eering A271--Defects 5 Why Analysis Summary (2018-19)--Review on 22.07.

19( Rama SAN MSIL)

S.No Department Date Part No. Part name Model Part/Defect photo Defect WHY-WHY Why 1 Why 2

1.End Piece got mix up

Occurrence at T-2
with OK Part at T-2
( earliertotal length of Rule was not available to
5410mm multiple of 05 deal with First and Last
@1080 --observed piece of process
59740M77P00 5400mm)
19-Apr-18

Pipe length
Cross Member

Occurrence at Agro
1 gurgaon weld Y9T short by
comp fuel tank 10mm
No Foolproofing to detect Welding fixture design
the length short part was inadequate to detect
during weld process the length short

Only visual inspoection

Outlow
was being done at PDI as
per PDI inspection sheet

Occurrence
59411M68P00

N/A N/A
30-Apr-18

MEMBER,COW YRA
2 manesar weld L SIDE N/A EXTRA HOLE
(DOM)-D IN PART
OUTER,R
Outlow
N/A N/A
 Occurrence
Preventive
Bottoming punch worn
maintenance plan not
out from one side
followed

58251M53M00
30-Apr-18 Member lamp Deep cut mark
3 gurgaon weld YE3
support RH on part.

Inspector considered

Outlow
Inspector passed the
the partially formed
partially formed
bottoming mark as
bottoming mark
normal

Occurrence
Because piercing
Burr observed in hole
punches found wear
and slot.
63312M76M01

out.
4-May-18

Burr in square
4 manesar weld Ext QTR inner YL7 slot & hole.

Outlow
Inadequate rework
No check point after
control system /PDI
burr rework inspection check point

Occurrence
Without nut part not
Without nut part mixup
with welded nut parts. reach in weld shop for
projection welding.
65722M
ay-18

Reinf Trunk lid YSD-NB Nut miss in

5 manesar weld
 65722M56R00
12-May-18
Reinf Trunk lid YSD-NB Nut miss in
5 manesar weld latch part

Visual inspection not

Outlow
done 100% by PDI PDI inspector not follow
Inspector the rules

Occurrence
Penetration less on pad Weld bead shifed up side
plate
49069M55R40

Foot Rest
21-May-18

plate tilted to
6 assy Brake pedal YSD-NB arm welding
bead shif

Inspector was checking No check point for mallet

Outlow
bead presence by visual checking in PDI Check
inspection sheet

Occurrence
Room lamp bracket (child
part) position NG in WL Child part damaged
Sensor not direction
65120M56R10

working in
18-Jun-18

MSIL fixture
Rail roof front YSD-NB
7 manesar weld due to Room
inner lamp bracket
position NG in
WL direction.
 Sensor not
65120M56R10

working in
18-Jun-18

MSIL fixture
Rail roof front YSD-NB
7 manesar weld due to Room
inner lamp bracket
position NG in
WL direction.

Only Visual inspection No check point for panel

Outlow
was being done as per PDI checker inspection in PDI
Check sheets Check sheets
 Nut miss--01

Occurrence
One nut missing made in Due to process cycle not
part completed (power
suddenly off)

65722M56R00
24-Aug-18

Reinf Trunk lid YSD-NB 01-Nut miss in

8 manesar weld latch part

Outlow
One nut missing part not Mix-up of nut miss part
detected by the inspector. into OK parts

Occurrence
Circlip fallen between Circlip fallen due to dia
transit (before fitment) Oversize
49069M68P40
22-Sep-18

Circlip missing
9 assy BRAKE PEDAL YRA11 in brake pedal

Only Visual inspection

was being done as per PDI No check point for width
check sheets

Outlow
(Part was not catchable checking of the circlip
at the time of EOL ,EOL afer insert was available
checks the presence not in PDI check sheets
circlip dia )
 Occurrence
Hanger Hook Broken at Hardness of Rod Was
Bend Area exceeding

59730 M 77P00
25-Oct-18
Cross Member Muffler Rod
10 gurgaon weld comp TM Y9T Broken
Mount
Requirement of non

Outlow
Broken Parts not detected destructive testing not
at PDI end addressed in PDI
standard

Wrong Sticker(P40)

Occurrence
pasted on P30 Pedal part Sticker not scanned due
MT BRAKE by dispatch bin Tag to grease presence
PEDAL FITTED scanning operator
49069M68P40

IN-- AT
8-Dec-18

VEHICLE DUE
11 assy Brake pedal YRA11 TO WRONG
STICKER(P40)
PASTED ON
P30 PART

Outlow
NG part Mix with the OK NG part handling rule not
part followed

Occurrence
Dent observed at Restrike Scrap chips stuck in the
die during restrike
operation operation
64520M82P00

HEAVY DENT
27-Dec-18

SIDE BODY YBA11- OBSERVED ON

12 gurgaon weld EXTENSION
OUTER RX LH (DOM)-D COMP SIDE
BODY OTR LH
 OBSERVED ON

20M82P00
SIDE BODY YBA11-

27-Dec-
12 gurgaon weld EXTENSION
OUTER RX LH (DOM)-D COMP SIDE
BODY OTR LH

PDI inspector did not

Outlow
check part 100% as per Inadequate Lux level
PDI Check sheets (very
-very small dents )

Occurrence
Pad Plate got shifted
Pad Plate tilt observed. one side during the
clamping.
49069M68P50

Pedal Arm
30-Mar-19

foot Rest
13 assy Brake Pedal YRA(EXP) PlateTilted
WRT Arm

Contact Area Of

Outlow
NG part Could not Checking pin was not
detect in Assy gauge able to detect the NG
part.

Occurrence
14

Outlow
 18
17
16
15

Outlow Occurrence Outlow Occurrence Outlow Occurrence Outlow Occurrence

 19

Outlow Occurrence
 Key weak Points
Why 3 Why 4 Why 5 Technical Root Cause System Root Cause

End Piece got mix 1.Rule was not

up with OK Part at T- available to deal
Non Availability of system 2 ( earliertotal with First and Last
for set up approvals / last length of 5410mm piece of process
part handling at T-2 multiple of 05 2. Inadequate
@1080 --observed PFMEA
5400mm)

No Foolproofing to 1.Welding fixture

detect the length design was
In adequate PFMEA short part during inadequate to detect
weld process/Press the length short
Process

This defect was

N/A N/A N/A N/A punched based on
miscommunications …

This defect was

N/A N/A N/A N/A punched based on
miscommunications …
Inadequate training to Preventive Inadequate training
preventive maintenance maintenance plan to preventive
team not followed maintenance team

No specific mention in Inspector considered

Inadequate PDI check Inadequate PDI
the inspector checksheet the partially formed
sheet and training to bottoming mark as
check sheet and
for bottoming mark training to inspector
inspector normal
shape

Non standard
Non standard punch & punch & bush are
Punches worn out
Punches worn out before bush are used instead Due to lack of used instead of
before to P/M
to P/M Frequency of punch industries awareness. punch
Frequency
/MISSUMI industries
/MISSUMI

Inadequate rework
No check point after
control system
Burr rework.
/PDI inspection

Part fallen in lift when Operator pickup the Without nut part
Non availiability of mixup with welded Non availiability of
move from press shop to fallen part and mixed
fallen part rule nut parts. fallen part rule
weld shop. with FG part
 Visual inspection
Inadequate trainings not done 100% by Inadequate
PDI Inspector trainings

Penetration was less on

pad plate because it
While changing the block shifed down as shim
The Plate was shifed from R30 to R40, 1.Jig maint. Operator of 2 mm was not 1.Inadequate design of
down with respect to the adjustment shim of 2 mm was not fully trained applied during change- Fixture
Arm, creating gap between was not placed below the 2. Inadequate design over from R30 to R40 2. Non adherence of
Arm and Pad Plate R40 block (on which the of weld jig variant. Shim was not preventive maintt
pad plate rests) applied as the change-
over was done by
under training person.

Inspector was
checking bead Inadequate PDI Check
presence by visual sheets
inspection

Storage of child part

storage of child part in WIP in WIP trolley was No rule available for
trolley was not No rule available for child Inadequate material not adequate ,part child part handling
adequate ,part touching part handling at WIP handling system touching with each
with each other and got stage at WIP stage
other and got
deformed damaged
CTQ Parameters not
defined in PDI Check Inadequate PDI
inspection check sheets
sheets
 No Rule was
No Rule was available Incomplete cycle part available when part
Incomplete cycle part when part produced mixed with OK Part due produced during
to Process adherence
mixed with OK parts during abnormal NG abnormal
condition condition(Power
shutdown)

PDI inspector not follow Mix-up of nut miss Inadequate training

the PDI rules part into OK parts

Rule was not defined in Rule was not defined

Circlip dia oversize when Circlip dia oversize
rework system for using in rework system for
its re-use when its re-use
of used circlip uses of used circlip

No check point for

width checking of
Inadequate PDI check the circlip afer Inadequate PDI
sheet insert was available check sheet
in PDI check sheets
 Unapproved RM
Shortage of Standard RM Improper planning at Hardness of Rod
Non standard RM used Source Used by Tier-
Tier-2 Was exceeding 2

Requirement of non
destructive testing Inadequate PDI
Inadequate inspection not addressed in PDI check sheet
standard standard --Muffler
ROD hanger

Wrong sticker pasted

Work Instruction manually replaced by
Bar Code Scanning Rework system not
inadequate for Grease (existing dirty) followed
application at IFM Station

NG part Mix with NG part handling rule

Inadequate trainings the OK part not followed

Scarp chips not cleaned Inadequate trainings to Scrap chips stuck in

the die during restrike Die Cleaning training
from die by operator operator operation inadequate to operator
 PDI inspector did
not check part 100%
as per PDI Check 1.Inadequate Lux
sheets (very -very level
small dents )

Shimmimg
1.Inadequate
Play was there between Shimmimg provision not Inadequate training provision not
Preventive System
pad plate and guide properly handled by to fixture maintt properly handled
block. & Inadequate
fixture maintt person. person. by fixture maintt
Fixture Design
person.

Contact Area Of
Checking pin face was Inadequate design of Inadequate design
Checking pin was
not covering the the Pin in checking of the Pin in
not able to detect
complete pad plate gauge checking gauge
the NG part.