QUALITY ENGINEERING

QUALITY ENGG
QUALITY RECEIPT VENDOR QUALITY ASSURANCE QUALITY MANUFACTURING

RECEIPT MATL. INS. LABS STANDARD ROOM

VENDOR QUALITY AUDIT

WARRANTY

CABIN / PAINT SHOP ENGINE T/MISSION VEHICLE ASSY. PRE- DISPATCH

TROUBLE SHOOTING

AUDIT & SAMPLES INSPECTION OF SML/ISUZU

IMPROVEMENTS OF SML / ISUZU COMPONENTS KAIZEN PROJECT

VENDOR VALIDATION

NEW RECEIVING GAUGES INTRODUCTION

ASSEMBLY AUDIT AT SML PRODUCTION LINE

FLOW CHART FOR VENDOR QUALITY ASSURANCE

DATA COLLECTION FOR PROBLEM FROM Q.E.RECEIPT Q.E.MANUFACTURING DATA COMPILATION BRAIN STORMING COMPONENT AUDIT STUDY REPORT W.R.T . PROBLEM VENDOR AUDIT FACILITIES AUDIT SYSTEM AUDIT IN COMING MATL. CONTROL IN PROCESS QUALITY CONTROL FINISHED PRODUCT Q.C. BATCH CODE CONTROL DRG. / SPECIFICATION CONTROL CALIBRATION NON CONFORMANCE LIST OF IMPROVEMENTS AS PER VENDOR VISIT IMPLEMENTATION OF IMPROVEMENTS STUDY OF IMPROVED LOTS FEED BACK FROM Q.E.(RECEIPT) Q.E.(MFG.) REPEAT IMPROVEMENT CYCLE IF REQUIRED TO ACHIEVE ZERO DEFECT REGULAR AUDIT HOLDING GAIN IMPLEMENTATION C.S.D. PROCESS AUDIT C.S.D

MANPOWER FACILITIES PRODUCTION CAPACITY INSPECTION FACILITIES LABORATORY FACILITIES

PREPRATION OF PROCESS SHEETS PROCESS STUDY ACCORDANCE TO MAN / MACHINE / MATERIAL TO ANALYSE THE PROBLEM

HOLDING GAIN
SWARAJ

MAZDA

"HOLDING GAIN" CONFIRMATION REPORT

SUPPLIER'S ADDRESS PART NO.: DATE :

PART NAME:

L. AUDIT DATE:

PREVIOUS IMPLEMENTED PARAMETERS

PRESENT STATUS

REMARKS

FOR M/S

FOR M/S SWARAJ MAZDA LTD.

AUDIT PLAN
I) AUDIT PLANS ARE MADE IN THE FORM OF BELOW FORMAT(SML/ISUZU)
P- 1 S.No. 1 COMPONENTS AUDIT PLAN - V.Q.A. CELL VENDOR NAME SWARAJ ENGINE COMPONENT NAME 1.CYL. BLOCK* 2.CONN. ROD* 3.CYL. HEAD* AREA : ENGINE AUDIT MONTH & DATE

MAHLE MIGMA

1.CAM SHAFT 2.TAPPET

II) AUDIT SUMMERY IS GENERATED TO REVIEW THE AUDIT REPORTS

COMPONENTS AUDIT STATUS SUMMERY ( Period : Nov. 07 ~ Dec.07)
Through : D.G.M.-(Q.A.) Total comp. audit : 30 Out of 30 comp. audited during the period of mid nov.~dec. 07, 22 nos. found accepted & 08 nos. are having discrepancies. The latest status for defective components is given below : S.No. 1 Comp. Name / Vendor Plate Thrust/ Fadral Mogul Audit Date
29/11/07

Accepted Defective Status

: 22 : 08

Defect Chamfer reqd. on both sides of bore

SWARAJ MAZDA
S.NO 1 PROBLEM

MAZOR IMPROVEMENTS
ACTION TAKEN AFTER ANALYSIS VARIOUS CORRECTIONS DONE AT VENDOR END LIKE WELDING FIXTURE CORRECTED FOR DIM. 121+/-0.2 & 263, RECEIVING GAUGE ALSO MODIFIED ACCORDINGLY. AT SML IN BODY SHOP WELDING POSITION OF CROSS MEMBER NO.-4 ALSO MAINTAINED BY RECTIFYING THE ELEMENTS. ELEMENTS FOR BRKT. CAB. MTG. ALSO REPLACED STATUS FIVE POINT FIXTURE IS SEATED IN EVERY CHASSIS

FIVE POINT FIXTURE SEATING PROBLEM DURING ASSY. OF CHASSIS

BREAKAGE OF CONNECTOR BOLT IN FEILD

TORQUE REQD. AT ASSY. LINE IS 1~1.6 Kgm. IS CONTROLLED BY SMALL GUN IW4 & WITH THE INSTALLATION OF FRL UNIT. MATERIAL OF BOLT CONNECTOR CHANGED TO COLD FORGING. RECEIVING GAUGE ALSO INTRODUCED TO CHECK THE CENTRILITY OF HOLE

NO CASE REPORTED THEREAFTER FROM FEILD

BUZZER BEEP PROBLEM OCCURRED AT PDI OF VEHICLE

IT WAS DUE ELONGATION OF VALVE ASSY. DURING TIGHTENING IN THE BODY ASSY. A SPECIAL TYPE OF TORQUE WRENCH IS INTRODUCED AT VENDOR END TO CONTROL THE TORQUE 1.8 Kgm. IT WAS DUE TO CASTING VARIATION, A FLYWHEEL FOULING RECEIVING GAUGE IS INTRODUCED AT BOTH SML & VENDOR END TOOTH ROOFING ANGLE 45* OF 2ND GEAR IMPROVED AT PTL, WHICH CAUSED THE SLIPPAGE OF HUB SLEEVE DURING ENGAGED CONDITION IT WAS DUE THE LACK OF LUBRICATION BETWEEN THR RESTING FACES DURING THE CLIMBING CONDITION, OIL GROOVE DEPTH & PROFILE IMPROVED IN 3RD GEAR TO PROVIDE PROPER OIL FILM

NO BUZZER PROBLEM REPORTED FROM PDI

FLYWHEEL FOULING IN HSG. CLUTCH

WHERE GAUGE FOUL IS MANNUAL GRINDED TRIAL DONE IN NAGPUR & MANDI AREA , SUCCEED NO SEIZURE REPORTED FROM THE FIELD FOR LAST SIX MONTH TRIAL MADE & NO FAILURE REPORTED

2ND GEAR SLIPPAGE STRIKED OUT FROM THE FEILD

3RD GEAR SEIZURE REPORTED FROM THE FEILD

AUXILLARY GEAR SLIPPAGE REPORTED FROM FEILD

DESIGN OF HUB CLUTCH IMPROVED AS PER 4WD SHAFT OUT-PUT

BELT COMING OUT FROM PULLEY V-GROOVE

BRIDGE STRENGTHENED BY PROVIDING STRIPS ON BOTH SIDES

BELT COMING OUT PROBLEM SOLVED

MAZOR IMPROVEMENTS
ISUZU
S.NO . PROBLEM ACTION TAKEN STATUS

Gear lever assy. Excess Play leads to vibrations Consequentially gear slippage Occurred

Major improvements are carried out in improving all child parts Like Support Change Lever, Arm select, Gear Lever, Relay Lever, Plate Change Lever by rectifying dies & introducing new receiving Gauges like Self centering & vertical play checking fixture at M/S New Swan & Plastic part Spherical cover & Seat change lever from Plastic comp.

Vibration controlled Gear slippage due to Gear Lever stopped

Serration worn out in Worm Types Clamps at specified torque 0.5+/-02 Kgmf

MS Worm types clamps are not suitable for High Pressure Pipes Like Turbo Replaced with the Stainless worm types clamps

No failure Ouccur Up to 1.4 Kgmf

Relay Lever Select / Shift ,all CD Variations & hard movement leads to hard gear Shifting & cable failure

Various Improvements are carried out at M/S Dev engg. In Process , New Receiving gauges and welding & assy. fixtures introduced

Free movement of Levers observed

Cable Shift / Select rubber Seal Coming out & Ball end fixed length variations

Cables end makes as per Isuzu / NQR Ball joints end fixed as per drawing to overcome manual adjustment at line

No seal coming out & manual adjusting Done at line

Rod Shift / Select ball end fixed Length variation

Assy. Fixtures made at vendor end to fix ball end joints length

No adjustment required

Various dimn. Variations in Pedal Board leads to fitment & stress on outrigger front

All CDs improved in process & receiving gauge rectified accordingly

No fitment problem & twist observed at Outrigger front

KAIZEN

VENDOR VALIDATION
SOURCE APPROVAL REPORT
QUALITY ENGINEERING SWARAJ MAZDA

Basic Information 1.Vendor name & address: 2. Contact Person Mobile No.

i)

ii)

Tel. No.: E.mail:

Fax:

iii)

3. Date of visit: 5. Technical Expertise : Self / Dependent 7. Ownership Structure :Ltd. / Pvt. Ltd. / Prop. / Part./Ship

4. Overall Turnover (Last financial year) 6. OEM Supplier : 8. Available Quality Systems : ISO / QS / TS / Any other

RATING
GENERAL OBSERVATIONS RATING 0 i) Infrastructure a) Machine Condition b) Fixture & Tooling c) Building & Environment ii) Owner/ Employee Attitude iii) Employee Motivation iv) Skilled Supervision v) Skilled Manpower vi) Quality System a) Inspection Procedure (raw / in-process / finish ) b)Instrument both at Line & PDI c) Receiving Gauges & calibration d) Calibration of Jigs/ M/c/Tooling & Instruments e) NCR feedback system f) Traceability of In-Process rejected material vii) Material Handling vii) Packing & Storage of finish part 1 2 3 Remarks

GRADING & STATUS

** Grading : "0" No System / "1" Average / "2" Adequate / "3" Excellent ** Add up all the grading points :

** Calculate the percentage of points scored out of total ;

** if the score is : More than 85% 60% To 85% Systems are excellent & source is approved Systems are good but the source may be reviewed for approval only after the improvements are carried out in

deficient area.

Less than 60% Remarks:

Source is rejected

Validated By

Approved By

RECEIVING GAUGES
RECEIVING GAUGE TO CHECK FOULING OF FLY-WHEEL IN CLUTCH HOUSING, IMPLEMENTED BOTH AT SML & VENDOR END

RECEIVING GAUGE TO CHECK CENTER DISTANCE OF ARM KNUCKLE (4WD)

INCSPECTION PIN TO CHECK TAPER HOLE PROFILE OF ARM KNUCKLE

RECEIVING GAUGES

DIAL RECEIVING GAUGE TO CHECK FACE RUN-OUT OF FILTER MOUNTING FACE OF BODY ASSEMBLY A SELF-CENTERING FIXTURE TO CHECK PRE-LOAD (2 ~ 3 Kgf )OF ISUZU GEAR LEVER

ASSEMBLY AUDIT
TO :- ASSEMBLY (MAIN LINE) S.NO. 1 2 3 4 5 6 7 8 9 CHECK POINT SHACKLE ASSY. NUT TORQUE FIVE POINT FIXTURE SEATING SILENCER BRKT. MTG. BOLT TORQUE TRANSMISSION BRKT. MTG.BOLTS TORQUE ENGINE MTG. BRKT. GEAR & PITMAN MTG. BOLT TORQUE CNG CYLINDER MTG. BRKT. BOLT TORQUE TIE ROD NUT TORQUE HUB NUT TORQUE THROUGH : D.G.M-Q.A. CONTROL SPEC. 12~15 Kgm SEAT 100% 4.4 ~ 6.2 Kgm 5.6~8.2 Kgm 5.6~8.2 Kgm 8~9.5 Kgm 6~7.5 Kgm 10 ~ 12 Kgm 45~50Kgm (Front) (Rear) 45~50Kgm (Front) PDI AREA 10 STABLIZER BAR MTG. NUT TORQUE CNG AREA 11 CYLINDER MTG. BRKT. BOLT TORQUE AXLE AREA 12 FREE MOVEMENT OF BOLT AUDIT PLANS ALSO MADE FOR ENGINE / TRANS 6 ~ 7.5 Kgm (Rear) 3.8 ~ 4.6 Kgm MAIN LINE DATE :REMARKS