

DJ161115 Y a CPV_08_DR_005

39241404 N

7 LH 7 Y

a CPV_08_DR_006

a CPV_08_DR_007 Coupler type design

8 LH 8 Chain Y a CPV_08_DR_008 Identification for direction

9 LH 9 Y a CPV_08_DR_009 Fixed clamp


Rear LH bracket

Difficult to identify correct bracket for fitment

Bold embossing with colour filling to be provided on bracket for clear identification


Bold embossing with colour filled

LH center bracket





Allen bolt ( M 8 )

Magneto connection

Difficult to access coupler for magneto connection

Harness length increase for easy access

Pre Pilot Production5 _ 5

50mm more length for every coupler connection.

Difficult to assemble neutral coupler due to bullet type

Bullet type connection to be change to coupler type



Difficult to identify correct direction chain while routine

Yellow color strip with clear identificaion provided on chain for clear identification



Magneto cable band

Separate band required to tie up on chassis for holding magneto cable

Fixed clamp to be provided on chassis itself to route magneto cable



Category


Stage No


Y / N 1.1

P

rep

ara

tory

1.2

. D

ifficu

lt

To A

ssem

ble

1.3

. D

ifficu

lt

To A

ccess

1.4

. D

ifficu

lt

To I

den

tify

10 LH 10

52DH0309 Y a CPV_08_DR_010 Relieve to avoid fouling

Bolts ( M 6 ) DH161283 N

washer Y a CPV_08_DR_011 Combine

11 LH 11

DH101397 Y a CPV_08_DR_012

DJ101211 N

Bolt ( M6 ) 39167304 N

Metal ring


Rubber ring

M 6 Bolt N

Chain case fitment


Difficult to assemble upper & lower chain case on vehicle due to touching of chain case to swing arm welding gusset.

Relieve provided on upper & lower chain case to avoid touching of chain case to swing arm at welding gusset for easy matching


Required to make s/a of bolt & washer for chain case fitment

Flange bolt provided instead of separate bolt & washer



Gear shift lever

Difficult to maintain correct position of GSL during fitment

GSL mouting boss to be modified , instead of surretion it should be square or hexagonal type.


Square / Hexagonal design instead of serretion

Rear cover RR

Required to make s/a of metal & rubber rings for fitment




Category


Stage No


Y / N 1.1

P

rep

ara

tory

1.2

. D

ifficu

lt

To A

ssem

ble

1.3

. D

ifficu

lt

To A

ccess

1.4

. D

ifficu

lt

To I

den

tify

12 LH 12

DJ161130 N

M8 Bolts 39231004 Y a CPV_08_DR_014 Pre coated

N


14 LH 14N

Washer N

15 LH 15

DG181008 Y a CPV_08_DR_015 Clamping from out side

DJ181009 Y a CPV_08_DR_016 Combine

AC Box clip DH121142 Y a CPV_08_DR_017 Sufficient clearance

16 LH 16

Carburettor DJ101232 Y a CPV_08_DR_018 Identification

N


LH main step

Required to make s/a of spring washer with bolt for main step fitment

Precoated bolts provided for LH main step fitment


Spring washer

Handle bar fitment


Center Fork bolts


Allen bolts ( M 8 )

Mud guard brace fender bolt tightening is not easy due to mounting from in side

Mud guard with brace fender mounting provided from out side



Hammer & special tool required for pressing rubber cap on fork

Instead of allen bolt , hexagonal bolt to be provided to cover cavity of fork bracket


Difficult to assemble carburettor clip on carburettor bellow

AC Box clip diameter increased from 50 mm to 52 mm


Carburettor fitment

Difficult to identify correct carburettor for fitment as per model

Model identification sticker pested on carburettor for easier identification


Earthing cable grommet


Category


Stage No


Y / N 1.1

P

rep

ara

tory

1.2

. D

ifficu

lt

To A

ssem

ble

1.3

. D

ifficu

lt

To A

ccess

1.4

. D

ifficu

lt

To I

den

tify

17 LH 17 A C Box clip Y a CPV_08_DR_019 Sufficient access

18 LH 18 N

19 LH 19 Y a CPV_08_DR_020

20 LH 20DH161310 Y a CPV_08_DR_021 Projection for easy removal

DH141002 N

21 LH 21 N

22 LH 22

Y a CPV_08_DR_022 Enough space

Y a CPV_08_DR_023 Wire type bracket

23 LH 23

Petrol Tank DJ710122 N

Bolt 39155604 N

Washer 39074011 Y a CPV_08_DR_024 Combine


Difficult to access carburettor clip due to clip tightening screw head located behind chassis pipe

Provide access for tightening.






Difficult to access LH harness coupler for connection

Harness length increased by 50mm for easy access of harness coupler for connection




LH side decal

Difficult to take out decal rapper for pesting on seat cowl

Cut section provided on decal for easy removal


PT drain pipe clip

Battery Connection

LH Bellow insertion

LH bellow insertion

Hard to insert bellow inside fairing cavity

Fairing cavity to be increased


Case meter connection

Hard to insert case meter cable upper grommet in number plate bracket

Number plate bracket should be modified like Discover brake kit


Petrol Tank fitment

Required to make s/a of PT bolt with washer

Bolt with integrated washer provided



Category


Stage No


Y / N 1.1

P

rep

ara

tory

1.2

. D

ifficu

lt

To A

ssem

ble

1.3

. D

ifficu

lt

To A

ccess

1.4

. D

ifficu

lt

To I

den

tify

24 LH 24Grab handle DJ161263 N

Bolt N

25 LH 25

Side panel 52DK5506 N

33161018 N


26 LH 26

52DJ0182 Y a Tackle modified CPV_08_DR_026 Access for tackle

52DH0248 N

52DH0248 N

75261601 N

PV card 75118821 N

Grab Handle fitment


Side lock grommet

Side panel lock






Difficult to insert tackle hook in chassis for lifting - No space between A C Box & Chassis frame.


Bearing Race Upper

Bearing Race lower

Barcode sticker

HOME WORK

DESIGN REVIEW MANUALTheme :- Design For AssemblyCell :- Pulsar ( RHS )


Category



2 RH 2

DJ151034 N

DH151060 N

Bearing ball Y a CPV_08_DR_027 Single piece

Grease N

3 RH 3

Fork 52DJ0130 N

DH181025 N

DH181014 Y aCPV_08_DR_028 Combine

Fork Nut 30181018 Y a

Y aCPV_08_DR_013 Combine

4 RH 4


DH161258 Y a CPV_08_DR_015 Clamping from out side

DG181008 N

N

Sr No

Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

Rear Wheel Loading


Rear wheel spacer

Rear brake panel

Bearing ball is to place on fixture for collecting with the help of tool for fitment on bearing races

Ball cage provided instead of loose balls


Fork fitment stage

Bearing Cone

Cup Steering First to place stearing cup on

bearing cone & then tightening fork with lock nut

Lock nut welded with stearing cup


Metal & rubber ring

Required to make s/a of metal & rubber ring for fitment

Metal ring with rubber coating



Brace fender

Mud guard brace fender bolt tightening is not easy due to mounting from in side

Mud guard with brace fender mounting provided from out side


Allen bolts ( M 6 )

Painted set loading


Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

5 RH 5

52DH0317 N

Bolt Y a

Single piece CPV_08_DR_029 CombineY a

Spacer Y a

DH121130 N

DJ151041 N

6 RH 6

Front wheel N

Case meter DH151062 Y a CPV_08_DR_030 Strong design

Spacer DS151058 N


39078111 N

7 RH 7

DH161190 Y a CPV_08_DR_004

DJ161271 Y a CPV_08_DR_005

Front Number Plate Fitment

Front number plate

Required to make s/a of bolt , washer & spacer


Plain washer

Magnet ( Self cancellation )

Front axle with grease application

Front wheel fitment

Difficult to assemble case meter in front due to clip bending

Strengthening required to improve for the clip to avoid bending


Front axle lock nut

Split pin required to fit on front axle

Lock nut introduced instead of simple nut


Front axle washer


RH front bracket





RH rear bracket






Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

7 RH 7

59150005 Y a CPV_08_DR_032 Identification



Difficult to identify correct nut for fitment

Passivation of nut be change for clear identification



Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

8 RH 8 N

9 RH 9

39245504 N

59150005 N

DH171019 N

10 RH 10 N

11 RH 11 59150003 Y a CPV_08_DR_033 Pre coated

12 RH 12

Lock nuts DH161245 Y a CPV_08_DR_032 Identification

Simple nuts 59150005 Y a CPV_08_DR_032 Identification

13 RH 1352DJ0226 N

M13 bolts 39258204 N





Rear axle nut


Fairing Assembly



Locktite to apply on bolt before fitment

Pre locktite bolt introduced for brake kit fitment


Engine tightening stage

Difficult to identify correct nut for fitment ( Lock nut & simple nut )

Passivation of simple nut & lock nut to be change


Difficult to identify correct nut for fitment ( Lock nut & simple nut )

Passivation of simple nut & lock nut to be change



RH step holder


Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

14 RH 14

Rod end 15191026 N

39231004 N

Y a CPV_08_DR_034 Pre coated

DJ161131 N

Adjuster nut DH191045 N

Spring 30191035 N

39019811 Y a

15 RH 15

Brake padel DH191001 Y a CPV_08_DR_035

39176904 N

30151096 N

16 RH 16


DH171019 N

39079415 N


M8 main step bolt

Spring washer

Required to make s/a of spring washer with bolt

Pre coated bolt to be introduced for main step fitment


Main step RH

Plain washer


Difficult to identify correct position of brake padel on vehicle

Brake padel mouting boss to be modified , instead of surretion it should be square or hexagonal type.



Flange bolt (M12)

Torque rod bolt



Spring washer required to place on bolt before nut tightening

Flange lock nut to be introduced





Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

17 RH 17

N


Nut N

18 RH 18 N

19 RH 19 Seat cowl DK7303ZZ N

20 RH 20 Y a CPV_08_DR_020

21 RH 21 Y a CPV_08_DR_020

22 RH 22 Y a CPV_08_DR_020



Spring washer

Starter motor on engine from engine assembly with spring washer & nut - During connection spring washer & nut has to take out then after keeping terminal connection to be done with placing spring washer & nut

Instead of spring washer , surreted nut in loose condition directly at final assembly stage






Difficult to access required coupler on harness for connection















Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

23 RH 23

Silencer DJ101259 N


39024811 N

DD161071 N

Flange bolts 39185004 N

Flange nuts 59150005 N

Gasket DJ101064 N

24 RH 24 Snap pin DH151055 Y a CPV_08_DR_039

25 RH 25

39194304 N

Washers 39178924 Y a CPV_08_DR_040 Combine

26 RH 26 Y a CPV_08_DR_041 Sufficient access


Plain big washer

Big plain washer has to place at rear mounting

Press fit bush with washer introduced


Small washer

Lock nuts (M17)


Difficult to insert snap pin on troque rod bolt hole due to sharp bending

Bend provided on snap pin round area for getting grip to thump fingure to apply force for insertion on torque rod bolt hole


Bend for thumb support

Seat cowl tightening stage

Flange bolts (M6)

Required to make s/a of plastic washer with tightening bolt

Bolt with press fitment plastic washer



Difficult to access clip tightening mounting head due to chassis tube

Provide access for tightening for tightening.



Category


Stage No


Y / N

1.1

Pre

para

tory

1.2

. D

ifficu

lt T

o

Assem

ble

1.3

. D

ifficu

lt T

o

Access

1.4

. D

ifficu

lt T

o

Iden

tify

27 RH 27 N

28 RH 28

Side panel N

N

N


29 RH 29 Vehicle inspection Y a CPV_08_DR_043 Easy access




Side lock grommet

Side panel lock





Difficult to remove battery negative terminal

Negative terminal taken to front side of battery


HOME WORK

DESIGN REVIEW MANUALTheme :- Defect Loss Cell :- Pulsar ( LHS )


CATEGORY


2 LH 2

Y CPV_08_DR_044 Combine

Y CPV_08_DR_045 Identification

3 LH 3 Rear axle DJ151032 Y CPV_08_DR_046 Identification


Battery Band DJ161247 N

DJ201125 N

CDI DH111064 Y CPV_08_DR_047 Identification

Sr No

Stage No

Defect Loss Applicability

Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR


Sprocket Assembly

2.2 MissingPossibility of rear wheel rubber damper missing

Rubber damper in single piece


2.5 Wrong part assembly

Possibility of wrong part assembly of sprocket assembly ( K1 & K2 )

Sprocket passivation to be change for sprocket ( Blue for K1 & Golder for K2 )


Rear Axle Insertion

2.5 Wrong Part assemblyPulsar rear axle can be interchange with JC or JM rear axle

Passivation to be different for Pulsar & JC rear axle



2.5 Wrong part assemblyPossibility of CDI mis match ( K1 & K2 )

Body colour to be change for K1 & K2 CDI for identification



CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

5 LH 5DJ161132 N CPV_08_DR_048 Commonisation

Bolt ( M6 ) 39168004 N


DJ161081 Y CPV_08_DR_004

39245504 N

7 LH 7

Bolt 39241304 N

DJ161114 Y CPV_08_DR_005

DJ161115 Y CPV_08_DR_006

39241404 N

8 LH 8 Y CPV_08_DR_049 Coupler type design

9 LH 9 Y CPV_08_DR_008 Identification for direction



2.5 Wrong part assemblyPossibility of LH side hook fitted on RH side & vice a versa

Common design for LH & RH side harness hook



2.5 Wrong part assemblyPossibility of wrong hanging plate fitment

Bold embossing with colour fill to be change for hanging plates



Bolts (M8*65 & M8*55)


Rear LH Bracket

2.5 Wrong part assemblyPossibility of wrong bracket fitment




LH Center Bracket

2.5 Wrong part assemblyPossibility of wrong bracket fitment




Allen bolt ( M8 )

Magneto Connection

2.5 Loose

Possibility of loose connection of magneto due to bullet type terminal.

Coupler type terminal introduced.


Engine Torque Checking

Chain Routine

2.1 ReversePossibility of reverse direction of chain.

Yellow colour clip added on chain link for knowing correct direction chain.



CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

10 LH 10

Y CPV_08_DR_009 Fixed clamp

Y CPV_08_DR_051 Both side identification

11 LH 11

52DH0309 Y CPV_08_DR_052 Relieve to avoid fouling

Bolts (M10) DH161283 N

Washer Y CPV_08_DR_011 Combine

12 LH 12

DH101397 Y CPV_08_DR_053

DJ101211 N

Bolt ( M 6 ) 39167304 N

Metal RingY CPV_08_DR_013 Combine

N

Rubber RingY CPV_08_DR_013 Combine

N

M6 Bolt N

Rear Wheel Alignment

Magneto cable band

2.3 Loose Possibility of loosening of magneto cable due to cable holding with band

Fixed clamp to be on chassis itself to hold magneto cable firmly


2.8 Adjustment Not Good

Possibility of chain adjuster marking adjustment not done correctly

Marking provided on both side of chain adjuster for easy and correct adjustment.


Chain case fitment

Upper and Lower Chain case

2.7 Not MatchingPossibility of upper & lower chain case not matching with each other

Relieve provided on upper & lower chain case to avoid touching of chain case to swing arm at welding gusset for complete matching


2.2 MissingPossibility of washer missing

Flange bolt instead of washer.



Gear Shift Lever

2.6 Mis orientationPossibility of wrong positioning of gear shift lever

GSL mouting boss to be modified , instead of surretion it should be square or hexagonal type for correct position.



Rear Cover (RR cover)

2.2 MissingPossibility of metal ring missing.



2.2 MissingPossibility of rubber ring missing.




CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

13 LH 13

DJ161130 N

M8 Bolts 39231004 N

Y Precoated bolts CPV_08_DR_014 Pre coated


15 LH 15N

Washer N

16 LH 16

DG181008 Y CPV_08_DR_015 Clamping from out side

DJ181009 Y CPV_08_DR_016 Combine

AC Box Clip DH121142 N

17 LH 17

Carburettor DJ101232 Y CPV_08_DR_018 Identification

N

18 LH 18 N

19 LH 19 N

20 LH 20 Y CPV_08_DR_054 Coupler type design

21 LH 21 N


LH Main Step Fitment

Spring washer

2.2 MissingPossibility of spring washer missing


Handle bar fitment


Center Fork bolts

LH Mud guard fitment

Allen Bolts (M8)

2.2 MissingPossibility of brace fender mud guard bolt missing

Bolt mounting from out side for clear visibility


Fork cap - Rubber Grommet

2.4 Not tightened fullyPossibility of fork cap rubber grommet not pressed fully

Instead of allen bolt , hexagonal bolt to be provided to cover cavity of fork bracket


Carburettor Fitment

2.5 Wrong part assemblyPossibility of wrong carburettor fitment

Model identification sticker on carburettor cap


Earthing Cable Gromet

A C Box Clip Tightening





2.3 Loose

Possibility of loose connection of harness due to incomplete pressing of bullet terminal

Coupler type connector provided instead of bullet type connector


Battery Connection


CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

22 LH 22

DH161310 N

DH141002 N

23 LH 23

N

Y CPV_08_DR_055 Wire type design

24 LH 24

Petrol Tank DJ710122 NBolt 39155604 N

Washer 39074011 Y CPV_08_DR_024 Combine

25 LH 25Grab Handle DJ161263 N

Bolt N

26 LH 26

Side Panel 52DK5506 Y

N

33161018 N

Y CPV_08_DR_056 Strong design

1 LH 1

52DJ0182 N

Y CPV_08_DR_057 Non contact design

52DH0248 N

52DH0248 N

75261601 N

PV card 75118821 N

LH Seat Cowl Decal Pesting

LH Side Decal

Petrol Tank Drain Pipe Clip

LH Bellow Insertion

LH bellow insertion


2.3 Loose

Possibility of incomplete insertion of case meter cable upper grommet in number plate bracket

Number plate bracket should be modified like Discover brake kit


Petrol Tank Fitment

2.2 MissingPossibility of PT washer missing

Bolt with integrated washer


Grab Handle Fitment

LH Side Panel Fitment

2.3 Loose

RH Side Seat Cowl Decal

Side Lock Grommet

Side panel lock

2.3 LoosePossibility of side panel getting loose due to bracket bend

Provided strengthened bracket for side panel locking.




Side stand switch

2.9 PDI / EFR

Side stand switch mechanism not working due to mud accumulation on actuating button

Side stand switch mechanism change from mechanical type to electromagnetic type


Bearing Race Upper

Bearing Race lower

Barcode sticker

HOME WORK

DESIGN REVIEW MANUALTheme :- Defect Loss Cell :- Pulsar ( RHS )


CATEGORY



2 RH 2

DJ151034 N

DH151060 N

Bearing ball Y CPV_08_DR_027 Single piece

Grease N

3 RH 3

Fork 52DJ0130 N

DH181025 N

Cup Steering DH181014 N

Fork Nut 30181018 N

Metal ring Y CPV_08_DR_013 Combine

Rubber ring Y CPV_08_DR_013 Combine

Sr No

Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

Rear Wheel Loading


Rear Wheel Spacer

Rear Brake Panel

2.2 MissingPossibility of bearing ball missing

Ball cage instead of loose balls


Fork fitment stage

Bearing Cone

2.2 MissingPossibility of metal ring missing.

Rubber ring coating on metal ring. Design Basic

4.1 _ 4b

2.2 MissingPossibility of rubber ring missing.

Metal ring with rubber coating. Design Basic

4.1 _ 4b


CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

4 RH 4


DH161258 N

DG181008 Y CPV_08_DR_015 Mounting from out side

N

5 RH 5

52DH0317 N

Bolt N

Plain washer Y

Single piece CPV_08_DR_029 CombineSpacer Y

DH121130 N

DJ151041 N

6 RH 6

Case Meter DH151062 N

Spacer DS151058 N

59150003 N

39078111 N

Split pin Y CPV_08_DR_031 Combine


Brace fender

Allen Bolts (M6) 2.2 Missing

Possibility of mud guard bolt missing due to mounting

from inside

Mud guard mounting from out side


Painted set loading

Front Number Plate fitment

Front Number plate

2.2 MissingPossibility of number plate plain washer missing


2.2 MissingPossibility of number plate spacer missing

Magnet (Self canceling indicator)

Front Axle ( With grease application )

Front wheel fitment

Front Axle Nut

Front Axle Washer

2.2 MissingPossibility of front axle split

pin missingLock nut instead of castle

nut & split pinDesign Basic

4.1 _ 4b


CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

7 RH 7 Engine DJ101231 N

8 RH 8

DH161190 Y CPV_08_DR_004

DJ161271 Y CPV_08_DR_005

59150005 Y CPV_08_DR_032 Identification

9 RH 9

39245504 N

N

59150005 N

DH171019 N

10 RH 10 N

11 RH 11 59150003 Y Pre loctite bolt CPV_08_DR_033 Pre coated

12 RH 12

Lock Nuts DH161245 Y CPV_08_DR_032 Identification

Simple Nuts 59150005 Y CPV_08_DR_032 Identification

Engine Fitment Stage

Engine Bracket Fitment Stage

RH Front bracket

2.5 Wrong part assemblyPossibility of wrong bracket fitment due to identification

Bold embossing with colour filling to be provided on

bracket for clear identification



RH Rear bracket


Bold embossing with colour filling to be provided on

bracket for clear identification



Hanging plate Nuts (M8)


Different passivation to be provided to the nuts for

clear identification


Center Bracket Tightening Stage

Center Bracket Bolt ( M12 )

Plastic washer

Hanging Plate Nuts ( M 8 )

Rear Axle Nut


Fairing Assembly

Front Brake Kit Routing Stage

Bolt ( with loctite application )

2.2 MissingPossibility of loctite

application missing on boltDesign Basic

4.1 _ 4b

Engine Tightening Stage

2.5 Wrong part assemblyPossibility of wrong nut

fitment due to identification

Passivation of nut to be change for simple & lock nuts.


2.5 Wrong part assemblyPossibility of wrong nut

fitment due to identification

Passivation of nut to be change for simple & lock nuts.



CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

13 RH 1352DJ0226 N

M13 Bolts 39258204 N

14 RH 14

Rod End 15191026 N

39231004 N

Y CPV_08_DR_034 Pre coated

DJ161131 N

Adjuster Nut DH191045 N

Spring 30191035 N

Plain Washer 39019811 N

15 RH 15

Brake pedal DH191001 Y CPV_08_DR_035

39176904 N

30151096 N

16 RH 16

39078912 Y CPV_08_DR_036 Combine

DH171019 N

39079415 N

Front Wheel Tightening Stage

RH Step Holder

Brake Connection Stage

M8 Main Step Bolt

Spring washer

2.2 MissingPossibility of spring washer missing during main step fitment

Pre coated bolt to be introduced


Main Step RH

Brake Pedal Fitment Stage

2.6 Mis orientationPossibility of brake padel orientation wrong wrt main step

Brake padel mouting boss to be modified , instead of surretion it should be square or hexagonal type.



Flange bolts (M 12)

Torque Rod Bolt

Rear Wheel Tightening Stage

Spring Washer - T Rod

2.2 MissingPossibility of spring washer missing during torque rod

bolt fitment

Flange lock nut to be provided instead of spring

washer


Center Axle Nut (M 22)

Torque Rod Nut (M 14)


CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

17 RH 17

N

Star Washer Y CPV_08_DR_037 Combine

Nut N

18 RH 18 N

19 RH 19 DK7303ZZ N

20 RH 20

Y CPV_08_DR_020

Y CPV_08_DR_020 Coupler type design

Y Common harness introduce. CPV_08_DR_020 Commonisation

21 RH 21

Y CPV_08_DR_020



22 RH 22

Y CPV_08_DR_020



Starter Motor Connection Stage

Starter Motor Gromet

2.2 MissingPossibility of star washer missing

Instead of star washer , surreted nut to be

implement


Front Brake Kit tightening Stage


Seat Cowl Fitment Stage

Seat Cowl insertion

RH Harness Connection Stage

2.3 Loose Possibility of harness wire

connection loose

Harness length increase by 50mm with introduction of coupler type connection instead of bullet type.



2.4 Not tightened fullyPossibility of blinker bullet

connection not pressed fully

Coupler type connection introduced instead of bullet

type.


2.5 Wrong part assembly Possibility of wrong harness

fitment on chassisDesign Basic

4.1 _ 4b



connection loose







type.




4.1 _ 4b



connection loose







type.




4.1 _ 4b


CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

23 RH 23

Silencer DJ101259 N

39242511 Y Press fit bush with washer CPV_08_DR_038 Combine

39024811 N

DD161071 N

39185004 N

59150005 N

Gasket DJ101064 N

24 RH 24 Snap Pin DH151055 Y CPV_08_DR_039 Bend for thumb support

25 RH 25

39194304 N

Washers 39178924 Y CPV_08_DR_040 Combine

26 RH 26 Y CPV_08_DR_041 Sufficient access

Silencer Fitment Stage

Plain Big washers

2.2 MissingPossibility of plain washer

missingDesign Basic

4.1 _ 4b

Small washers

Lock Nuts (M 17)

Flange Bolts (M 14)

Flange Nuts (M 12)

Silencer Tightening Stage

2.4 Not tightened fully

Possibility of incomplete insertion of snap pin on torque rod bolt due to

difficult to press.

Bend provided on snap pin for better contact area on thumb for insertion


Seat Cowl Tightening Stage

Flange Bolts (M 6)

2.2 MissingPossibility of plastic washer

missingBolt with press fit plastic

washerDesign Basic

4.1 _ 4b

Carburetor Clip Tightening Stage

2.4 Not tightened fullyPossibility of carburettor clip not tightened fully due to no

access

Provide access for tightening for tightening.



CATEGORY


Stage No


Y / N

2.1

. R

evers

e2

.2.

Mis

sin

g2

.3.

Loose

2.4

. N

ot

tig

hte

ned

fu

lly

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g2

.8.

Ad

justm

en

t n

ot

good

2.9

. P

DI

/ EFR

27 RH 27 Y

CPV_08_DR_042 Strong Design

28 RH 28

Side Panel DK730822 Y CPV_08_DR_053 Strong Design

DH161013 N

31161018 N

N

Clutch Connection Stage

2.4 Not tightened fully Possibility of incomplate insertion of clutch cable

grommet on cable

Clutch bracket design change for easy insertion of grommet


Side Panel Sub Assembly Stage

2.3 LoosePossibility of side panel lock coming out of chassis bracket

Provided strengthened bracket for side panel locking.


RH Side Seat Cowl Decal

Side Lock Grommet

Side panel lock

HOME WORK

DESIGN REVIEW MANUALTheme :- Cost ReductionCell :- Pulsar ( LHS )


Category

Activity / Problem Idea Cost saved by ( Rs ) Status DR Point For Review

1 LH 1

52DJ0182

52DH0248

52DH0248

75261601

PV card 75118821

2 LH 2

3 LH 3 Rear axle DJ151032


Battery Band DJ161247

Battery foam Y a Rs …… / Veh Impl

DJ201125 Y a Rs …… / Veh Impl

CDI DH111064

Sr No

Stage No

Cost Loss Applicability

Y / N

3.1

. M

ate

rial

Ch

an

ge

3.2

. Len

gth

R

ed

ucti

on

3.3

. Ele

men

t D

ele

tion

3.4

Yeild



Side stand switch

Bearing Race Upper

Bearing Race lower

Barcode sticker


Sprocket Assembly

Rear Axle Insertion

Foam required for resting battery on metallic surface from back side

AC Box design change for resting battery on AC Box itself

AC Box design for accomodating battery.


Separate bracket required for battery fitment

AC Box design change for accomodating battery on AC Box itself

AC Box design for accomodating battery.


Category

Activity / Problem Idea Cost saved by ( Rs ) Status DR Point For ReviewSr No

Stage No


Y / N

3.1

. M

ate

rial

Ch

an

ge

3.2

. Len

gth

R

ed

ucti

on

3.3

. Ele

men

t D

ele

tion

3.4

Yeild

5 LH 5

DJ161132

Bolt ( M6 ) 39168004 Y a Rs….. / Veh Plan

6 LH 6 Engine InsertionDJ161081

39245504

7 LH 7

Bolt 39241304

DJ161114

DJ161115

39241404

8 LH 8

9 LH 9 Chain

10 LH 10

11 LH 11

52DH0309 Y a Impl

Bolts ( M 6 ) DH161283

washer Y a Impl



Cost involved by using M6 bolt

Bolt can be replaced with smalle size

Provide harness hook tightening bolt with size ……


Bolts (M8*65 & M8*55)


Rear LH bracket

LH center bracket

Allen bolt ( M 8 )

Magneto connection



Magneto cable band

Chain case fitment


Extra material provided on chain case

Chain case width reduced

Cost saved By………

Separate bolt & washer required for chain case fitment

Flange bolt introduced instead of separate bolt & washer

Cost saved by……….

Use flange bolt of dimension ……… for chain case fitment


Category


Stage No


Y / N

3.1

. M

ate

rial

Ch

an

ge

3.2

. Len

gth

R

ed

ucti

on

3.3

. Ele

men

t D

ele

tion

3.4

Yeild

12 LH 12

DH101397

DJ101211

Bolt ( M6 ) 39167304

Metal ring

Rubber ring

M 6 Bolt

13 LH 13

LH main step DJ161130

M8 Bolts 39231004

Spring washer

14 LH 14

Y a Grommet deleted Impl

Handle bar 52DH0169 Y a Impl

15 LH 15Washer

16 LH 16

DG181008

DJ181009

AC Box clip DH121142

17 LH 17

Carburettor DJ101232 Y a Impl


Gear shift lever

Rear cover RR


Handle bar fitment

Main key grommet

Rubber grommet used on main key switch

Cost saved by Rs ………..

Provide main key with out rubber grommet

Separate cable required for choke connection

Choke lever included in carburettor body itself

Cost saved by Rs ………..

Provide carburettor with choke lever itself


Center Fork bolts


Allen bolts ( M 8 )


Carburettor fitment

Carburettor metallic diaphragm cover

Cover change from metallic to fybre

Cost saved by Rs………..

Provide fyber material cover for diaphragm inplace of metallic cover

Earthing cable grommet


Category


Stage No


Y / N

3.1

. M

ate

rial

Ch

an

ge

3.2

. Len

gth

R

ed

ucti

on

3.3

. Ele

men

t D

ele

tion

3.4

Yeild

18 LH 18 A C Box clip Y a Impl

19 LH 19

20 LH 20

21 LH 21LH side decal DH161310 Y a Impl

DH141002

22 LH 22

23 LH 23

24 LH 24

Petrol Tank DJ710122

Y a Screw deleted Impl

Drain pipe Y a Pipe length reduced Impl

Bolt 39155604

Washer 39074011


Separate bolt,washer & spacer required for AC Box fitment

Step bolt introduced

Cost saved by Rs…………

Provide step bolt for AC Box fitment






Seat cowl decal with size………….

Size reduced to…………….

Cost saved by Rs……….

Provide seat cowl decal with size……………

PT drain pipe clip

Battery Connection

LH Bellow insertion

LH bellow insertion


Petrol Tank fitment

PT cap inner screw

Anti theft screw required on inner side of petrol tank cap

Cost saved by Rs………

Provide PT cap with out anti theft screw mounting

More length of PT drain pipe


Provide drain pipe with reduced length of …..mm


Category


Stage No


Y / N

3.1

. M

ate

rial

Ch

an

ge

3.2

. Len

gth

R

ed

ucti

on

3.3

. Ele

men

t D

ele

tion

3.4

Yeild

25 LH 25Grab handle DJ161263 Y a Impl

Bolt

26 LH 26

Side panel 52DK5506

33161018

Grab Handle fitment

Grab handle of material………….

Grab handle material change from……….to……….

Cost saved by Rs…………..

Provide grab handle with material…………….


Side lock grommet

Side panel lock

HOME WORK

DESIGN REVIEW MANUALTheme :- Cost ReductionCell :- Pulsar ( LHS )


Category

Activity / Problem Idea Status DR Point For Review

1 RH 1 Rear Wheel DJ151019

2 RH 2

DJ151034 Y a Plan

Y a Single piece Impl

DH151060 Y a a Impl

Rear shock Y a Impl

Grease

Sr No

Stage No


Y / N

Cost saved by ( Rs )

3.1

. M

ate

rial

Ch

an

ge

3.2

. Len

gth

R

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Rear Wheel Loading


Rear Wheel Spacer

Rear wheel spacer with yellow passivation

Passivation change from yellow to green.

Provide rear wheel spacer with green passivation

Rear wheel damper

6 groove rear wheel damper

Provide 4 groove damper for rear wheel

Rear Brake Panel

1] Platted sprocket on brake panel2] Platted rear brake arm3] Sprocket mounting on 6 bolts

1] Instead of platting , green passivation provided2] Passivation change3] Sprocket mounting on 4 bolts

1] Provide green passivated sprocket2] Provide green passivated rear brake arm3] Provide sprocket mounting on 4 bolts

Separate dome nut , plain washer & spring washer required for shock lower fitment

Bracket addd on swing arm for mounting shock lower with flange bolt

Use flange bolt for rear shock lower mounting instead of dome nut , plain washer & spring washer

Bearing ball


Category

Activity / Problem Idea Status DR Point For ReviewSr No

Stage No


Y / N


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3 RH 3 Fork fitment stage

Fork 52DJ0130 Y a Thread length reduced Impl

Y a Friction plate deleted Impl

Y a Allen bolt introduced Impl

DH181025

DH181014 Y a Impl

Fork Nut 30181018

Metal ring

4 RH 4

Mud guard 52DH0278 Y a Impl

DH161258 Y a Impl

DG181008

More threaded length

Provide fork with thread length ….. Mm

Friction Plate

Friction plate required

Fork side bracket

Separate bolt & nut required for side bracket fitment

Bearing Cone

Cup Steering

Black passivation for cup stearing

Passivation change from black to green

Provide cup stearing with green pasivation

Rubber ring


1] Mud guard mounting from inner side - required bolt & washer assembly2] Rubber grommet on LH side of mud guard

1] Mud guard mounting from outer side with allen bolt2] Rubber grommet deleted

1] Provide mud guard mounting from out side with allen bolt

Brace fender

Separate clamp required to fastened with brace fender for brake kit hose grommet fitment

Brace fender with clamp

Provide clamp welded with brace fender for brake kit hose grommet fitment.

Allen Bolts (M6)


Category


Stage No


Y / N


3.1

. M

ate

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4 RH 4

5 RH 5

52DH0317 Y a Impl

Bolt

Spacer

DH121130

DJ151041

6 RH 6

Case meter DH151062 Y a Impl

Spacer DS151058

Split pin Y a Impl

59150003


Painted set loading

Front Number Plate fitment

Front Number plate

Separate bracket is to fastened with number plate for brake kit hose clamp pipe.

Front number plate with bracket

Provide welded bracket to FNP for brake kit hose.

Plain washer

Magnet (Self canceling indicator)

Front Axle ( With grease application )

Front wheel fitment

Front wheel

Case meter cost more due to

magnetic type

Case meter design change from gear type

to magnetic type

Cost saved By Rs………

Provide case meter with magnetic type

Castle nut & split pin required for front

wheel fitment

Instead of castle nut & split pin - lock nut used

Provide lock nut of size ………. For front wheel fitment

Front axle lock nut


Category


Stage No


Y / N


3.1

. M

ate

rial

Ch

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3.2

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R

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3.3

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3.4

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6 RH 6

39078111

Front wheel fitment

Front axle washer


Category


Stage No


Y / N


3.1

. M

ate

rial

Ch

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3.2

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3.4

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7 RH 7

DH161190

DJ161271

59150005

8 RH 8

9 RH 9

39245504

Y a Impl

59150005

DH171019

10 RH 10

11 RH 11 59150003

12 RH 12Lock nuts DH161245

59150005


RH front bracket

RH rear bracket





Plastic washer

Starter relay & OEN relay

Separate starter relay & OEN relay

required

Starter relay combined with OEN relay

Cost saved by Rs……….

Provide single piece device to functon for starter & OEN relay


Rear axle nut


Fairing Assembly



Engine tightening stage Simple

nuts


Category


Stage No


Y / N


3.1

. M

ate

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Ch

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3.2

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3.4

Yeild

13 RH 1352DJ0226 Y a Impl

M13 bolts 39258204

14 RH 14

Rod end 15191026

39231004

DJ161131

DH191045

Spring 30191035

39019811

15 RH 15

DH191001

39176904

30151096

16 RH 16

39078912

DH171019

39079415


RH step holder

Pillion step fitment on step holder with

"O" ring , plain washer & split pin

Pillion step mounting with circlip


Provide circlip of size…… for pillion step fitment


M8 main step bolt

Spring washer

Main step RH

Adjuster nut

Plain washer


Brake padel

Flange bolt (M12)

Torque rod bolt






Category


Stage No


Y / N


3.1

. M

ate

rial

Ch

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3.2

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3.3

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3.4

Yeild

17 RH 17

Nut

18 RH 18

19 RH 19 Seat cowl DK7303ZZ

20 RH 20

21 RH 21

22 RH 22

23 RH 23

Silencer DJ101259 Y a Impl

39242511

39024811

DD161071

39185004

Flange nuts 59150005

Gasket DJ101064

24 RH 24 Snap pin DH151055



Spring washer








Silencer with platting………..

Platting change from…………..to………

…….

Cost saved by Rs………….

Provide silencer with platting………….

Plain big washer

Small washer

Lock nuts (M17)

Flange bolts



Category


Stage No


Y / N


3.1

. M

ate

rial

Ch

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3.2

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Yeild

25 RH 25

39194304

DG Screw Y a Impl

Washers 39178924

26 RH 26

27 RH 27

28 RH 28

Side panel

29 RH 29 Vehicle inspection

Seat cowl tightening satge

Flange bolts (M6)

DG screw required for seat cowl fitment

Bolt introduced for seat cowl fitment

Cost saved by Rs…………..

Provide bolt for seat cowl fitment





Side lock grommet

Side panel lock


final pulsar

Documents