Action Plan & Details of Defect Elimination Throug

Total defects elimination Plan - 17 No's

Total defects eliminated - 15 No's
Total defects pending for implementation - 02 No.
Sr.
No.

Defect

Idea
generation
date

Reported
At

Fuel neck screw not fitted /

Cross fitted / Scratch inside fuel flap

03.09.11

CSC

Wheel Spanner not fitted

02.06.11

CSC

FRH Door sill protector not fitted

08.07.11

CSC

Body earhing wire on battery

bracket not fitted

27.07.11

Final Line

Wire loom not fully tightened

17.08.11

CSC

RLH Brake lamp not working

15.09.11

RFI

Scratch on rear cross member

( Inside decklid)

03.10.11

ANOVA -C

Rear Applique nut not fully

tightened

24.10.11

CSC

Rear Applique nut not fitted

04.12.11

CSC

10

Battery magic eye white

05.12.11

CSC

11

Fr. Sh.Ab. Spring dislocation

08.01.12

CSC

12

Speaker grill lug broken

14.01.12

Trim 3

13

Audio wrong part

19.02.12

SIW

14

Ski Rack base plate nut not tightened

29.02.12

SIW

15

Audio wrong part

19.02.12

SIW

16

Rear monogram - Mahindra position

shifted

29.02.12

ANOVA-C

17

Anteena Missing

08.03.12

SIW

Defect Elimination Through "Human Error Prevention Concept"

BWT Name - Trim 3 & Final Line

Countermaeasure Taken

Principle
Used

Target
Date

Responsibility

Status

White dot provided on fuel neck at required area

Facilitation

27.06.11

Vitthal /
PSM

Closed

Self marking at workstation & Cross

marking at buy off initiated - near decklid hinge -RH Side

Facilitation

24.07.11

PSM

Closed

Extra checkpoint added at VEP Checking stage to ensure the

presence before fitment of protective paper

Mitigation

16.10.11

PSM

Closed

Replacement

21.08.11

Jitendra
/ PSM

Closed

Wire loom routine changed at Underbody

area for BS III & BS IV Vehicles

Facilitation

14.09.11

Vitthal /
PSM

Closed

VEP Wattage band madified for brake lamp

( From 70 to 80 W)

Detection

18.09.11

Shailesh K.
/ PSM

Closed

Provided protection cover before

sparewheel placement in Vehicle

Facilitation

12.11.11

Jitendra
/ PSM

Closed

Closed

Closed

Magnetic tip socket provided to remove & fitment of nut

Threaded stud & threaded nut to be provided Take care & part developed in Case-1 Project
Trial conducted for 6 vehicles & found OK

Elimination

01.04.12

Rahul/
Avinash /
PSM

Self marking at workstation & Cross

marking at buy off initiated near Decklid spring - LH Side

Facilitation

05.12.11

PSM

Detection of battery condition ( OK / NOT OK) based on bateery

charge principle

Detection

PSM /
Priyanka

Open

Self marking at workstation & Cross

marking at buy off initiated near Fr. Sh. Ab. Cup

Facilitation

12.01.12

PSM

Closed

Heater to be provided to eliminate the defect of Lug broken

Facilitation

18.02.12

PSM
Shailesh K.

Closed

Vehicle start rolled with Face plate resulted into ease identification of
audio type at Buy off.

Facilitation

20.02.12

PSM

Closed

Self marking at workstation & Cross

marking at buy off initiated on Fender bolt -Both sides

Facilitation

01.03.12

PSM

Closed

Vehicle start rolled with Face plate resulted into ease identification of
audio type at Buy off.

Facilitation

20.02.12

PSM

Closed

Different places for different fixtures of Case -0 & Taxi varient,which

prevent the use of wrong fixture for fixing the mahindra logo

Facilitation

01.03.12

PSM

Closed

Anteena to be send alongwith accessories box of vehicle

Elimination

PSM /
RahulD.
/Milind D.

Open

Action Plan & Details of Defect Elimination Through "Human Error Pr

BWT Name - underbo

Total defects elimination Plan - 21 No's
Total defects eliminated - 16 No's
Total defects pending for implementation - 05No.
Sr.
Defect
No.

Idea
generation
date

Reported
At

Countermeasure Taken

Fog lamp connection missing

10.10.11

Final line

Pig tail added

Abs pipe block pipe loose

10.10.11

Final line

Poka yoke to ne installed

ABS undebody brake joint loose

17.5.11

Engine mtg bolt loose RH

10.8.11

SIW

self Check mark modified

Radiator mtg loose

23.10.11

CSC-D

Self check mark after operation completion

Fr bumper screw loose

14.6.11

Final line

TO collect screw and gun together

Pendular bkt stud wrong fitment-BS3

16.11.11

SIW

BS4 engine mtg stud parking location change

Speedo sensor wrong fitment

15.10.11

IC

ABS & Non ABS sensor operation done in different stage

Negative cable wrong fitted

15.11.11

IC

Common cable use for all type engine

10

Gear box oil wastage

16.11.11

IO

Overflow drain leaded back to the main storage drum

11

Wrong gear lever rod fitted

18.11.11

IC

Diesel & petrol part location change

12

Degazer tank clip open

14.12.11

IC

Proper tool provided, (Screw driver & flair)

Finalextra
line /check
YARD point added at Fuel protector plate fitment stage by brake b

13

Rotating element wrong fitted

15.12.11

IC

Rotating element arranged in sequence on material trolley

14
15

GEP earthing missing

Lower arm bolt loose

15.12.11
8.1.12

ID
ID

Poka yoke installed

Poka yoke installed

16

Tie rod nut loose

15.1.12

ID

Poka yoke installed

17

Engine falling down from trolley

20.3.12

BWT

Extra support to be provided

18
19
20
21

Steering mtg loose

Shock absorber mtg loose
AC pressure switch back out
Flexible brake pipe loose

15.1.12
18.1.12
20.12.12
16.8.11

ID
ID
IO
ID

Poka yoke
Poka yoke
Connector to
Poka yoke

installed
installed
be modified
installed

tion Through "Human Error Prevention Concept"

BWT Name - underbody / Eng. Prep.

Target
Date

Responsibility

Status

Facilitation

9.11.11

Vitthal

Closed

Facilitation

15.11.11

Vitthal

Closed

Detection

18.5.11

Vitthal

Closed

Mitigation

11.8.11

Vitthal

Closed

Detection

25.10.11

Vitthal

Closed

Mitigation

15.6.11

Vitthal

Closed

Facilitation

18.11.11

Vitthal

Closed

Facilitation

18.10.11

Vitthal

Closed

Replacement

15.11.11

Vitthal

Open

Facilitation

18.12.11

Vitthal

Closed

Facilitation

20.12.11

Vitthal

Closed

Facilitation

16.1.12

Vitthal

Closed

Priciple used

Facilitation

18.2.12

Vitthal

Closed

Facilitation
Facilitation

15.2.12

Vitthal
Vitthal/ Priyanka

Closed
Open

Facilitation

Vitthal/ Priyanka

Open

Facilitation

Rahul

Closed

Facilitation
Facilitation
Replacement
Facilitation

Vitthal/ Priyanka
Vitthal/ Priyanka
SQA / Vitthal
Vitthal/ Priyanka

Open
Open
Open
Closed

Action Plan & Details of Defect Elimination Throug

Total defects elimination Plan - 05 No's

Total defects eliminated -05 No's
Total defects pending for implementation - 00 No.
Sr.
No.

Defect

Idea
generation
date

Reported
At

Door moulding wrong

13.10.11

IO

Head lamp fitment wrong

14.10.11

IC

Spoiler fitment wrong

13.10.11

ID

Door handle wrong

2.11.11

IO

Scalph fitment wrong

27.01.12

IC

Defect Elimination Through "Human Error Prevention Concept"

BWT Name - Trim Line

Principle
Used

Target
Date

Responsibility

Status

Color code provided

Detection

13.10.11

Kanade

Closed

Rack changed at different location

Detection

15.10.11

Kanade

Closed

Horizontal deployment done along with door moulding

Detection

13.10.11

Kanade

Closed

Color code provided

Detection

2.11.11

Kanade

Closed

Color code provided

Detection

27.01.12

Kanade

Closed

Countermaeasure Taken

Action Plan & Details of Defect Elimination Throug

Total defects elimination Plan - 10No's

Total defects eliminated -08No's
Total defects pending for implementation - 02 No.
Defect

Idea
generation
date

Reported
At

LH indicator not working/RH Brake lamp Not

working

03.11.11

RFI

Fuel Flap Sticker Missing

12.11.11

CSC-S

One Side Decal Missing

03.11.11

SIW

RH tie Rod Nut Loose

05.01.12

ID

Head lamp wrong part( pearl white mix

with regular head lamp)

15-1-12

CSC-S&SIW

Head lamp to bumper grill gap uneven

22-1-12

NoVA-C

Scratch on B-pillar near Check Arm

05.01.11

CSC-S & SIW

Decklid Badge wrong

06.01.12

CSC-S

Upper Head Lamp Bolt loose

14-1-12

CSC

Combonation switch wrong

4/2/2011

CSC-D

Sr.
No.

10

Defect Elimination Through "Human Error Prevention Concept"

BWT Name - QA

Countermaeasure Taken

Principle
Used

Target
Date

Responsibility

Status

tail lamp connection checking done with the help of Mirror provide
at SIW stage

Mitigation

04.11.11

Niranjan

closed

check point added at trim 1 checkman stage

Mitigation

13-11-11

P.Kanade

closed

Replacement

10.11.11

Anirdha
Rajurkar

closed

implimenting one fiber block on rest bar in roller area which it

results exact torque

Facilitaion

08.01.11

latesh

closed

use diffrant bin for regular & Festive edition vehicle

facilitation

25-1-12

Latsh/ajay

closed

Robot cutting Front cross member at supllier end

Replcement

05.02.11

latesh

closed

use magnetic protector on pnumatic gun

Facilitation

28-1-12

latsh/ajay

closed

classify according to D2,D4,D6 Vehicle

Facilitation

18.01.12

Latsh/ajay

closed

CHECKING TO BE DONE AFTER REWORK AND Then REVEP

Mitigation

18-1-12

Latsh/anirrudh
a

closed

use diffrant Binalong with Variant of the model

Facilitation

15-2-12

latsh/kanade

open

Sign after decal fitment (Self check)

Action Plan & Details of Defect Elimination Throug

Total defects elimination Plan - 5 No's

Total defects eliminated - 5 No's
Total defects pending for implementation - 00 No.
Sr.
No.

Defect

Idea
generation
date

Reported
At

Head lamp aiming not ok

18.10.11

SIW

AC reading not written on history card

15.11.11

SIW

Smoke reading missing

15.11.11

SIW

Vehicle offer to SIW witth rework pending

18.11.11

SIW

Manual ,safety triangle spare bulb missing

09.02.12

RFI

Defect Elimination Through "Human Error Prevention Concept"

BWT Name - CSC

Principle
Used

Target
Date

Responsibility

Status

second check can be added in shower test to check HLA

Mitigation

18.10.11

AAR

Closed

Second check point can be added at CSC-D stage

Mitigation

18.11.11

AAR

Closed

Second check point can be added at CSC-D stage

Mitigation

18.11.11

AAR

Closed

Every operator is instructed to sign on history card before sending

the car to SIW

Mitigation

18.11.11

AAR

Closed

Kitting of manual , spare bulb and safety triangle done

Facilitation

13.02.11

AAR

Closed

Countermaeasure Taken

Before Oct 10
CSC
MQA
Trim 3 & Final
U/B,Eng Prep.
Trim 1 & 2
Monthly Total
Monthly Cum.

Oct-11

3
6
9
9

1
0
3
4
2
10
19

Nov-11
3
3
1
3
0
10
29

Dec-11

Jan-12
0
0
0
3
2
5
34

0
6
1
0
0
7
41

Feb-12
1
0
0
0
2
3
44

Mar-12
0
0
0
1
4
5
49

Total
5
9
5
14
16
49

50

41

45
40

44

34

35

29

30
25

19

20
15
10
5
0
Oct-11

Nov-11

Dec-11

Jan-12

Feb-12

49
41

Jan-12

44

Feb-12

Mar-12