Sr. no. Process Contributing sub-process Activity Observation

1 Body Eng. Room Line -Respot line -

2 Paint

ELPO ok

Body Sealer not ok

3 GA Assembly ok

Sr. no.

1

2

3

Before and after check by passing bolt on 25 vehicles

applied some sealer to child part's nut and tightened on

bench wise using wrench

SOS followed; DC tool calibrated; Happy tool ok;

Torque ok- QCOS sheet

Part Activity Observation

Engine mount Found 1 part which washed out 1 vehicle Not ok

Bolt ok

Longi with M10 nut-Body Not ok

Visual check and hand tightened random 20 bolts on good child part

check by passing bolt at Body shop (Out of 433, 13 part not ok)

Month No. of washouts

April20

May

0010

June

2330

July

2240

Aug

0111

Sept

4252

Oct

0117

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280

1

2

3

4

5

6

7

8

No. of washouts (Defects Booked in GSIP)

No. of washouts

Started working on the issue

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280

1

2

3

4

5

6

7

8

No. of washouts (Defects Booked in GSIP)

No. of washouts

Started working on the issue

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280

1

2

3

4

5

6

7

8

No. of washouts (Defects Booked in GSIP)

No. of washouts

Started working on the issue

Sr no

123456789

101112131415161718

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280

1

2

3

4

5

6

7

8

No. of washouts (Defects Booked in GSIP)

No. of washouts

Started working on the issue

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280

1

2

3

4

5

6

7

8

No. of washouts (Defects Booked in GSIP)

No. of washouts

Started working on the issue

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280

1

2

3

4

5

6

7

8

No. of washouts (Defects Booked in GSIP)

No. of washouts

Started working on the issue

Date 9/24/2013 9/25/2013Shift B A

Mr. Roshan

Total checked 106 51

2 2

Supplier Manpower

Mr. Swapnil Jadhav

Found Not ok and reworked

9/26/2013 10/2/2013 10/3/2013

TotalA A B B

Mr. Roshan Mr. Roshan Mr. Roshan

81 62 83 51 434

4 1 3 1 13

Mr. Swapnil Jadhav

Sr. no. ModelObservation

AGV no.Hand pre-tight (before) Assembly (After)

1 M300 ok ok -2 M300 ok ok -3 M300 ok ok -4 M300 ok ok -5 SGM ok ok -6 M300 ok ok -7 M300 ok ok -8 SGM ok NOT ok (RH RR) 99 M300 ok ok 7

10 SGM ok ok 611 M300 ok ok 412 M300 ok ok 113 M300 ok NOT ok (RH FRT) 914 SGM ok ok 715 SGM ok ok 616 SGM ok ok 417 SGM ok ok 118 M300 ok ok 919 M300 ok ok 720 SGM ok ok 621 M300 ok ok 422 SGM ok ok 123 M300 ok 924 SGM ok ok 725 M300 ok ok 626 SGM ok ok 427 M300 ok ok 128 M300 ok 929 M300 ok ok 730 M300 ok ok 631 SGM ok ok 432 SGM ok ok 133 M300 ok 934 M300 ok ok 735 M300 ok ok 636 SGM ok ok 437 M300 ok ok 138 M300 ok ok 939 SGM ok ok 740 M300 ok ok 641 SGM ok ok 4

Finally ok (but CROSS initially RH FRT)

Finally ok (but CROSS initially RH FRT)

ok (Vishal Took considerable time)

42 SGM ok ok 143 M300 ok ok 944 SGM ok ok 745 SGM ok ok 646 SGM ok ok 447 SGM ok ok 148 M300 ok ok 9

Observation: Since nut were visually checked as well as hand pre-tightened before assembly and found ok conclusion is that incoming material at GA is ok

operator

LH RHDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay Prashant

Vishal VanrajVishal VanrajVishal VanrajVishal VanrajVishal VanrajVishal VanrajVishal VanrajVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj Vishal

Vanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj Vishal

Observation: Since nut were visually checked as well as hand pre-tightened before assembly and found ok conclusion is that

Sr. no. ModelObservation

AGV no.Hand pre-tight (before) Assembly (After)

8 SGM ok NOT ok (RH RR) 99 M300 ok ok 7

10 SGM ok ok 611 M300 ok ok 412 M300 ok ok 113 M300 ok NOT ok (RH FRT) 923 M300 ok 928 M300 ok 933 M300 ok 943 M300 ok ok 944 SGM ok ok 745 SGM ok ok 646 SGM ok ok 447 SGM ok ok 148 M300 ok ok 9

Finally ok (but CROSS initially RH FRT)Finally ok (but CROSS initially RH FRT)

ok (Vishal Took considerable time)

Observation: Since nut were visually checked as well as hand pre-tightened before assembly and found ok conclusion is that incoming material at GA is ok

operator

LH RHDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay PrashantDhananjay Prashant

Vishal VanrajVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj VishalVanraj Vishal

Observation: Since nut were visually checked as well as hand pre-tightened before assembly and found ok conclusion is that