Professional Documents
Culture Documents
PU KM
Date
Total Prod. Total Rew. Rew. % Total Scrap
2 0 0 #DIV/0! 0
16 0 0 #DIV/0! 0
23 0 0 #DIV/0! 0
24 1,367 0 0 126
25 1,703 0 0 184
26 961 0 0 78
27 3,123 0 0 110
29 0 0 #DIV/0! 0
30 0 0 #DIV/0! 0
31 0 0 #DIV/0! 0
#DIV/0! 0 0 #DIV/0! 0
4.5930232558 0 69 #DIV/0! 0
0.4812319538 1,776 0 0 0
#DIV/0! 1,569 0 0 0
#DIV/0! 0 0 #DIV/0! 0
#DIV/0! 0 0 #DIV/0! 0
#DIV/0! 0 0 #DIV/0! 0
0 1,256 0 0 0
#DIV/0! 0 0 #DIV/0! 0
0 1,790 0 0 0
0 1,531 0 0 0
0.4199475066 2,682 0 0 0
0 2,279 0 0 0
0 2,653 0 0 0
0 2,917 0 0 0
0.2777777778 1,822 0 0 0
0 1,894 0 0 0
#DIV/0! 2,170 0 0 0
0.1646090535 2,209 0 0 0
0.0902527076 2,933 0 0 0
0.521648409 2,249 0 0 0
0 2,901 0 0 0
0 2,686 0 0 0
0 2,004 0 0 0
#DIV/0! 2,048 0 0 0
0 2,448 0 0 0
0 2,406 0 0 0
0 2,646 0 0 0
0 2,783 0 0 0
0.0775193798 1,133 0 0 0
0.5728314239 3,001 0 0 0
0.0961538462 2,583 0 0 0
0.9222661397 1,688 0 0 0
0.3484320557 2,346 0 0 0
0 2,177 0 0 0
#DIV/0! 0 0 #DIV/0! 0
#DIV/0! 0 0 #DIV/0! 0
#DIV/0! 0 0 #DIV/0! 0
0.1209325871 61,235 0 0 0
Scrap%
#DIV/0!
0
0
#DIV/0!
#DIV/0!
#DIV/0!
0
DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Wednesday, February 01, 2017
PU (KM 1) Stitching PU (KM 1)
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 335 353 365 1,053 39 47 44 130 12.35 4 3 4 11 1.04 150 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
7 Vespa (MY15) 43 59 60 162 12 21 29 62 38.27 0 1 0 1 0.62 151 0 0.00 0 0.00 6 Voids 42 0 0 0 0 0 0 12 0 34 0 0 81 10 22 19 30 55 305 8.90
8 JY (MY 16) 0 60 0 60 0 9 13 22 36.67 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 21 0 0 0 0 0 0 0 0 6 0 0 16 0 3 10 6 3 65 1.90
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 130 0 0 0 0 0 0 22 0 62 0 0 148 33 80 75 64 70 684 19.95
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0!
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
13 K4 Front 145 178 63 386 69 40 39 148 38.34 2 0 2 4 1.04 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 1 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 1 0 5 0.15
14 K4 Rear 146 176 185 507 10 13 10 33 6.51 0 0 1 1 0.20 90 0 0.00 0 0.00 2 Release Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
15 K10 Front 98 122 186 406 29 22 29 80 19.70 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 3 0.09
16 K 10 Rear 101 120 126 347 24 23 28 75 21.61 0 1 0 1 0.29 650 0 0.00 0 0.00 4 Collapse 4 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 1 0 7 0.20
17 MY17 Front 62 63 124 249 11 22 31 64 25.70 1 2 2 5 2.01 95 0 0.00 0 0.00 5 Soft 6 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 8 #DIV/0!
18 MY17 Rear 66 65 64 195 15 28 27 70 35.90 0 0 0 0 0.00 120 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 63 63 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 996 1,196 1,236 3,428 209 225 250 684 19.95 7 7 9 23 0.67 1,256 0 0.00 0 0.00 Total 11 0 0 0 0 0 0 0 0 1 0 0 4 1 1 0 5 0 23 0.67
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 280 0 0 280 40 0 0 40 14.29 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 19.95 25.4974 0.67 2.95815
15 K10 Front 396 0 0 396 64 0 0 64 16.16 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 13.73 15.7156 0.00 0.12093 14.36 0.35
16 K 10 Rear 338 0 0 338 33 0 0 33 9.76 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 218 0 0 218 16 0 0 16 7.34 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 102 0 0 102 22 0 0 22 21.57 0 0 0 0 0.00 0 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 Qty 16 7 0 0
TOTAL 1,850 0 0 1,850 254 0 0 254 13.73 0 0 0 0 0.00 Total 0 0 0 8 9 13 0 0 0 0 49 40 64 33 16 22 254 0 % 0.47 0.20 0.00 0.00
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY #DIV/0! 15.7156 #DIV/0! 0.12093 #DIV/0! #DIV/0!
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 384 440 0 824 39 59 0 98 11.89 2 2 0 4 0.49 750 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 273 0 0 273 24 0 0 24 8.79 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 19.18 25.4974 0.45 2.95815
15 K10 Front 69 0 0 69 18 0 0 18 26.09 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 19.29 15.7156 0.00 0.12093 11.87 0.15
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 485 445 0 930 97 85 0 182 19.57 3 6 0 9 0.97 1,050 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 35 0 0 35 6 0 0 6 17.14 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 14.76 15.7156 0.00 0.12093 11.81 0.93
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 568 333 0 901 110 48 0 158 17.54 1 4 0 5 0.55 950 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 888 0 0 888 59 0 0 59 6.64 6 0 0 6 0.68 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 6 6 PU 22.04 25.4974 2.06 2.95815
15 K10 Front 108 0 0 108 21 0 0 21 19.44 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 2 2 ASSLY 12.65 15.7156 0.42 0.12093 10.49 0.76
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 333 420 0 753 62 64 0 126 16.73 5 3 0 8 1.06 1,135 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
7 Vespa (MY15) 50 58 0 108 29 15 0 44 40.74 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 6 Voids 62 0 0 0 0 0 0 3 0 16 0 0 50 0 0 0 27 38 196 10.21
8 JY (MY 16) 48 59 0 107 5 3 0 8 7.48 0 1 0 1 0.93 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 12 0 0 0 0 0 0 0 0 13 0 0 12 0 0 0 0 1 38 1.98
9 KHI F 0 0 0 0 12 0 0 12 #DIV/0! 2 0 0 2 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 126 0 0 0 0 0 0 8 0 44 12 0 91 7 0 0 41 48 377 19.65
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0!
11 DT Front 44 122 0 166 0 0 0 0 0.00 10 27 0 37 22.29 73 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 43 122 0 165 0 0 0 0 0.00 9 12 0 21 12.73 73 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
13 K4 Front 0 162 0 162 47 44 0 91 56.17 1 0 0 1 0.62 240 0 0.00 0 0.00 1 Vent trap 2 0 0 0 0 0 2 1 0 0 0 0 1 0 0 0 0 0 6 0.31
14 K4 Rear 0 0 0 0 5 2 0 7 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 854 1,065 0 1,919 184 193 0 377 19.65 28 43 0 71 3.70 2,279 0 0.00 0 0.00 Total 7 0 0 0 0 37 21 1 0 0 2 0 1 0 0 0 1 1 71 3.70
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 107 0 0 107 23 0 0 23 21.50 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 19.65 25.4974 3.70 2.95815
15 K10 Front 157 0 0 157 27 0 0 27 17.20 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 15.20 15.7156 0.00 0.12093 10.66 1.23
16 K 10 Rear 403 0 0 403 17 0 0 17 4.22 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 121 0 0 121 21 0 0 21 17.36 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 109 0 0 109 19 0 0 19 17.43 0 0 0 0 0.00 0 0 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 Qty 13 15 0 43
TOTAL 1,553 0 0 1,553 236 0 0 236 15.20 0 0 0 0 0.00 Total 0 0 0 21 18 25 0 0 0 0 65 23 27 17 21 19 236 0 % 0.68 0.78 0.00 2.24
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 329 374 0 703 57 62 0 119 16.93 10 3 0 13 1.85 585 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
7 Vespa (MY15) 49 51 0 100 46 18 0 64 64.00 0 0 0 0 0.00 50 0 0.00 0 0.00 6 Voids 59 0 0 0 0 0 0 12 0 30 0 0 83 20 0 0 22 49 275 12.32
8 JY (MY 16) 49 56 0 105 8 11 0 19 18.10 0 1 0 1 0.95 242 0 0.00 0 0.00 7 Loose Skin 4 0 0 0 0 0 0 0 0 19 0 0 13 0 0 0 0 0 36 1.61
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 119 0 0 0 0 0 0 19 0 64 0 0 124 38 0 0 35 57 456 20.42
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0!
11 DT Front 135 96 0 231 0 0 0 0 0.00 31 17 0 48 20.78 148 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 131 71 0 202 0 0 0 0 0.00 15 6 0 21 10.40 128 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
13 K4 Front 167 164 0 331 68 56 0 124 37.46 1 1 0 2 0.60 404 0 0.00 0 0.00 1 Vent trap 2 0 0 0 0 3 5 0 0 0 0 0 0 0 0 0 0 0 10 0.45
14 K4 Rear 113 164 0 277 24 14 0 38 13.72 0 0 0 0 0.00 492 0 0.00 0 0.00 2 Release Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,112 1,121 0 2,233 235 221 0 456 20.42 57 44 0 101 4.52 2,653 0 0.00 0 0.00 Total 13 0 0 16 0 48 21 1 0 0 0 0 2 0 0 0 0 0 101 4.52
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
15 K10 Front 215 0 0 215 54 0 0 54 25.12 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 1 0 0 0 0 1 0 0 0 2 0 ASSLY 19.58 15.7156 0.00 0.12093 11.35 1.66
16 K 10 Rear 165 0 0 165 40 0 0 40 24.24 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 78 0 0 78 14 0 0 14 17.95 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 44 0 0 44 6 0 0 6 13.64 0 0 0 0 0.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Man Machine Method Material
19 Diwali 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Qty 21 20 0 60
TOTAL 1,195 0 0 1,195 234 0 0 234 19.58 0 0 0 0 0.00 Total 0 0 0 21 11 28 0 22 0 0 15 23 54 40 14 6 234 0 % 0.94 0.90 0.00 2.69
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 423 428 851 84 60 50 194 22.80 0 4 6 10 1.18 1,125 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
7 Vespa (MY15) 0 61 60 121 37 32 24 93 76.86 1 0 0 1 0.83 0 0 #DIV/0! 0 #DIV/0! 6 Voids 101 0 0 0 0 0 0 0 30 52 0 0 85 44 44 29 47 74 506 18.09
8 JY (MY 16) 0 63 62 125 20 13 12 45 36.00 0 1 0 1 0.80 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 23 0 0 0 0 0 0 0 0 15 0 0 18 2 1 0 0 0 59 2.11
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 194 0 0 0 0 0 0 0 45 93 0 0 134 62 126 91 76 102 923 33.00
15 K10 Front 0 123 120 243 51 41 34 126 51.85 0 0 1 1 0.41 237 0 0.00 0 0.00 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 1 0.04
16 K 10 Rear 0 116 122 238 33 32 26 91 38.24 0 1 2 3 1.26 471 0 0.00 0 0.00 4 Collapse 0 0 0 0 0 0 1 0 0 0 0 0 1 4 0 0 0 1 7 0.25
17 MY17 Front 0 62 61 123 33 25 18 76 61.79 0 0 1 1 0.81 116 0 0.00 0 0.00 5 Soft 8 0 0 0 0 1 0 0 0 0 0 0 0 0 1 2 0 0 12 #DIV/0!
18 MY17 Rear 0 62 62 124 32 41 29 102 82.26 0 4 6 10 8.06 15 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 9 1 0 0 0 0 0 0 0 0 0 0 0 10 0.36
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0.04
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1 0.04
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 19 2 0 0 0 0 0 0 0 0 0 0 0 21 0.75
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 17 25 0 0 0 0 0 0 0 0 0 0 0 42 1.50
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 0 1,518 1,279 2,797 370 301 252 923 33.00 38 63 19 120 4.29 2,917 0 0.00 0 0.00 Total 10 0 0 0 0 52 32 1 0 1 0 0 5 4 1 3 1 10 120 4.29
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 529 0 0 529 36 0 0 36 6.81 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 33.00 25.4974 4.29 2.95815
15 K10 Front 138 0 0 138 47 0 0 47 34.06 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 0 ASSLY 10.14 15.7156 0.00 0.12093 14.23 1.43
16 K 10 Rear 112 0 0 112 10 0 0 10 8.93 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 237 0 0 237 24 0 0 24 10.13 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 226 0 0 226 20 0 0 20 8.85 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 Qty 39 39 0 42
TOTAL 2,693 0 0 2,693 273 0 0 273 10.14 0 0 0 0 0.00 Total 0 0 0 21 39 28 0 0 0 0 47 36 47 10 24 20 272 0 % 1.39 1.39 0.00 1.50
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 500 470 0 970 100 54 0 154 15.88 2 0 0 2 0.21 350 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 117 114 0 231 41 24 0 65 28.14 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
16 K 10 Rear 108 119 0 227 39 35 0 74 32.60 0 0 0 0 0.00 158 0 0.00 0 0.00 4 Collapse 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.03
17 MY17 Front 53 58 0 111 45 27 0 72 64.86 0 1 0 1 0.90 102 0 0.00 0 0.00 5 Soft 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
18 MY17 Rear 55 59 0 114 41 43 0 84 73.68 0 1 0 1 0.88 99 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 2 0.07
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.03
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 3 0.10
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 6 1 0 0 0 0 0 0 0 0 0 0 0 7 0.23
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 12 35 0 0 0 0 0 0 0 0 0 0 0 47 1.53
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,515 1,559 0 3,074 439 269 0 708 23.03 28 41 0 69 2.24 1,822 0 0.00 0 0.00 Total 2 0 0 0 1 20 40 1 0 0 0 0 3 0 0 0 1 1 69 2.24
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
15 K10 Front 81 0 0 81 37 0 0 37 45.68 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 3 3 ASSLY 21.57 15.7156 0.28 0.12093 15.75 1.20
16 K 10 Rear 196 0 0 196 20 0 0 20 10.20 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 171 0 0 171 24 0 0 24 14.04 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 131 0 0 131 19 0 0 19 14.50 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 9 0 0 9 0 0 0 0 0.00 0 0 0 0 0.00 Qty 8 14 0 47
TOTAL 1,080 0 0 1,080 233 0 0 233 21.57 3 0 0 3 0.28 Total 0 0 0 7 20 32 0 14 0 0 28 32 37 20 24 19 233 3 % 0.26 0.46 0.00 1.53
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 292 378 0 670 68 76 0 144 21.49 4 3 0 7 1.04 625 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
7 Vespa (MY15) 31 0 0 31 0 0 0 0 0.00 0 0 0 0 0.00 140 0 0.00 0 0.00 6 Voids 81 0 0 23 0 0 0 9 0 0 0 0 69 17 13 21 36 57 326 13.08
8 JY (MY 16) 47 57 0 104 18 14 0 32 30.77 0 0 0 0 0.00 175 0 0.00 0 0.00 7 Loose Skin 10 0 0 0 0 0 0 0 0 0 0 0 20 3 0 6 0 5 44 1.76
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 144 0 0 29 0 0 0 32 0 0 0 0 125 30 34 41 60 76 571 22.90
15 K10 Front 91 98 0 189 10 24 0 34 17.99 0 0 0 0 0.00 100 0 0.00 0 0.00 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
16 K 10 Rear 89 109 0 198 10 31 0 41 20.71 1 0 0 1 0.51 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 2 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 3 0.12
17 MY17 Front 43 53 0 96 29 31 0 60 62.50 2 2 0 4 4.17 134 0 0.00 0 0.00 5 Soft 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 #DIV/0!
18 MY17 Rear 47 57 0 104 31 45 0 76 73.08 0 0 0 0 0.00 162 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1 #DIV/0!
19 Diwali (Front) 0 5 0 5 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0.04
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 4 0 0 0 0 0 0 0 0 0 0 0 0 4 0.16
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.04
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 2 0.08
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 8 6 0 0 0 0 0 0 0 0 0 0 0 14 0.56
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 8 11 0 0 0 0 0 0 0 0 0 0 0 19 0.76
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,069 1,424 0 2,493 242 329 0 571 22.90 35 39 0 74 2.97 1,894 0 0.00 0 0.00 Total 7 0 0 0 3 23 33 0 0 0 0 0 1 3 0 0 4 0 74 2.97
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 312 0 0 312 21 0 0 21 6.73 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 22.90 25.4974 2.97 2.95815
15 K10 Front 255 0 0 255 16 0 0 16 6.27 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 0 ASSLY 11.84 15.7156 0.00 0.12093 12.67 1.19
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 577 0 577 37 92 0 129 22.36 5 4 0 9 1.56 347 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 0 114 0 114 28 24 0 52 45.61 1 0 0 1 0.88 555 0 0.00 0 0.00 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
16 K 10 Rear 0 112 0 112 26 18 0 44 39.29 0 0 0 0 0.00 156 0 0.00 0 0.00 4 Collapse 9 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 10 0.58
17 MY17 Front 0 60 0 60 24 23 0 47 78.33 0 0 0 0 0.00 136 0 0.00 0 0.00 5 Soft 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
18 MY17 Rear 0 58 0 58 29 41 0 70 120.69 0 0 0 0 0.00 36 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0.06
20 Diwali (Rear) 0 50 0 50 0 0 0 0 0.00 1 2 0 3 6.00 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 3 0.17
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 29 6 0 0 0 0 0 0 0 0 0 0 0 35 2.03
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 4 11 0 0 0 0 0 0 0 0 0 0 0 15 0.87
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 0 1,720 0 1,720 205 265 0 470 27.33 44 35 0 79 4.59 2,170 0 0.00 0 0.00 Total 9 0 0 0 0 39 26 0 0 0 0 0 1 2 0 0 0 0 77 4.48
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
15 K10 Front 0 0 0 0 9 0 0 9 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY #DIV/0! 15.7156 #DIV/0! 0.12093 13.86 2.03
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 714 495 0 1,209 84 72 0 156 12.90 4 2 0 6 0.50 368 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 100 0 0 0 0 0 0 10 0 0 0 0 61 18 14 10 0 41 254 7.68
8 JY (MY 16) 82 78 0 160 3 19 0 22 13.75 0 2 0 2 1.25 72 0 0.00 0 0.00 7 Loose Skin 6 0 0 0 0 0 0 0 0 0 0 0 12 0 0 0 0 2 20 0.60
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 156 0 0 0 0 0 0 22 0 0 0 0 109 53 53 65 0 70 528 15.97
15 K10 Front 132 93 0 225 31 22 0 53 23.56 1 0 0 1 0.44 420 0 0.00 0 0.00 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
16 K 10 Rear 64 93 0 157 42 23 0 65 41.40 0 1 0 1 0.64 160 0 0.00 0 0.00 4 Collapse 3 0 1 0 1 1 0 0 0 0 0 0 0 0 1 1 0 0 8 0.24
17 MY17 Front 65 47 0 112 0 0 0 0 0.00 0 3 0 3 2.68 268 0 0.00 0 0.00 5 Soft 2 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 5 #DIV/0!
18 MY17 Rear 0 15 0 15 29 41 0 70 466.67 1 0 0 1 6.67 269 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0.03
20 Diwali (Rear) 60 7 0 67 25 3 0 28 41.79 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 2 0 7 0.21
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1 0.03
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 5 7 0 0 0 0 0 0 0 0 0 0 0 12 0.36
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 16 8 0 0 0 0 0 0 0 0 0 0 0 24 0.73
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,870 1,436 0 3,306 310 248 0 558 16.88 33 37 0 70 2.12 2,209 0 0.00 0 0.00 Total 6 0 1 0 2 29 21 2 0 0 0 3 0 0 1 1 3 1 70 2.12
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 356 0 0 356 39 0 0 39 10.96 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 16.88 25.4974 2.12 2.95815
15 K10 Front 18 0 0 18 7 0 0 7 38.89 1 0 0 1 5.56 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 2 2 ASSLY 20.91 15.7156 0.16 0.12093 12.07 1.07
16 K 10 Rear 238 0 0 238 47 0 0 47 19.75 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 97 0 0 97 19 0 0 19 19.59 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 188 0 0 188 28 0 0 28 14.89 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 18 28 0 24
TOTAL 1,215 0 0 1,215 254 0 0 254 20.91 2 0 0 2 0.16 Total 0 20 25 12 10 0 0 0 0 0 47 39 7 47 19 28 254 2 % 0.54 0.85 0.00 0.73
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 758 707 343 1,808 39 43 48 130 7.19 4 5 4 13 0.72 745 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 455 0 0.00 0 0.00 1 Vent trap 28 0 0 18 0 0 0 5 0 0 0 0 18 16 0 2 12 30 129 2.79
3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 6 0 0 0 0 0 0 0 0 0 0 0 3 6 0 0 1 3 19 0.41
4 Ktm Front 61 60 69 190 38 12 36 86 45.26 0 0 1 1 0.53 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 30 0 0 0 0 0 0 11 0 0 0 0 27 10 3 2 25 3 111 2.40
5 Ktm Rear 65 60 69 194 0 0 0 0 0.00 0 0 1 1 0.52 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 5 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 261 0 0.00 0 0.00 6 Voids 57 0 0 65 0 0 0 22 0 0 0 0 76 23 6 4 45 96 394 8.53
8 JY (MY 16) 122 112 71 305 23 15 0 38 12.46 2 1 0 3 0.98 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 9 0 0 3 0 0 0 0 0 0 0 0 14 0 1 0 0 1 28 0.61
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 130 0 0 86 0 0 0 38 0 0 0 0 138 55 10 8 83 133 681 14.75
15 K10 Front 60 0 0 60 34 0 0 34 56.67 1 0 0 1 1.67 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 ASSLY 18.14 15.7156 0.09 0.12093 10.17 0.73
16 K 10 Rear 175 0 0 175 22 0 0 22 12.57 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 173 0 0 173 0 0 0 0 0.00 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 157 0 0 157 0 0 0 0 0.00 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 24 28 0 10
TOTAL 1,108 0 0 1,108 201 0 0 201 18.14 1 0 0 1 0.09 Total 0 14 4 22 16 17 0 11 0 0 16 45 34 22 0 0 201 1 % 0.52 0.61 0.00 0.22
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 783 286 0 1,069 88 57 0 145 13.56 3 2 0 5 0.47 1,400 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 63 0 140 203 32 0 0 32 15.76 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
16 K 10 Rear 67 0 141 208 23 0 0 23 11.06 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
17 MY17 Front 0 57 70 127 34 47 38 119 93.70 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 5 Soft 5 0 0 0 0 0 0 1 0 0 0 0 1 1 0 0 0 0 8 #DIV/0!
18 MY17 Rear 0 57 68 125 44 35 49 128 102.40 0 0 0 0 0.00 145 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 2 0.06
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 4 2 0 0 0 0 0 0 0 0 0 0 0 6 0.17
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 5 1 0 0 0 0 0 0 0 0 0 0 0 6 0.17
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 3 15 0 0 0 0 0 0 0 0 0 0 0 18 0.51
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,759 1,143 648 3,550 368 249 127 744 20.96 22 28 0 50 1.41 2,249 0 0.00 0 0.00 Total 5 0 0 0 1 13 27 2 0 0 0 0 1 1 0 0 0 0 50 1.41
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 397 0 0 397 43 0 0 43 10.83 7 0 0 7 1.76 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 1 1 PU 20.96 25.4974 1.41 2.95815
15 K10 Front 297 0 0 297 53 0 0 53 17.85 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 1 0 0 0 0 2 6 0 0 0 0 9 9 ASSLY 12.62 15.7156 0.52 0.12093 12.78 0.78
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 293 272 0 565 31 29 0 60 10.62 0 0 0 0 0.00 918 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 213 0 0 213 0 0 0 0 0.00 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 23.24 25.4974 0.48 2.95815
15 K10 Front 193 0 0 193 0 0 0 0 0.00 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 0.00 15.7156 0.00 0.12093 7.15 0.15
16 K 10 Rear 241 0 0 241 0 0 0 0 0.00 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 148 0 0 148 0 0 0 0 0.00 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 4 0 0 4 0 0 0 0 0.00 0 0 0 0 0.00 Qty 1 5 0 4
TOTAL 1,776 0 0 1,776 0 0 0 0 0.00 0 0 0 0 0.00 Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 % 0.05 0.24 0.00 0.19
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 847 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 399 0 0 399 0 0 0 0 0.00 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU #DIV/0! 25.4974 #DIV/0! 2.95815
15 K10 Front 125 0 0 125 0 0 0 0 0.00 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 0.00 15.7156 0.00 0.12093 0.00 0.00
16 K 10 Rear 101 0 0 101 0 0 0 0 0.00 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 33 0 0 33 0 0 0 0 0.00 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 164 0 0 164 0 0 0 0 0.00 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 5 0 0 5 0 0 0 0 0.00 0 0 0 0 0.00 Qty 0 0 0 0
TOTAL 1,569 0 0 1,569 0 0 0 0 0.00 0 0 0 0 0.00 Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 % #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 300 292 0 592 43 37 0 80 13.51 1 3 0 4 0.68 850 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 469 0 0 469 0 0 0 0 0.00 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 23.58 25.4974 1.71 2.95815
15 K10 Front 141 0 0 141 46 0 0 46 32.62 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 10.66 15.7156 0.00 0.12093 11.57 0.63
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 201 377 0 578 29 81 0 110 19.03 1 3 0 4 0.69 975 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 0 0 0 0 14 0 0 14 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY #DIV/0! 15.7156 #DIV/0! 0.12093 12.76 0.45
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 792 734 758 2,284 0 0 0 0 0.00 24 50 3 77 3.37 1,000 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 82 116 125 323 0 0 0 0 0.00 1 2 0 3 0.93 270 0 0.00 0 0.00 3 Tearing 63 2 0 0 0 0 0 0 1 0 0 0 1 2 2 0 0 0 71 1.44
16 K 10 Rear 83 121 133 337 0 0 0 0 0.00 2 1 1 4 1.19 192 0 0.00 0 0.00 4 Collapse 10 2 0 0 0 0 0 0 0 0 0 0 2 4 0 1 0 1 20 0.41
17 MY17 Front 76 62 60 198 0 0 0 0 0.00 4 3 0 7 3.54 191 0 0.00 0 0.00 5 Soft 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 1 0 4 #DIV/0!
18 MY17 Rear 78 61 64 203 0 0 0 0 0.00 4 0 0 4 1.97 100 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,457 1,695 1,782 4,934 0 0 0 1,139 23.08 42 63 6 111 2.25 2,448 0 0.00 0 0.00 Total 77 5 1 0 0 0 0 0 1 0 0 0 3 6 3 4 7 4 111 2.25
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 227 0 0 227 31 0 0 31 13.66 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 23.08 25.4974 2.25 2.95815
15 K10 Front 24 0 0 24 10 0 0 10 41.67 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 12.26 15.7156 0.00 0.12093 14.93 1.26
16 K 10 Rear 178 0 0 178 16 0 0 16 8.99 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 126 0 0 126 13 0 0 13 10.32 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 139 0 0 139 17 0 0 17 12.23 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 91 20 0 0
TOTAL 1,395 0 0 1,395 171 0 0 171 12.26 0 0 0 0 0.00 Total 0 15 14 0 0 23 0 0 0 0 32 31 10 16 13 17 171 0 % 1.84 0.41 0.00 0.00
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 442 415 0 857 0 0 0 0 0.00 28 16 0 44 5.13 1,000 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 76 122 0 198 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 28 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 29 1.17
16 K 10 Rear 71 100 0 171 0 0 0 0 0.00 2 5 0 7 4.09 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0.08
17 MY17 Front 38 61 0 99 0 0 0 0 0.00 0 0 0 0 0.00 48 0 0.00 0 0.00 5 Soft 6 0 0 0 0 0 0 1 0 0 0 0 1 1 0 7 0 0 16 #DIV/0!
18 MY17 Rear 37 63 0 100 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 2 0.08
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,038 1,431 0 2,469 0 0 0 2,060 83.43 35 26 0 61 2.47 2,406 0 0.00 0 0.00 Total 44 1 0 0 0 1 1 1 1 0 0 0 4 1 0 7 0 0 61 2.47
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 240 0 0 240 52 0 0 52 21.67 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 83.43 25.4974 2.47 2.95815
15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 16.39 15.7156 0.00 0.12093 36.89 0.99
16 K 10 Rear 124 0 0 124 20 0 0 20 16.13 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 145 0 0 145 8 0 0 8 5.52 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 81 0 0 81 11 0 0 11 13.58 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 57 4 0 0
TOTAL 1,275 0 0 1,275 209 0 0 209 16.39 0 0 0 0 0.00 Total 0 15 15 0 16 0 0 0 0 0 72 52 0 20 8 11 209 0 % 2.31 0.16 0.00 0.00
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 415 364 0 779 0 0 0 0 0.00 22 5 0 27 3.47 850 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 132 125 0 257 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 17 3 0 2 0 0 0 0 0 2 0 0 2 1 0 0 0 0 27 0.87
16 K 10 Rear 83 64 0 147 0 0 0 0 0.00 6 0 0 6 4.08 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 6 0 0 0 1 0 0 0 0 0 0 0 0 1 0 6 0 0 14 0.45
17 MY17 Front 67 64 0 131 0 0 0 0 0.00 0 1 0 1 0.76 158 0 0.00 0 0.00 5 Soft 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 2 #DIV/0!
18 MY17 Rear 67 63 0 130 0 0 0 0 0.00 0 0 0 0 0.00 105 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.03
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,566 1,545 0 3,111 0 0 0 2,440 78.43 41 12 0 53 1.70 2,646 0 0.00 0 0.00 Total 27 3 0 3 2 0 0 0 1 2 0 0 6 2 0 6 1 0 53 1.70
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 260 0 0 260 66 0 0 66 25.38 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 78.43 25.4974 1.70 2.95815
15 K10 Front 233 0 0 233 45 0 0 45 19.31 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 19.89 15.7156 0.00 0.12093 37.79 0.73
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 135 0 0 135 0 0 0 0 0.00 21 0 0 21 15.56 1,050 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 203 0 0 203 65 0 0 65 32.02 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 0.00 25.4974 9.32 2.95815
15 K10 Front 101 0 0 101 16 0 0 16 15.84 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 23.02 15.7156 0.00 0.12093 6.91 1.07
16 K 10 Rear 223 0 0 223 32 0 0 32 14.35 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 110 0 0 110 24 0 0 24 21.82 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 102 0 0 102 28 0 0 28 27.45 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 0 0 0 0
TOTAL 1,429 0 0 1,429 329 0 0 329 23.02 0 0 0 0 0.00 Total 0 18 8 16 25 16 0 0 0 0 81 65 16 32 24 28 329 0 % 0.00 0.00 0.00 0.00
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 985 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 109 0 0 109 24 0 0 24 22.02 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU #DIV/0! 25.4974 #DIV/0! 2.95815
15 K10 Front 169 0 0 169 19 0 0 19 11.24 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 ASSLY 16.67 15.7156 0.08 0.12093 8.87 0.04
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 8 865 0 873 0 0 0 0 0.00 0 102 0 102 11.68 1,236 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 418 0 0 418 67 0 0 67 16.03 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 0.00 25.4974 9.22 2.95815
15 K10 Front 85 0 0 85 17 0 0 17 20.00 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 ASSLY 25.20 15.7156 0.57 0.12093 5.51 2.38
16 K 10 Rear 111 0 0 111 20 0 0 20 18.02 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 75 0 0 75 12 0 0 12 16.00 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 156 0 0 156 48 0 0 48 30.77 1 0 0 1 0.64 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 0 0 0 0
TOTAL 1,222 0 0 1,222 308 0 0 308 25.20 7 0 0 7 0.57 Total 0 11 5 20 16 16 0 0 0 0 76 67 17 20 12 48 308 7 % 0.00 0.00 0.00 0.00
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 462 359 0 821 0 0 0 0 0.00 68 39 0 107 13.03 800 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 53 0 0 53 0 0 0 0 0.00 5 0 0 5 9.43 239 0 0.00 0 0.00 3 Tearing 70 12 2 1 1 0 0 0 0 0 0 0 7 4 4 0 9 2 112 6.58
16 K 10 Rear 38 0 0 38 0 0 0 0 0.00 1 0 0 1 2.63 380 0 0.00 0 0.00 4 Collapse 37 7 1 2 3 0 0 0 0 0 0 0 2 2 1 1 4 2 62 3.64
17 MY17 Front 46 34 0 80 0 0 0 0 0.00 8 5 0 13 16.25 72 0 0.00 0 0.00 5 Soft 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
18 MY17 Rear 48 32 0 80 0 0 0 0 0.00 3 1 0 4 5.00 96 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 0 10 0 0 0 0 0 0 0 0 0 0 0 10 0.59
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 1,014 689 0 1,703 0 0 0 0 0.00 111 73 0 184 10.80 2,583 0 0.00 0 0.00 Total 107 19 3 3 4 0 10 0 0 0 0 0 9 6 5 1 13 4 184 10.80
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
15 K10 Front 171 0 0 171 42 0 0 42 24.56 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 ASSLY 24.42 15.7156 0.10 0.12093 4.77 3.47
16 K 10 Rear 161 0 0 161 31 0 0 31 19.25 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 83 0 0 83 17 0 0 17 20.48 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 60 0 0 60 21 0 0 21 35.00 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 112 72 0 0
TOTAL 1,040 0 0 1,040 254 0 0 254 24.42 1 0 0 1 0.10 Total 0 17 25 21 11 6 0 0 0 0 69 0 42 26 17 21 255 1 % 6.58 4.23 0.00 0.00
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 83 567 0 650 0 0 0 0 0.00 0 36 0 36 5.54 950 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
14 K4 Rear 154 0 0 154 14 0 0 14 9.09 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 PU 0.00 25.4974 8.12 2.95815
15 K10 Front 120 0 0 120 34 0 0 34 28.33 5 0 0 5 4.17 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 ASSLY 25.69 15.7156 0.92 0.12093 5.72 2.49
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 426 328 239 993 0 0 0 0 0.00 34 0 0 34 3.42 1,250 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 52 143 105 300 0 0 0 0 0.00 5 0 0 5 1.67 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 12 0.38
16 K 10 Rear 62 140 70 272 0 0 0 0 0.00 5 0 0 5 1.84 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 10 5 4 0 0 0 0 0 0 0 0 0 8 4 3 2 5 1 42 1.34
17 MY17 Front 36 47 71 154 0 0 0 0 0.00 7 0 0 7 4.55 170 0 0.00 0 0.00 5 Soft 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 3 0 0 4 #DIV/0!
18 MY17 Rear 39 47 36 122 0 0 0 0 0.00 2 0 0 2 1.64 170 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 36 36 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Deforme 10 0 0 3 3 0 0 0 0 0 0 0 4 0 2 0 1 0 23 0.74
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 8 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 10 15 0 0 0 0 0 0 0 0 0 0 0 25 0.80
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 0 0.00 0 0.00 13 Pit Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 0 0.00 0 0.00 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 994 1,247 882 3,123 0 0 0 0 0.00 110 0 0 110 3.52 2,346 0 0.00 0 0.00 Total 34 5 4 3 3 10 15 1 0 0 0 0 12 4 5 5 7 2 110 3.52
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
15 K10 Front 152 0 0 152 28 0 0 28 18.42 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 ASSLY 26.60 15.7156 0.35 0.12093 3.62 1.79
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 1,293 491 508 2,292 61 88 21 170 7.42 11 7 5 23 1.00 1,550 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
2 JD Front 99 128 104 331 39 42 15 96 29.00 1 1 1 3 0.91 10 0 0.00 0 0.00 1 Vent trap 20 11 25 0 25 0 0 15 0 0 0 0 15 21 29 30 15 38 244 4.56
3 Jd Rear 95 118 67 280 11 42 20 73 26.07 2 2 2 6 2.14 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0.07
4 Ktm Front 48 58 50 156 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 12 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 19 0.36
5 Ktm Rear 49 59 54 162 24 62 24 110 67.90 0 1 0 1 0.62 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 5 Deforme/ Prepol 82 28 16 0 54 0 0 30 0 0 0 0 60 40 72 85 47 67 581 10.86
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 180 0 0.00 0 0.00 6 Voids 52 50 32 0 31 0 0 18 0 0 0 0 67 7 35 24 31 44 391 7.31
8 JY (MY 16) 47 63 56 166 18 30 15 63 37.95 0 0 1 1 0.60 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 170 96 73 0 110 0 0 63 0 0 0 0 142 68 136 139 93 149 1239 23.15
15 K10 Front 68 51 54 173 50 61 25 136 78.61 0 1 0 1 0.58 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0.11
16 K 10 Rear 72 48 55 175 40 62 37 139 79.43 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 10 2 4 0 0 0 2 1 0 0 0 0 1 0 1 0 2 0 23 0.43
17 MY17 Front 38 59 55 152 21 45 27 93 61.18 1 0 2 3 1.97 100 0 0.00 0 0.00 5 Soft 4 1 2 0 1 0 3 0 0 0 0 0 0 0 0 0 0 0 11 #DIV/0!
18 MY17 Rear 47 59 55 161 32 65 52 149 92.55 1 1 2 4 2.48 0 0 #DIV/0! 0 #DIV/0! 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 20 0 0.00 0 0.00 7 Deforme 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 4 0.07
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 25 0 0.00 0 0.00 8 Voids 0 0 0 0 0 15 5 0 0 0 0 0 0 0 0 0 0 0 20 0.37
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
22 4W DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 10 Rexine cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
23 CO DR.CUSH 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 11 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
24 4W RSC 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 12 De- Lamination 0 0 0 0 0 20 8 0 0 0 0 0 0 0 0 0 0 0 28 0.52
25 4W 40%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 13 Pit Mark 0 0 0 0 0 10 2 0 0 0 0 0 0 0 0 0 0 0 12 0.22
26 4W 60%BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 14 Power Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
27 Assly Return 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 15 Assly Return 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
TOTAL 2,237 1,626 1,489 5,352 361 592 286 1,239 23.15 59 50 32 141 2.63 2,177 0 0.00 0 0.00 Total 23 3 6 0 1 74 24 1 0 0 0 0 1 0 1 0 3 4 141 2.63
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
15 K10 Front 53 0 0 53 0 0 0 0 0.00 0 0 0 0 0.00 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY 19.94 15.7156 0.00 0.12093 16.88 1.64
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY #DIV/0! 15.7156 #DIV/0! 0.12093 #DIV/0! #DIV/0!
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY #DIV/0! 15.7156 #DIV/0! 0.12093 #DIV/0! #DIV/0!
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 14 Rexine Over Heat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ASSLY #DIV/0! 15.7156 #DIV/0! 0.12093 #DIV/0! #DIV/0!
Sr. Prod. Rework Status Scrap Status Rework & Rejection Status DEFECT WISE REWORK AND REJECTION ANALYSIS (PU)
MODEL Prod
NO. A B C Total A B C Total % A B C Total % Rework % Rejection % Rework Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
1 Pulsar 150 10,331 10,765 2,641 23,737 1,068 1,054 163 2,285 9.63 257 302 22 581 2.45 23,841 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
2 JD Front 425 520 194 1,139 59 60 15 134 11.76 34 14 2 50 4.39 1,011 0 0.00 0 0.00 1 Vent trap 527 14 40 57 50 0 0 62 12 29 7 0 187 202 261 297 112 276 2133 3.38
3 Jd Rear 417 509 166 1,092 39 55 20 114 10.44 13 4 3 20 1.83 1,007 0 0.00 0 0.00 2 Release Mark 49 0 5 0 0 0 0 17 1 11 1 0 43 55 28 6 29 16 261 0.41
4 Ktm Front 563 761 216 1,540 127 121 64 312 20.26 7 23 1 31 2.01 803 0 0.00 0 0.00 3 Tearing 337 7 9 5 1 0 0 94 7 56 4 0 213 91 87 20 167 22 1120 1.77
5 Ktm Rear 598 783 226 1,607 104 136 24 264 16.43 19 11 1 31 1.93 809 0 0.00 0 0.00 4 Collapse 0 0 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 6 0.01
6 Vespa R 53 153 0 206 11 4 0 15 7.28 4 2 0 6 2.91 237 0 0.00 0 0.00 5 Deforme 97 28 16 0 54 0 0 37 0 0 0 0 60 40 72 85 47 67 603 0.96
7 Vespa (MY15) 380 424 184 988 171 92 53 316 31.98 5 2 0 7 0.71 912 0 0.00 0 0.00 6 Voids 1055 69 38 238 159 0 0 191 32 167 0 0 914 242 211 220 540 861 4937 7.82
8 JY (MY 16) 1,061 1,249 383 2,693 225 177 52 454 16.86 9 12 1 22 0.82 2,132 0 0.00 0 0.00 7 Loose Skin 223 16 6 12 0 0 0 1 4 64 0 0 252 30 11 16 9 12 656 1.04
9 KHI F 36 48 0 84 12 0 0 12 14.29 2 0 0 2 2.38 0 0 #DIV/0! 0 #DIV/0! Total 2,288 134 114 312 264 0 0 402 56 327 12 0 1,675 660 670 644 904 1,254 9716 15.40
10 KHI R 38 88 0 126 0 0 0 0 0.00 2 6 0 8 6.35 0 0 #DIV/0! 0 #DIV/0!
11 DT Front 998 1,355 138 2,491 0 0 0 0 0.00 196 194 13 403 16.18 2,224 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 920 1,176 77 2,173 0 0 0 0 0.00 138 163 6 307 14.13 2,134 0 0.00 0 0.00 NO Pulsar JD-F JD-R KTM-R DT F DT R KHI-F KHI-R K4 Front K4 Rear Total %
MY-F (MY16) R (MY 15) Front Rear Front Rear
13 K4 Front 2,665 3,104 765 6,534 887 651 161 1,699 26.00 48 30 2 80 1.22 6,225 0 0.00 0 0.00 1 Vent trap 33 1 5 5 17 41 59 10 2 0 0 2 18 8 3 0 20 31 255 0.40
14 K4 Rear 2,690 2,880 1,031 6,601 286 241 56 583 8.83 25 14 4 43 0.65 6,167 0 0.00 0 0.00 2 Release Mark 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0.00
15 K10 Front 1,218 1,306 730 3,254 355 252 88 695 21.36 15 6 1 22 0.68 3,322 0 0.00 0 0.00 3 Tearing 205 18 2 3 1 0 0 3 1 2 0 1 11 7 6 0 14 7 281 0.45
16 K 10 Rear 1,206 1,226 647 3,079 313 257 91 661 21.47 17 13 3 33 1.07 3,808 0 0.00 0 0.00 4 Collapse 128 17 11 3 6 5 3 1 2 1 0 0 19 24 9 14 12 5 260 0.41
17 MY17 Front 1,028 1,316 510 2,854 372 399 139 910 31.89 31 35 7 73 2.56 3,189 0 0.00 0 0.00 5 Soft 50 1 2 1 1 2 3 3 0 0 2 3 4 3 1 15 6 1 98 #DIV/0!
18 MY17 Rear 912 1,282 421 2,615 433 629 194 1,256 48.03 24 27 10 61 2.33 2,973 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 1 1 0 1 0 0 0 0 0 0 1 1 5 #DIV/0!
19 Diwali (Front) 71 5 99 175 0 0 0 0 0.00 1 0 0 1 0.57 180 0 0.00 0 0.00 7 Deforme 33 0 0 3 4 7 5 4 0 0 0 2 6 0 2 0 6 11 83 0.13
20 Diwali (Rear) 60 57 0 117 25 3 0 28 23.93 1 2 0 3 2.56 242 0 0.00 0 0.00 8 Voids 0 0 0 1 0 75 9 0 0 0 0 0 10 0 0 0 4 1 100 0.16
21 4W DR.BACK 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 9 Loose Skin 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 0.01
TOTAL 25,670 29,007 8,428 63,105 4,487 4,1311,120 9,738 15.43 848 860 76 1,784 2.83 61,235 0 0.00 0 0.00 Total 457 37 20 31 29 403 306 22 5 4 2 8 68 42 21 30 63 57 1,605 2.54
ASSLY
DEVELOPMENT & TRAIL SAMPLE
Sr. Prod. Rework Status Scrap Status
MODEL DEFECT WISE REWORK AND REWORK & REJECTION ANALYSIS (ASSLY)
NO. A B C Total A B C Total % A B C Total % PU Assly Stitching
14 K4 Rear 6,192 0 0 6,192 818 0 0 818 13.21 13 0 0 13 0.21 13 Rexine Cut 0 0 0 0 0 0 0 1 0 0 0 7 0 0 0 0 8 9 PU 15.43 25.4974 2.83 2.95815
15 K10 Front 3,396 0 0 3,396 664 0 0 664 19.55 7 0 0 7 0.21 14 Rexine Over Heat 0 0 0 0 0 5 0 2 0 0 3 6 2 0 0 4 22 23 ASSLY 3.45 15.7156 0.03 0.12093 5.36 0.64
16 K 10 Rear 3,326 0 0 3,326 417 0 0 417 12.54 0 0 0 0 0.00 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching 0.00 0 0.00 0
17 MY17 Front 3,073 0 0 3,073 372 0 0 372 12.11 0 0 0 0 0.00 16 Seat Base N. OK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4M
18 MY17 Rear 2,887 0 0 2,887 407 0 0 407 14.10 3 0 0 3 0.10 Man Machine Method Material
19 Diwali 103 0 0 103 0 0 0 0 0.00 0 0 0 0 0.00 Qty 724 546 0 335
TOTAL 86,897 0 0 161,767 5,588 0 0 5,588 3.45 43 0 0 43 0.03 Total 0 270 194 381 330 467 15 89 0 0 1,169 818 625 395 372 407 5,532 42 % 1.15 0.87 0.00 0.53
400
350 335
98.31 99.22 99.74 99.87 100.00
94.54 96.49
300 92.33
89.86
78.80
250
62.94
200
149
150 43.56 122
100 85
50
19 17 15 14 7 4 1 1
0
0
tails Feb/17
2,173 7,811 Contribution
% Rej %
Cum %
DT R Total
6.90 335 4.29 43.56 43.56
2.62 149 1.91 19.38 62.94
2.72 122 1.56 15.86 78.80
0.41 85 1.09 11.05 89.86
0.23 19 0.24 2.47 92.33
0.14 17 0.22 2.21 94.54
0.51 15 0.19 1.95 96.49
0.37 14 0.18 1.82 98.31
0.14 7 0.09 0.91 99.22
0.00 4 0.05 0.52 99.74
0.05 1 0.01 0.13 99.87
0.00 1 0.01 0.13 100.00
0.00 0 0.00 0.00 100.00
14.08 769 9.85
120.00
80.00
60.00
40.00
20.00
4 1 1
0.00
0
Production 23,737 1,139 1,092 84
S NO DEFECTS Pulsar JD -F JD -R KHI F
1 Vent trap 205 0.864 18 0.016 2 0.002 0
2 Release Mark 128 0.539 17 0.015 11 0.010 0
3 Tearing 33 0.139 1 0.001 5 0.005 0
4 Collapse 50 0.211 1 0.001 2 0.002 2
5 Soft 33 0.139 0 0.000 0 0.000 0
6 Hard 0 0.000 0 0.000 0 0.000 0
7 Deforme 8 0.034 0 0.000 0 0.000 0
8 Voids 0 0.000 0 0.000 0 0.000 0
9 Loose Skin 0 0.000 0 0.000 0 0.000 0
10 Rexine cut 0 0.000 0 0.000 0 0.000 0
11 Wrinkle 0 0.000 0 0.000 0 0.000 0
12 De- Lamination 0 0.000 0 0.000 0 0.000 0
13 Pit Mark 0 0.000 0 0.000 0 0.000 0
14 Power Fail 0 0.000 0 0.000 0 0.000 0
15 Assly Return 0 0.000 0 0.000 0 0.000 0
TOTAL 457 1.925 37 0.032 20 0.018 2
300
277
250 243
96.65
89.00
200
78.11
62.20
150
133
100 91
33.13
64
50
0
Vent trap Release Mark Tearing Collapse Soft Ha
50
0
Vent trap Release Mark Tearing Collapse Soft Ha
PU (Non FIP Model)Rejection Details
84 6,601 1,194 2,693 6,534 6,601
KHI F KHI R Vespa JY K4 F K4 R
0.000 1 0.015 3 0.251 3 0.111 11 0.168 7
0.000 0 0.000 3 0.251 1 0.037 19 0.291 24
0.000 2 0.030 2 0.168 10 0.371 18 0.275 8
2.381 3 0.045 0 0.000 3 0.111 4 0.061 3
0.000 2 0.030 0 0.000 4 0.149 6 0.092 0
0.000 0 0.000 0 0.000 0 0.000 10 0.153 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 1 0.084 1 0.037 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
0.000 0 0.000 0 0.000 0 0.000 0 0.000 0
2.381 8 0.121 9 0.754 22 0.817 68 1.041 42
64
15
8
4 1
120.00
80.00
60.00
40.00
20.00
0.00
e cut 0
Wrinkle 0
De- Lamination 0
Pit Mark 0 Fail
Power Assly 0Return
20.00
0.00
e cut 0
Wrinkle 0
De- Lamination 0
Pit Mark 0 Fail
Power Assly 0Return
Feb/17
61,477
% Rej Contribution % Cum %
Total
277 0.45 33.13 33.13
243 0.40 29.07 62.20
133 0.22 15.91 78.11
91 0.15 10.89 89.00
64 0.10 7.66 96.65
15 0.02 1.79 98.44
8 0.01 0.96 99.40
4 0.01 0.48 99.88
1 0.00 0.12 100.00
0 0.00 0.00 100.00
0 0.00 0.00 100.00
0 0.00 0.00 100.00
0 0.00 0.00 100.00
0 0.00 0.00 100.00
0 0.00 #VALUE!
836 1.34
120.00
100.00
80.00
60.00
40.00
20.00
0.00
0Return
20.00
0.00
0Return
Production 23,737 1,139 1,092 84
S NO DEFECTS Pulsar JD -F JD -R KHI F
1 Voids 1055 4.445 69 0.061 38 0.035 0
2 Vent trap 527 2.220 14 0.012 40 0.037 7
3 Tearing 337 1.420 7 0.006 9 0.008 4
4 Loose Skin 223 0.939 16 0.014 6 0.005 0
5 Deforme 97 0.409 28 0.025 16 0.015 0
6 Release Mark 49 0.206 0 0.000 5 0.005 1
7 Collapse 0 0.000 0 0.000 0 0.000 0
TOTAL 2288 9.639 134 0.118 114 0.104 12
5000
4500
4329
4000
3500 8
3000 71.95
2500
51.11
2000
1765
1500
1027
1000
500
0
Voids Vent trap Tearin
PU Rework Details
84 6,601 1,194 2,693 6,534 6,601
KHI F KHI R Vespa JY K4 F K4 R
0.000 0 0.000 199 16.667 191 7.092 914 13.988 242
8.333 0 0.000 41 3.434 62 2.302 187 2.862 202
4.762 0 0.000 63 5.276 94 3.491 213 3.260 91
0.000 0 0.000 68 5.695 1 0.037 252 3.857 30
0.000 0 0.000 0 0.000 37 1.374 60 0.918 40
1.190 0 0.000 12 1.005 17 0.631 43 0.658 55
0.000 0 0.000 0 0.000 0 0.000 6 0.092 0
14.286 0 0.000 383 32.077 402 14.928 1675 25.635 660
97.18
91.55
84.07
1027
633
477
120.00
80.00
60.00
40.00
20.00
477
233
6
0.00
eforme Release Mark Collapse
Feb/17
61,477
% Rej Contribution % Cum %
Total
4329 7.04 51.11 51.11
1765 2.87 20.84 71.95
1027 1.67 12.13 84.07
633 1.03 7.47 91.55
477 0.78 5.63 97.18
233 0.38 2.75 99.93
6 0.01 0.07 100.00
8470 13.77
120.00
100.00
80.00
60.00
40.00
20.00
0.00
Production 126,210 746 752
3000
2747
2500
85.97
2000 80.08
72.72
63.05
1500
49.66
72.72
63.05
1500
49.66
1000
741
535
500
407
326
0
Wrinkle Gapnotok Staple Mis loose staple Pre Assly N.ok
Assly. Rework Details
2,203 2,187 0 0 1,148
98.25 98.88 99
97.20
91.72
85.97
80.08
407
326 318 303
58 35 22
staple Pre Assly N.ok Rubber Missing Pu Pad Problem Collar Missing Stitiching not ok Fitment N
rk Details
2,933 6,611 6,192 3,396 3,326
JY K4 F K4 R K10 F K10 R
321 10.944 512 7.745 466 7.526 241 7.097 203 6.103
0 0.000 298 4.508 16 0.258 166 4.888 1 0.030
64 2.182 83 1.255 88 1.421 61 1.796 45 1.353
29 0.989 76 1.150 55 0.888 33 0.972 40 1.203
0 0.000 135 2.042 128 2.067 6 0.177 32 0.962
14 0.477 4 0.061 10 0.161 83 2.444 51 1.533
25 0.852 50 0.756 39 0.630 11 0.324 21 0.631
6 0.205 8 0.121 0 0.000 22 0.648 0 0.000
0 0.000 0 0.000 0 0.000 0 0.000 0 0.000
0 0.000 0 0.000 2 0.032 0 0.000 0 0.000
5 0.170 3 0.045 6 0.097 2 0.059 0 0.000
g not ok Fitment Nok Rexine Over Heat Loose Threds Rexine Cut 0
Parts Missing Rexene0Def
Feb/17
120.00
80.00
60.00
60.00
40.00
20.00
0.00
Missing Rexene0Defect 0 N. OK
Seat Base