Concern Resolution Process

for In-house Manufacturing

QC Story

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 QC STORY PROJECT
PROJECT TITLE :-
Elimination of V1+ Concern of Brake bleeding related issues in ALFA 3
Wheeler Assembly (A long pending V1+ concern)

Mahindra and Mahindra Ltd, Zaheerabad Plant, Vehicle PU

Plan Actual
Start Date 25/06/12 25/06/12

Completion 29/11/12 27/12/12

Date

Current Status:
COMPLETED

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 Phase II – QC Story
• Team Information
 Step1: Select the Theme
 Step 2: Justify the choice
 Step 3: Understand the current situation
 Step 4: Select Targets
 Step 5: Analysis (Level 1 Analysis)
 Step 6: Implement corrective measures
 Step 7: Confirm the Effects
 Step 8: Standardize
 Step 9: Summarize & Plan future actions
• Guidelines to user

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 Cross Functional Team
No Description Name Designation Dept Email

1 Team Leader K. Vamsi Krishna Graduate Vehicle PU [email protected]

Engineering Trainee (MQA)
2 Mentor Mr. Abburi Purna Asst Manager Vehicle [email protected]
PU(MQA)
3 Member 1 D Suresh Manager-Mfg Vehicle [email protected]
Quality PU(MQA)
4 Member 2 K Chakravarthy Manager- Vehicle PU [email protected]
Production
5 Member 3 K Chaitanya Asst Manager Vehicle PU [email protected]
Kumar
6 Member 4 Gr suresh Dy. Manager- Vehicle PU [email protected]
Production
7 Member 4 Sateesh Asst Manager Industrial [email protected]
Jampana Engineering
8 Member 5 V.G.S. Prasad Dy Manager SQA [email protected]

9 Member 6 Bhanu Prakash Asst Manager SQA [email protected]

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 1. Select the Theme
Brief description of Problem

What: Brake bleeding issues

Where: In all Alfa 3 Wheeler models
When: Identified after brake bleeding
Who: Reported by the stage operator and intermediate Buy Off
operators
Why:
How: * It got noticed during the inspection at buy off stage
* 3271 vehicles have undergone manual brake bleeding sinceF-11

3271 vehicles were caught as defective units due to poor brake

application in ALFA 3 wheeler all models reported by the stage
operator after brake bleeding and also by the Buy off
inspectors since F-11

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1. Select the Theme
How much:
Rework time: 20 Min Per veh,
Manpower required: 2
persons Rework time: 20 min
per veh
Rework cost for brake
bleeding on1 veh: Rs.35
Total rework cost to do
rework of 2482 vehs’ is
= 35*2482= INR 86,870 COPQ(in Rs)
10000
8925
9000 8330 8190
8000 7595 7735
7350
7000
6000 5530
5000 4550 4375 4620
4025 3990 4200
4000
3780 3675
3000
2000
1000
0
APR'11 MAY'11 JUNE'11 JULY'11 AUG'11 SEP'11 OCT'11 NOV'11 DEC'11 Jan'12 Feb'12 Mar'12 Apr'12 May'12 Jun'12

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Finance Approval letter

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 2a. Justify the choice (reasons)
PARETO OF BRAKE BLEEDING RELATED CONCERNS
FROM PERIOD Apr’11 TO Jun’12

Trivial many
Vital Few
7000 100.00
90.00
6000
Occurence

80.00
5000 70.00
4000 60.00
50.00
3000 2482 40.00
2000 1655 30.00
741 520 20.00
1000 425 324 290 10.00
125 97 76 55 51 33 29 27 26 25 23 22
0 0.00

• Vehicles undergoing rework due to Brake bleeding issues were very high (Apr’11 to Jun’12- High Occurrence) : 2482
• High severity rating: 10

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2b. Immediate Containment Action

• Manual Brake Bleeding done at Rework Area

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3. Understand the current situation

L0 analysis carried out and found O.K

Observations of conformity Analysis.

GOOD POINTS
• Operator Working as per SOP
• Bleeding not ok Veh is detected by operator at
stage and inspector at buyoff

NOT GOOD POINTS

• Repetitive concern(V1+concern)
• Failure mode not identified

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3. Understand the current situation
Manual Process for Brake Bleeding
Process flow inside Brake Bleeding Machine
Front flexible
hose torquing Vacuuming
(18Nm) Set Value: 0.3 m bar

Tightening of
TMC mtg bolts Defect
Vacuum Leak Check
(22.5Nm) Generation

Placing of NOTOK
adopter over the
TMC head and
lock it to the OK
stoppers
Found OK Press the green Re-vacuuming
button and start
the Brake bleeding Found Not Ok
Machine
Filling
automatically
Set Value: 4 Bar Pressure
Re-check for the
Pass the Vehicle Leaks at all the joints
to next stage Leveling
Of loop
(Levels the quantity of
Brake fluid till the mark
On TMC)

Re-Torque to
all the Process COMPLETE
joints

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3. Understand the current situation
Occurrence Trend from F'11, F,12 & F'13(Apr’12 to Jun’12) concern wise

1400
1207
1200
1000
800 F'11
600
423 420 393
400
166 150 F'12
200 200 217
95
0
F'13
Brake Bleeding Brake bleeding
not done not ok Brake pedal
travel
Description of brake bleeding concerns more
 Brake bleeding not done – V1+
 Brake bleeding not okay – V1+
 Brake pedal travel more – V1+
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3. Understand the current situation
Quality indicators Effected (FB0)
TOTAL:
TOTAL TOTAL F-
DATE F-11 12 APR'12
FBO FBO TOTAL FBO
Buyoff EFFECTED EFFECTED to EFFECTED IN
S.No Concern ATTR Location IN % IN % JUN’12 %
(F13)
PASS 24556 25336 5840
LC 10658 11891 4350
TOTAL 35214 37227 10190

1 166
Brake bleeding not ok CFT 1ST 0.47% 393 1.06% 150 2.20%
2 Brake pedal travel more 200 CFT 1ST 0.57% 217 0.58% 95 1.40%
3 Brake bleeding not done 423 CFT 1ST 1.20% 1207 3.24% 420 6.30%
• TheTotal
above table clearly shows that FBO Effected in F-11, F12 and F13 due
789 2.24% 1817 4.88% 665 9.90%
to these issues is very high
• Defect per vehicles increased
• Quality effected
• Manual brake bleeding leads to brake inefficiency which leads to customer
dissatisfaction

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4. Select Target
Identify the target: Target is the number indicating level of improvement to be achieved

Present Avg. of 230 vehicles occurrence from Jan’12 to Jun’12

Level:
Target: Zero Defect in next 6 months, i.e. Jan’13

Brake Bleeding related issues(Occurrence/Month))

300
255
250 238 234
217 221 210
200

150

100

50
0
0
Jan'12 Feb'12 Mar'12 Apr'12 May'12 Jun'12 JAN'13

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5. Analysis 5.1 Identify possible causes:

1. SOP not followed Brain storming session done on basis of

2. Incomplete fitment of previous operation past experience and Gemba
3. NVA movements
4. Operator skill transformation
5. Operator stress condition
6. New operator at stage
7. Wrong Bundy tube assembled
8. Torque wrench end worn out
9. Motor HP is insufficient
10. Vacuuming pressure not maintained
11. Brake bleeding pressure not achieved
12. Leak detection poor
13. TMC vacuum leakage
14. Bundy tube inside passage block
15. TMC flange face to shackle hole center dimensional variation
16. Wrong fitment sequence for brake adjustments
17. T-joint wrong thread assembled
18. Key point miss in SOP
19. TMC Mtg brackets distance fired
20. Process time not sufficient
21. Brake fluid level less
22. Less torque applied
23. No of operations more
24. Inadequate SOP
25. Brake stud position wrong
26. TMC Brkt cross welded
27. TMC Brkt hole offset
28. Brake fluid less viscous
29. TMC inside passage hole miss
30. Wheel brake cylinder rubber cut

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5. Analysis
5.1 Identify possible causes:

Operator stress condition

Man Method Process time not

sufficient
SOP not followed
New operator at stage Brake fluid level less

BRAKE BLEEDING REALTED ISSUES

Incomplete fitment of previous Less torque applied
Wrong fitment sequence for
operation brake adjustments

No of operations more
T-joint wrong thread
NVA movements
assembled

Wrong Bundy tube assembled Key point miss in

Operator skill Inadequate SOP
SOP

Brake stud
TMC Mtg brackets distance position wrong
Torque wrench end worn out Leak detection poor fired
TMC Brkt cross welded
Motor HP is insufficient TMC Vacuum leakage

TMC brkt hole offset

Vacuuming pressure not
Bundy tube inside passage block
maintained
Brake fluid less viscous
TMC flange face to shackle
Brake bleeding hole center dimensional TMC inside passage hole miss
pressure not achieved variation

Wheel brake cylinder rubber cut

Machine Material

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5. Analysis
5.1 Identify possible causes:

Operator stress condition

Man Method Process time not
sufficient

BRAKE BLEEDING REALATED ISSUES

SOP not followed
New operator at stage Brake fluid level less

Incomplete fitment of previous Less torque applied

Wrong fitment sequence for
operation brake adjustments

No of operations more
T-joint wrong thread
NVA movements assembled

Wrong Bundy tube assembled Key point miss in

Operator skill Inadequate SOP
SOP

TMC Mtg brackets distance Brake stud

fired position wrong
Leak detection poor-Brake
Torque wrench end worn out
Bleeding machine
TMC Brkt cross welded
Motor HP is insufficient
TMC Vacuum leakage
TMC brkt hole offset
Vacuuming pressure not
maintained Bundy tube inside passage block Brake fluid less viscous

Brake bleeding TMC flange face to shackle

hole center dimensional TMC inside passage hole miss
pressure not achieved
variation
Wheel brake cylinder rubber cut
Machine Material

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5. Analysis
Identify the root causes
Probable Causes: (Based on experience & Knowledge)

6 Probable causes selected for testing out of 30 possible causes,

i.e. establishing root causes.

S. No Probable Cause
1 TMC Vacuum leakage

2 TMC Mtg brackets distance fired

3 Leak detection poor-Brake bleeding machine

4 Wrong fitment sequence for brake adjustments

5 TMC flange face to shackle hole center dimensional variation

6 Brake bleeding pressure not achieved

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5. Analysis
5.2 Confirm the probable cause:
No Testing Observations Conclusion
Probab
le method By Observing the vacuuming leak not ok parts
Cause we found the reservoir grommet only present in Hypothesis
TMC Vacuum
1 Visually the one port and other port the grommet
leakage
missing, this clearly indicates the vacuuming not Valid
ok.

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 5. Analysis
5.2 Confirm the probable cause:
By comparing all the mtg brackets actual
TMC Mtg dimensions with drawing we found there is
2
brackets Steel rule variation in between TMC mtg bracket and brake Hypothesis
distance /vernier pedal stud.(Total 130 vehicles inspected and Valid
fired results, Out of 130 vehicles 126 vehicles out of
In confi rming the above ca use we observed the tot al production and found the center
spec.

beam mounting TMC bracket to Brake pedal stud (201.3+/-0.6mm) is in out of specification
limits as resulting TMC push rod should be adjusted to Max threads as to let Brake pedal
height which will be fatal to the end customer and blocking TMC mtg hole by disturbing
the positions of primary and secondary pistons. TOP view of TMC brkt to Brake stud

201.3+/-0.6 mm

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 5. Analysis
5.2 Confirm the probable cause:
 Data cross check for TMC Mtg brackets distance fired
TMC mtg TMC mtg
Pedal brkt center Brake Pedal height brkt center Brake pedal mtg
Brake Brake pedal TMC Adjuster
height hole to Brake Brake
S.N Pedal S.N Pedal after brake hole to brake stud height from TMC Adjuster
o Chassis No. after brake brake stud mtg stud height Threads(from Brake ok
not
Brake ok o Chassis No. threads not ok ok
Height from floor supplier) Height applied stud split pin floor
applied split pin center hole
center hole
100 205 97 4 ok 31 71158 145 74 204 4 ok
1 Chassis No.

170 2 140 80 205 97 4 ok 32 71159 153 75 4 ok

94
71128 140 80 205 94 4 ok 33 71160 170 90 7 ok
204
3 71129 150 75 204 96 4 ok 34 71161 140 70 4 ok
4 71130 140 75 206 93 4 ok 35 71163 145 72 98 4 ok
5 71131 152 80 204 95 4 ok 204
36 71164 154 80 4 ok
6 71132 150 85 204 96 4 ok
37 71165 144 70 4 ok
158 86 204 97 4 ok 99
7 71133 38 71166 165 85 4 ok
8 71134 148 78 204 90 4 ok 205
39 71167 155 85 4 ok
9 71135 150 78 205 96 4 ok
40 71168 155 75 95 4 ok
10 71136 140 72 207 97 4 ok
41 71169 155 78 204 4 ok
11 71137 142 74 207 96 4 ok
155 80 203 96 4 ok 42 71170 146 68 4 ok
12 71138 95
155 80 203 97 4 ok 43 71171 145 75 4 ok
13 71139 204
14 71140 148 80 205 96 4 ok 44 71172 152 75 4 ok
144 78 205 94 4 ok 45 71173 158 70 95 4 ok
15 71141
16 71142 150 76 205 97 4 ok 46 71174 146 68 205 4 ok
17 71143 147 70 206 94 4 ok 48 71176 144 68 4 ok
94
18 71144 140 72 206 95 4 ok
49 71177 145 68 4 ok
134 65 207 95 4 ok 201
19 71145 50 71178 162 75 4 ok
20 71146 155 90 203 98 4 ok 95
51 71179 152 80 4 ok
21 71147 164 85 203 97 4 ok
52 71180 150 75 202 4 ok
22 71148 155 75 203 96 4 ok
145 74 204 95 4 ok 53 71181 145 82 97 4 ok
23 71149
148 80 205 95 4 ok 54 71182 140 68 204 4 ok
24 71150
148 75 205 96 4 ok 55 71183 142 75 4 ok
25 71151
96 4 56 71184 138 72 99 3 ok
26 71152 148 76 204 ok
145 73 205 96 4 ok 57 71185 164 85 204 2 ok
27 71153
28 71154 143 72 205 96 4 ok 58 71186 150 78 4 ok
97
29 71155 158 76 203 97 4 ok 60 71188 151 76 4 ok
205
30 71156
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 5. Analysis
5.2 Confirm the probable cause:
TMC mtg TMC mtg
Brake pedal brkt center Brake pedal
Brake Pedal height brkt center Brake Pedal height hole to mtg stud TMC Adjuster Brake Brake
S. Chassis hole to mtg stud TMC Adjuster Brake Brake S.N
Pedal after brake o Chassis No. Pedal after brake brake stud height from threads not ok ok
No No. brake stud height from threads not ok ok Height applied
Height applied split pin floor
split pin floor
center hole center hole
61 71189 155 74 204 95 4 ok 91 71219 148 70 204 95 4 ok
62 71190 160 78 203 96 3 ok 92 71220 162 80 203 100 4 ok
63 71191 151 72 205 97 3 ok 93 71221 148 80 204 96 4 ok
64 71192 152 80 204 96 3 ok 94 71222 158 80 204 97 4 ok
65 71193 138 70 201 94 3 ok 95 71223 145 78 204 96 4 ok
66 71194 150 78 205 98 2 ok 96 71224 157 90 203 95 4 ok
67 71195 156 80 204 97 4 ok 97 71225 150 70 204 96 4 ok
68 71196 160 90 205 95 3 ok 98 71226 160 80 203 96 4 ok
69 71197 155 80 204 97 3 ok 99 71227 150 80 204 98 4 ok
70 71198 152 80 204 96 3 ok 100 71228 154 75 204 97 4 ok
71 71199 162 85 203 96 3 ok 101 71229 160 80 206 95 4 ok
72 71200 157 80 204 95 4 ok 102 71230 144 70 205 93 4 ok
73 71201 158 80 203 98 3 ok 103 71231 164 80 202 96 4 ok
74 71202 150 80 205 97 3 ok 104 71232 165 95 202 98 4 ok
75 71203 158 88 203 95 4 ok 105 71233 165 90 200 97 4 ok
76 71204 174 100 204 96 8 ok 106 71234 150 80 204 97 4 ok
77 71205 144 68 205 96 4 ok 107 71235 154 80 204 96 4 ok
78 71206 144 70 205 96 4 ok 108 71236 132 50 208 97 4 ok
79 71207 154 72 203 98 4 ok 109 71237 178 107 201 99 4 ok
80 71208 136 68 203 94 4 ok 110 71238 165 75 204 97 4 ok
81 71209 160 85 203 98 4 ok 111 71239 144 70 205 97 4 ok
82 71210 158 80 203 96 4 ok 112 71240 159 80 204 96 4 ok
83 71211 128 60 208 92 4 ok 113 71241 144 75 205 95 4 ok
84 71212 145 70 203 94 4 ok 114 71242 155 80 204 99 4 ok
85 71213 144 70 203 96 4 ok 115 71243 150 80 204 96 4 ok
86 71214 143 65 204 96 4 ok 116 71244 144 70 204 95 6 ok
87 71215 150 78 204 96 4 ok 117 71245 142 70 204 96 4 ok
88 71216 144 70 204 95 4 ok 118 71246 142 65 205 96 4 ok
89 71217 148 75 204 95 4 ok 119 71247 140 70 206 97 4 ok
90 71218 154 75 204 95 4 ok 120 71248 154 75 204 97 4 ok

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5. Analysis
5.2 Confirm the probable cause:
Mean as per Spec Mean deviated

Histogram for brackets dimesions (spec: 201.3+/-0.6mm)

60 Mean shift 52
50
Frequency

40
29
30 24
20
9
10 1 3 4 3 2
0 0 0
0

Distance between TMC mtg brkt and brake pedal stud

The above histogram clearly shows that The above histogram clearly shows that AS PER DRAWING SHOWN:
only 4 vehicles among 130 vehicles most of the vehicles received beyond  Brake pedal height before brake apply :
are received as per spec (201.3+/-0.6 spec (201.3+/-0.6 mm) 182+/2 mm
mm) Distance between TMC mtg brkt to
Brake
pedal stud:-201.3+/-0.6 mm

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 5. Analysis
5.2 Confirm the probable cause: Inference Analysis 1
Length from
TMC mtg brkt Brake Pedal Brake Pedal Brake pedal mtg
TMC Adjuster
S.No Chassis No. Height before height after stud height from Brake ok
center hole brake brake applied floor threads
to applied
brake stud split
pin center
hole
108 71236 208 132 mm 50 97 4 ok
109 71237 201 178 mm 107 99 4 ok
 VARIATION BEFORE BRAKE
Variation 7 mm APPLIED 46 mm: Due to 7mm
57 mm of variation
NRin the lengthNR
from TMC bracket center hole to
brake stud pin resulted in the variation of brake pedal height of 46mm. In this case, 1 mm variation from TMC mtg
brkt center hole to brake pedal stud results in 6.57 mm of brake pedal height variation before brake applied

 VARIATION AFTER BRAKE APPLIED: Due to 7mm of variation in the length from TMC bracket center hole to
brake stud pin resulted in the variation of brake pedal height of 57mm. In this case, 1 mm variation from TMC
mtg brkt center hole to brake pedal stud results in 8.14 mm of brake pedal height variation after brake applied
TMC mtg brkt Brake Pedal Pedal height after
S.No Chassis No. center hole to Height brake applied (add
brake stud split (add 6.57 8.14 cumulative)
pin center hole cumulative)
108 71236 208 mm 132.00 mm 50 mm
‘’ ‘’ 207 mm 138.57 mm 58.14 mm
‘’ ‘’ 206 mm 145.14 mm 66.28 mm
‘’ ‘’ 205 mm 151.71 mm 74.42 mm
‘’ ‘’ 204 mm 158.28 mm 82.56 mm
‘’ ‘’ 203 mm 164.85 mm 90.70 mm
‘’ ‘’ 202 mm 171.42 mm 98.84 mm
‘’ ‘’ 201 mm 178.00 mm 107.00 mm

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 5. Analysis
5.2 Confirm the probable cause: Inference Analysis 2
TMC mtg brkt
Brake Pedal center hole to Brake Pedal Brake pedal mtg
height after TMC Adjuster
S. No Chassis No. brake stud split Height before stud height from
threads Brake ok
brake applied pin center hole brake floor
applied
11 71138 207 140 72 97 4 Ok
51 71179 206 152 80 96 4 Ok

 VARIATION BEFORE BRAKE APPLIED: Due to 7mm of variation in the length from TMC bracket center hole to
brake stud pin resulted in the variation of brake pedal height of 46mm. In this case, 1 mm variation from TMC mtg
brkt center hole to brake pedal stud results in 6.57 mm of brake pedal height variation before brake applied

 VARIATION AFTER BRAKE APPLIED: Due to 7mm of variation in the length from TMC bracket center hole to
brake stud pin resulted in the variation of brake pedal height of 57mm. In this case, 1 mm variation from TMC
mtg brkt center hole to brake pedal stud results in 8.14 mm of brake pedal height variation after brake applied
TMC mtg brkt Brake Pedal Pedal height TMC mtg brkt Brake Pedal Pedal height after
center hole Height after brake S.No Chassis No. center hole to Height brake applied
S.No Chassis No. to brake stud (add 6.57 applied (add brake stud split (add 6.57 (add 8.14
split cumulative) 8.14 pin center hole cumulative) cumulative)
pin center cumulative) 51 71179 206 mm 152.00 mm 80.00 mm
hole ‘’ ‘’ 205 mm 156.57mm 88.14 mm
11 71138 207 mm 140.00 mm 72.00 mm ‘’ ‘’ 204 mm 163.14 mm 96.28 mm
‘’ ‘’ 206 mm 146.57mm 80.14 mm
‘’ ‘’ 203 mm 169.71 mm 104.42 mm
‘’ ‘’ 205 mm 153.14 mm 88.28 mm
‘’ ‘’ 202 mm 176.28 mm 112.56 mm
‘’ ‘’ 204 mm 159.71 mm 96.42 mm
‘’ ‘’ 203 mm 166.28 mm 104.56 mm ‘’ ‘’ 201 mm 182.85 mm 120.70 mm
INFERENCE clearly justifies that if TMC Mtg bracket to
‘’ ‘’ 202 mm 172.85 mm 112.70 mm
brake pedal stud received as per spec, The brake pedal
‘’ ‘’ 201 mm 179.42 mm 120.84 mm height before and after brake apply will be automatically
achieved with out adjusting TMC Push rod nut.

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5. Analysis
5.2 Confirm the probable cause:

By loosening the Front flexible brake hose Hypothesis

Leak slightly, We performed the bleeding operation,
3 detection Visually/Trail at vacuuming stage operation get failed, so on Invalid
poor performing certain trails on the machine we
found the machine problem is not evident.

Under torque spec given to Vacuum fault detected by Process fault shown on the Process fault shown on the
front flexible banjo bolt the brake bleeding machine machine as leak detected machine as leak detected

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5. Analysis
5.2 Confirm the probable cause:
No Testing Observations Conclusion
Probab
le fitment
Wrong method By observing all the sequence following in line
Causefor
sequence we found abnormality in adjusting TMC Push Hypothesis
4 Visually
brake rod before brake bleeding for achieving brake Valid
adjustments pedal height (182+/-2 mm).

S. No Fitment Sequence
1 13 joints torque application
2 TMC mtg to bracket
3 Applying torque to TMC
4 Placing brake pedal to stud
5 split pins fitment to brake pedal
6 Connect TMC push rod to brake pedal
Adjust TMC push rod threads to achieve brake
7 pedal height (182+/-2mm)

8 Brake bleeding through machine

9 Brake switch mtg to bracket

10 Process complete

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5. Analysis
Suspecting this lock nut as disturbed before brake
Sectional view of TMC bleeding &shackle moved outwards and there will be no
free play in pedal. This result in push rod moving in arrow
direction further moving of piston suspecting piston seal
May block 0.5 mm hole. (As hole will block completely
0.5mm the vacuuming process by the machine will not done
Dia hole completely in machine and some portion of air will left
Seal inside TMC , as air is compressible and Brake fluid is
incompressible, suspecting brake not ok

For testing the above observations we decided to take a trail, process

change as first brake bleeding through machine with out adjusting the
TMC mtg nut and after Brake Bleeding adjust the TMC nut to fulfill the
requirements of brake pedal height (182+/-2mm)

Mahindra Quality System (A. S.) 28

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 5. Analysis
5.2 Confirm the probable cause:
Conducted trial on 2 days full production (280 vehicles) by setting brake pedal height 182+/- 2 mm after brake bleeding in and found zero
occurrence of brake bleeding related issues hence hypothesis valid.
TMC Adjuster TMC Adjuster
TMC Adjuster TMC Adjuster Chassis Threads(from Brake Brake Chassis Threads(from Brake
S.No Chassis Threads(fromBrake not Brake ok S.No Chassis Threads(from Brake not Brake ok S.No S.No
No. ok No. ok No. not ok ok No. not ok
supplier) supplier) supplier) supplier) Brake
1 71128 4 ok 31 71158 4 ok 61 71189 4 ok 91 71219 4 ok
ok
2 71129 4 ok 32 71159 4 ok 62 71190 3 ok 92 71220 4 ok
3 71130 4 ok 33 71160 7 ok 63 71191 3 ok 93 71221 4 ok
4 71131 4 ok 34 71161 4 ok 64 71192 3 ok 94 71222 4 ok
5 71132 4 ok 35 71163 4 ok 65 71193 3 ok 95 71223 4 ok
6 71133 4 ok 36 71164 4 ok 66 71194 2 ok 96 71224 4 ok
7 71134 4 ok 67 71195 4 ok 97 71225 4 ok
37 71165 4 ok
8 71135 4 ok 68 71196 3 ok 98 71226 4 ok
38 71166 4 ok
9 71136 4 ok 69 71197 3 ok 99 71227 4 ok
39 71167 4 ok
10 71137 4 ok 70 71198 3 ok 100 71228 4 ok
40 71168 4 ok
11 71138 4 ok 71 71199 3 ok 101 71229 4 ok
41 71169 4 ok 72 71200 4 ok 102 71230 4 ok
12 71139 4 ok
42 71170 4 ok 73 71201 3 ok 103 71231 4 ok
13 71140 4 ok
14 71141 4 ok 43 71171 4 ok 74 71202 3 ok 104 71232 4 ok
15 71142 4 ok 44 71172 4 ok 75 71203 4 ok 105 71233 4 ok
16 71143 4 ok 45 71173 4 ok 76 71204 8 ok 106 71234 4 ok
17 71144 4 ok 46 71174 4 ok 77 71205 4 ok 107 71235 4 ok
18 71145 4 ok 48 71176 4 ok 78 71206 4 ok 108 71236 4 ok
19 71146 4 ok 49 71177 4 ok 79 71207 4 ok 109 71237 4 ok
20 71147 4 ok 80 71208 4 ok 110 71238 4 ok
50 71178 4 ok
21 71148 4 ok 81 71209 4 ok 111 71239 4 ok
51 71179 4 ok
22 71149 4 ok 82 71210 4 ok 112 71240 4 ok
52 71180 4 ok
23 71150 4 ok 83 71211 4 ok 113 71241 4 ok
53 71181 4 ok
24 71151 4 ok 84 71212 4 ok 114 71242 4 ok
54 71182 4 ok 85 71213 4 ok 115 71243 4 ok
25 71152 4 ok
55 71183 4 ok 86 71214 4 ok 116 71244 6 ok
26 71153 4 ok
27 71154 4 ok 56 71184 3 ok 87 71215 4 ok 117 71245 4 ok
28 71155 4 ok 57 71185 2 ok 88 71216 4 ok 118 71246 4 ok
29 71156 4 ok 58 71186 4 ok 89 71217 4 ok 119 71247 4 ok
90 71218 4 ok 120 71248 4 ok
30 71157 4 ok 60 71188 4 ok
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5. Analysis
5.2 Confirm the probable cause:
TMC flange face to We have cross verified 50 Tandem master
Hypothesis
shackle hole cylinders and found the dimension between the
5 center dimensional Vernier TMC flange face to Shackle hole center is with Invalid
variation in specification the tolerance range is (220 +/-
1.0 mm)

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5. Analysis
5.2 Confirm the probable cause:
In confirm the probable cause we have taken
Brake
the Filling pressure readings of the brake Hypothesis
bleeding
6 Visually/Trail bleeding machine and observed that the all the
pressure not Invalid
readings(not fall below the set value) (Set
achieved
value: 3.5 Bar)

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5. Analysis
5.2 Confirm the probable cause:

Following are the Probable causes identified for Brake bleeding related issues

S. No Probable Cause
1 TMC Vacuum leakage

2 TMC Mtg brackets distance fired

3 Wrong fitment sequence for brake adjustments

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WHY - WHY Analysis
5.3 Identify the root causes:
ACTION
S. No EFFECT WHY WHY

TO REPLACE IMPACT TYPE

Wrong air connections are
PUNCHING CYLINDER TO
Grommet missing inside the made to impact type
REGULAR DOUBLE
1 TMC Vacuum leakage secondary port not been punching cylinder and
ACTING CYLINDER TO
identified during reservoir test leakage inside impact type
AVOID OPERATING
punching cylinder
DURING TESTING CYCLE

ICA: TMC MTG BRKT TO

BRAKE PEDAL STUD
DISTANCE TO BE
CORRECTED AS PER
Distance variation is due to No fixture and gauge
TMC Mtg brackets DRAWING
2 fixture and gauge were not in monthly calibration and
distance fired PCA: MONTHLY
good condition maintenance
CALIBRATIONS FOR ALL
FIXTURES AND GAUGES
INITIATED AT SUPPLIER
END
PROPER PROCESS
Wrong fitment Inadequate SOP for pedal Improper process defined DEFINITION THAT BRAKE
3 sequence for brake height (182+/- 2mm) when the brake pedal height PEDAL ADJUSTMENT TO BE
adjustments adjustment. requirement raised by PVT DONE AFTER BRAKE
BLEEDING
PROCESS

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6. Implement the corrective measures
6.1 Actions Decided

Root Cause Action Plan Target Dt Resp. Status

To replace impact type

punching cylinder with regular
TMC Vacuum double acting cylinder to avoid 10.08.2012 VGS Prasad CLOSED
leakage operating during testing cycle.

ICA: TMC mounting brkt to rake

stud distance to be corrected as
TMC Mtg brackets per drawing
distance fired PCA: Monthly calibration of BHANU
CLOSED
all gauges and fixtures initiated 25.12.2013 PRAKASH
at supplier end.

Brake bleeding process to be

Wrong fitment changed, first brake bleeding
sequence for brake through machine and next
adjustment of TMC push rod nut K VAMSI CLOSED
adjustments 25.12.2013
to achieve brake pedal height
(182 +/- 2mm)

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6. Implement the corrective measures
Root Cause Action Plan Target Dt Resp. Status
To replace impact type punching
cylinder with regular double
TMC Vacuum acting cylinder to avoid operating 10.08.2012 VGS Prasad CLOSED
leakage during testing cycle.

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6. Implement the corrective measures

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6. Implement the corrective measures

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6. Implement the corrective measures

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6. Implement the corrective measures

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6. Implement the corrective measures

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6. Implement the corrective measures

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6. Implement the corrective measures
Impact type punching cylinder is replaced with regular double acting
cylinder to avoid operating during testing cycle.

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6. Implement the corrective measures
Root Cause Action Plan Target Dt Resp. Status

ICA: TMC mounting brkt to rake

stud distance to be corrected as
TMC Mtg per drawing
brackets PCA: Monthly calibration of all 25.12.2012 Bhanu Prakash CLOSED
distance fired gauges and fixtures initiated at
supplier end.

Brake stud and brake

switch bracket combined
fixture(modified)

The brake pedal stud mtg fixture and TMC mtg bracket fixtures are
corrected as per the required dimensions (202 mm Max dimension) and
fixture condition is monitored every 15 days at the supplier end frequently
and separate fixture audit will be done accordingly with plan

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6. Implement the corrective measures
Root Cause Action Plan Target Dt Resp. Status

Wrong fitment Brake bleeding process to be changed,

sequence for first brake bleeding through machine
brake and next adjustment of TMC push rod 25.12.2012 K vamsi CLOSED
nut to achieve brake pedal height (182
adjustments +/- 2mm)

S.no BEFORE AFTER (To be modified)

1 13 joints torque application 13 joints torque application
2 TMC mtg to bracket TMC mtg to bracket
3 Applying torque to TMC Applying torque to TMC
4 Placing brake pedal to stud Placing brake pedal to stud
5 split pins fitment to brake pedal split pins fitment to brake pedal
6 Connect TMC push rod to brake pedal Connect TMC push rod to brake pedal
Sequence
Adjust TMC push rod threads to achieve Brake bleeding through machine with out number 7 & 8
7 brake pedal height (182+/-2mm) adjusting TMC push rod interchanged

8 Brake bleeding through machine Adjust TMC push rod threads to achieve
brake pedal height (182+/-2mm)
9 Brake switch mtg to bracket Brake switch mtg to bracket
10 Process complete Process complete

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7. Check & confirm the results & effects
7.1 Verify Results:

Brake Bleeding related issues(occurrence/ Month)

300
238 255 234
250 217 221 210 225 201 195 190 186
200
PCA
150 203 2
100 PCA 1
50 0 0 0
0

7.2 Full Scale Implementation plan:

Root Cause Action Plan Target Dt Resp. Status

To replace impact type punching cylinder

with regular double acting cylinder to avoid 10.08.2012 VGS Prasad CLOSED
TMC Vacuum leakage operating during testing cycle.

Play should be arrested to free release to

cover the 2mm clearance of brake pedal 25.12.2013 BHANU PRAKASH CLOSED
TMC Mtg brackets distance shaft and center beam brkt hole
fired

Brake bleeding process to be changed, first

Wrong fitment sequence brake bleeding through machine and next
adjustment of TMC push rod nut to achieve 25.12.2013 K VAMSI CLOSED
for brake adjustments
brake pedal height (182 +/- 2mm)

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7. Check & confirm the results & effects
7.3 Tangible Benefits

1. Elimination of V1+ Concern

2. Improvement in quality indicators (FRC, FBO & DPV)
3. Rework cost saved (Avg 230veh/month-Rs. 96,600/- per year)
4.Rework at hold eliminated.
5. Brake efficiency increases.
6. Elimination of manual brake bleeding
7. Customer quality increases
8. Improved Delivery performance in PDI

7.3 Intangible Benefits

 Effective functioning of brakes

 Morale of the operator is increased.
 Customer satisfaction increases

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8. Standardisation
8.1 Updation of documents:

DCP documents PFC,PFMEA, CP & SOP updated

(PSW Ref no: ALFA/ASSY/PCRN/F’13/13)

PCRN (PCRN No: ALFA-F13-13)

Concern closure report (ZCB3Q46212)

Process sheets updated.

8.2 Training:

Concerned operators are given OPL’s and made familiar with the concept
regarding its function, operation

8.3 Additional Audit / Check

Process modification added in Process Audits

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9. Summarise & Plan future actions
9.1 Conclusion:

By doing the several analysis, concluding the results from analysis the process
change and the bracket correction from supplier eliminated the long pending,
Top FBO effected concern brake bleeding related issues completely thrown
out.
9.2 Horizontal Deployment:

Horizontal deployment can be applied for all 3-wheeler model manufacturers.

Information shared with HARIDWAR also.
9.3 Lessons Learnt:

TGR: By process change in brake bleeding process and brkt correction at

supplier end ,issue thrown out completely.
TGW: After Process change we felt that due to pressure of brake fluid the brake
shoe liners and padding may subjected to severe temperature changes and we
checked the temperature and found ok (No color fading observed to the Brake
shoe liners).

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QC STORY PLAN
JUL'12 AUG'12 SEP'12 OCT'12 NOV'12 DEC'12
SR ACTIVITY
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

1
Problem selection

2
Setting Goal

3 Data collection to understand

current situation

4
Analysis of cause

Validation and verification of

5 possible cause for brake
bleeding related issues
Validation and verification of
6 possible cause for brake
bleeding process
7 Counter measure of potential
root causes

8 PLAN
Standardization of action
COMPLETE

9 Conclusion (Sum-up &

Presentation)

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 Thank You

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