A

PU KM
Date
Total Prod. Total Rew. Rew. % Total Scrap

1 3,428 684 19.953325554 23

2 0 0 #DIV/0! 0

3 1,559 299 19.178960872 7

4 1,589 331 20.830711139 41

5 2,083 459 22.035525684 43

6 1,919 377 19.645648775 71

7 2,233 456 20.420958352 101

8 0 923 #DIV/0! 120

9 3,074 708 23.031880286 69

10 2,493 571 22.904131568 74

11 1,720 470 27.325581395 79

12 3,306 558 16.878402904 70

13 4,618 680 14.724989173 62

14 3,550 744 20.957746479 50

15 2,078 483 23.243503369 10

16 0 0 #DIV/0! 0

17 2,044 482 23.581213307 35

18 1,047 274 26.170009551 14

19 4,934 1,139 23.084718281 111

20 2,469 2,060 83.434588902 61

21 3,111 2,440 78.431372549 53

 22 547 0 0 51

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

28 5,352 1,239 23.150224215 141

29 0 0 #DIV/0! 0

30 0 0 #DIV/0! 0
31 0 0 #DIV/0! 0

TOTAL 60,308 15,377 25.497446442 1,784

 AVERAGE REWORK AND SCRAP DETAILS FEB-17
Assembly

Scrap% Total Prod. Total Rew. Rew. % Total Scrap

0.6709451575 1,850 254 13.72972973 0

#DIV/0! 0 0 #DIV/0! 0

0.4490057729 1,327 256 19.291635268 0

2.5802391441 1,274 188 14.7566719 0

2.0643302928 1,905 241 12.650918635 8

3.6998436686 1,553 236 15.196394076 0

4.5230631438 1,195 234 19.581589958 0

#DIV/0! 2,693 273 10.137393242 0

2.2446324008 1,080 233 21.574074074 3

2.9683112716 1,825 216 11.835616438 0

4.5930232558 0 69 #DIV/0! 0

2.1173623714 1,215 254 20.905349794 2

1.3425725422 1,108 201 18.140794224 1

1.4084507042 1,917 242 12.623891497 10

0.4812319538 1,776 0 0 0

#DIV/0! 1,569 0 0 0

1.7123287671 1,473 157 10.658520027 0

1.3371537727 0 121 #DIV/0! 0

2.249695987 1,395 171 12.258064516 0

2.470635885 1,275 209 16.392156863 0

1.7036322726 1,478 294 19.891745602 0

9.323583181 1,429 329 23.023093072 0

#DIV/0! 1,290 215 16.666666667 1

9.2172640819 1,222 308 25.204582651 7

10.804462713 1,040 254 24.423076923 1

8.1165452653 759 195 25.691699605 7

3.5222542427 861 229 26.596980256 3

2.634529148 1,048 209 19.942748092 0

#DIV/0! 0 0 #DIV/0! 0

#DIV/0! 0 0 #DIV/0! 0
#DIV/0! 0 0 #DIV/0! 0

2.9581481727 35,557 5,588 15.715611553 43

ILS FEB-17
Stitching

Scrap% Total Prod. Total Rew. Rew. % Total Scrap

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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 35 0 0 0 0 0 0 2 0 8 0 0 19 13 25 38 7 12 159 4.64

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 8 0 0 0 0 0 0 3 0 3 0 0 12 4 5 1 0 0 36 1.05
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 24 0 0 0 0 0 0 5 0 11 0 0 20 6 25 7 21 0 119 3.47
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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) 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

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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 9 0 0 0 0 9 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 3 7 11 0 0 0 0 31 22 23 19 9 11 136 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 2 2 0 0 0 0 4 4 5 6 3 3 29 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 3 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 13 3 2 4 22 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0
8 JY (MY 16) 47 0 0 47 13 0 0 13 27.66 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 20 0 0 20 8 0 0 8 40.00 0 0 0 0 0.00 10 Gapnotok 0 0 0 5 0 0 0 0 0 0 14 0 21 0 2 4 46 0
12 DT Rear 89 0 0 89 9 0 0 9 10.11 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 360 0 0 360 49 0 0 49 13.61 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 1 1 5 0 0 7 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Monday, January 02, 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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
14 K4 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
TOTAL 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
12 DT Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 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!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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!

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Friday, February 03, 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 150 384 440 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

2 JD Front 0 40 0 40 0 18 0 18 45.00 1 0 0 1 2.50 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 53 3 1 0 0 0 0 0 0 0 0 0 8 6 10 4 3 4 92 5.90

3 Jd Rear 0 46 0 46 0 13 0 13 28.26 1 0 0 1 2.17 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 2 0 2 0 0 0 0 1 0 1 0 0 0 3 2 0 0 0 11 0.71
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 9 0 4 0 0 0 0 14 0 1 0 0 1 5 4 0 5 0 43 2.76
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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) 27 0 0 27 14 0 0 14 51.85 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 6 Voids 22 13 5 0 0 0 0 7 0 7 0 0 0 40 1 0 2 18 115 7.38

8 JY (MY 16) 67 49 0 116 15 8 0 23 19.83 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 12 2 1 0 0 0 0 1 0 5 0 0 0 17 0 0 0 0 38 2.44
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 98 18 13 0 0 0 0 23 0 14 0 0 9 71 17 4 10 22 299 19.18

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! 51 0 0.00 0 0.00 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! 27 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 192 0 0 192 71 0 0 71 36.98 0 0 0 0 0.00 418 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0.06
14 K4 Rear 100 0 0 100 9 0 0 9 9.00 0 0 0 0 0.00 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

15 K10 Front 57 0 0 57 17 0 0 17 29.82 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.06

16 K 10 Rear 57 0 0 57 4 0 0 4 7.02 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0.13
17 MY17 Front 0 49 0 49 0 10 0 10 20.41 0 0 0 0 0.00 269 0 0.00 0 0.00 5 Soft 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 #DIV/0!
18 MY17 Rear 0 51 0 51 0 22 0 22 43.14 0 1 0 1 1.96 275 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 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.06
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 884 675 0 1,559 169 130 0 299 19.18 4 3 0 7 0.45 1,790 0 0.00 0 0.00 Total 4 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 7 0.45
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 8 3 81 5 0 0 0 9 17 6 6 6 17 158 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 1 1 8 2 0 0 0 3 4 2 3 2 6 32 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 1 0 0 0 0 3 0 0 0 0 0 4 0
6 Vespa R 80 0 0 80 15 0 0 15 18.75 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 3 0 3 0 0 0 0 3 2 3 0 3 17 0
7 Vespa (MY15) 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 239 0 0 239 90 0 0 90 37.66 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 75 0 0 75 29 0 0 29 38.67 0 0 0 0 0.00 10 Gapnotok 0 0 0 17 0 0 0 0 0 0 7 0 8 0 0 0 32 0
12 DT Rear 29 0 0 29 7 0 0 7 24.14 0 0 0 0 0.00 11 Fitment Nok 0 0 0 3 0 0 4 0 0 0 0 0 0 0 0 0 7 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 174 0 0 174 22 0 0 22 12.64 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 1 0 0 0 0 0 0 0 5 0 6 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 99 0 0 99 12 0 0 12 12.12 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 89 0 0 89 13 0 0 13 14.61 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 199 0 0 199 26 0 0 26 13.07 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 4 3 0 0
TOTAL 1,327 0 0 1,327 256 0 0 256 19.29 0 0 0 0 0.00 Total 0 0 0 29 7 90 15 0 0 0 22 24 18 12 13 26 256 0 % 0.26 0.19 0.00 0.00

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Saturday, February 04, 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 150 485 445 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

2 JD Front 43 0 0 43 13 0 0 13 30.23 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 55 0 12 0 0 0 0 0 0 0 0 0 4 12 0 0 0 11 94 5.92

3 Jd Rear 40 0 0 40 18 0 0 18 45.00 4 0 0 4 10.00 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 3 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 2 0 6 0.38
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 17 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 4 0 24 1.51
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 68 4 1 0 0 0 0 4 0 0 0 0 18 0 0 0 29 25 149 9.38

8 JY (MY 16) 54 60 0 114 4 0 0 4 3.51 3 2 0 5 4.39 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 39 9 5 0 0 0 0 0 0 0 0 0 2 2 0 0 1 0 58 3.65
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 182 13 18 0 0 0 0 4 0 0 0 0 25 17 0 0 36 36 331 20.83

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! 110 0 0.00 0 0.00 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! 91 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 55 96 0 151 0 0 0 0 0.00 6 0 0 6 3.97 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 4 0 0 0 0 2 0 0 0 0 0 0 0 0 4 6 16 1.01
14 K4 Rear 54 133 0 187 0 0 0 0 0.00 0 0 0 0 0.00 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

15 K10 Front 0 0 0 0 25 0 0 25 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 2 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 4 9 0.57

16 K 10 Rear 0 0 0 0 17 0 0 17 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.06
17 MY17 Front 0 60 0 60 15 21 0 36 60.00 4 1 0 5 8.33 80 0 0.00 0 0.00 5 Soft 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 6 #DIV/0!
18 MY17 Rear 0 64 0 64 9 27 0 36 56.25 10 2 0 12 18.75 200 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 6 0 0 0 0 1 7 0.44
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 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0.13
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 731 858 0 1,589 198 133 0 331 20.83 30 11 0 41 2.58 1,531 0 0.00 0 0.00 Total 9 0 4 0 0 0 0 5 0 0 0 0 6 0 0 0 5 12 41 2.58
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 5 3 0 0 0 0 8 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 9 7 9 0 0 0 0 35 14 3 3 8 20 108 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 2 2 5 0 0 0 0 6 6 1 2 2 5 31 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 74 0 0 74 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 2 2 0 2 6 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 166 0 0 166 15 0 0 15 9.04 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0 6 0
11 DT Front 140 0 0 140 21 0 0 21 15.00 0 0 0 0 0.00 10 Gapnotok 0 0 0 4 0 0 0 0 0 0 10 0 0 0 0 0 14 0
12 DT Rear 121 0 0 121 10 0 0 10 8.26 0 0 0 0 0.00 11 Fitment Nok 0 0 0 4 0 0 0 0 0 0 0 0 0 0 0 0 4 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 280 0 0 280 58 0 0 58 20.71 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 2 1 1 0 0 0 0 2 2 0 1 0 2 11 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 96 0 0 96 25 0 0 25 26.04 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 20.83 25.4974 2.58 2.95815

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

16 K 10 Rear 7 0 0 7 8 0 0 8 114.29 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 175 0 0 175 16 0 0 16 9.14 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 180 0 0 180 29 0 0 29 16.11 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 31 10 0 0
TOTAL 1,274 0 0 1,274 188 0 0 188 14.76 0 0 0 0 0.00 Total 0 0 0 21 10 15 0 0 0 0 58 25 6 8 16 29 188 0 % 1.95 0.63 0.00 0.00

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Friday, May 05, 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 150 568 333 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

2 JD Front 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 28 0 0 0 0 0 0 5 0 0 0 0 10 7 0 0 4 12 66 3.17

3 Jd Rear 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 10 0 0 0 0 0 0 0 0 0 0 0 4 4 0 0 1 0 19 0.91
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 12 0 0 0 0 0 0 9 0 0 0 0 18 12 0 0 8 0 59 2.83
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 2 0 0 0 0 0 0 4 0 0 0 0 0 0 0 0 0 0 6 0.29

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 71 0 0 0 0 0 0 14 0 0 0 0 84 5 0 0 53 39 266 12.77

8 JY (MY 16) 65 46 0 111 17 15 0 32 28.83 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 35 0 0 0 0 0 0 0 0 0 0 0 18 0 0 0 0 0 53 2.54
9 KHI F 13 36 0 49 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! Total 158 0 0 0 0 0 0 32 0 0 0 0 134 28 0 0 66 51 469 22.52

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 90 0 90 0 0 0 0 0.00 0 14 0 14 15.56 126 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 0 92 0 92 0 0 0 0 0.00 0 17 0 17 18.48 65 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 161 145 0 306 69 52 0 121 39.54 4 0 0 4 1.31 360 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 8 0 0 0 0 0 0 3 0 0 0 0 11 0.53
14 K4 Rear 159 145 0 304 20 8 0 28 9.21 3 0 0 3 0.99 563 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 264 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 304 0 0.00 0 0.00 4 Collapse 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0.14
17 MY17 Front 66 49 0 115 39 27 0 66 57.39 0 0 0 0 0.00 50 0 0.00 0 0.00 5 Soft 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 #DIV/0!
18 MY17 Rear 64 49 0 113 18 36 0 54 47.79 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 1 0 0 0 0 1 3 0 0 0 0 0 0 0 0 0 0 0 5 0.24
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 6 0 0 0 0 0 0 4 0 0 0 0 0 10 0.48
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 7 6 0 0 0 0 0 0 0 0 0 0 0 13 0.62
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 1,098 985 0 2,083 273 186 0 459 22.04 8 35 0 43 2.06 2,682 0 0.00 0 0.00 Total 5 0 0 0 0 14 17 0 0 0 0 0 4 3 0 0 0 0 43 2.06
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 9 0 0 0 0 9 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 3 5 20 0 26 0 0 40 26 15 0 7 9 151 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 3 3 0 3 0 0 8 14 2 0 1 2 36 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 3 4 0 0 0 7 0
7 Vespa (MY15) 98 0 0 98 31 0 0 31 31.63 1 0 0 1 1.02 6 Collar Missing 0 0 0 4 0 0 0 0 0 0 0 0 0 0 0 0 4 0
8 JY (MY 16) 151 0 0 151 23 0 0 23 15.23 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 0
11 DT Front 92 0 0 92 16 0 0 16 17.39 0 0 0 0 0.00 10 Gapnotok 0 0 0 6 0 0 0 0 0 0 8 0 0 0 0 0 14 0
12 DT Rear 87 0 0 87 8 0 0 8 9.20 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 198 0 0 198 56 0 0 56 28.28 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 3 0 0 0 1 0 0 0 1 0 0 2 1 8 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 97 0 0 97 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 75 0 0 75 14 0 0 14 18.67 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 111 0 0 111 13 0 0 13 11.71 1 0 0 1 0.90 Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 17 13 0 13
TOTAL 1,905 0 0 1,905 241 0 0 241 12.65 8 0 0 8 0.42 Total 0 0 0 16 8 23 0 31 0 0 56 59 21 0 14 13 241 8 % 0.82 0.62 0.00 0.62

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Tuesday, February 07, 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 150 333 420 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 32 0 0 0 0 0 0 3 0 3 7 0 7 4 0 0 1 9 66 3.44

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 0 0 0 0 0 0 0 1 0 1 1 0 8 0 0 0 2 0 13 0.68
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 20 0 0 0 0 0 0 1 0 11 4 0 14 3 0 0 11 0 64 3.34
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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) 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

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 373 0 0.00 0 0.00 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0.05

16 K 10 Rear 121 0 0 121 0 0 0 0 0.00 0 0 0 0 0.00 385 0 0.00 0 0.00 4 Collapse 2 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 3 0.16
17 MY17 Front 119 61 0 180 15 26 0 41 22.78 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 5 Soft 3 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 5 #DIV/0!
18 MY17 Rear 48 61 0 109 9 39 0 48 44.04 1 0 0 1 0.92 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 1 1 #DIV/0!
19 Diwali (Front) 48 0 0 48 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

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 0 0 0 0 0 0 0 0 0 0 0 0 9 0.47

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 2 1 0 0 0 0 0 0 0 0 0 0 0 3 0.16

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 25 18 0 0 0 0 0 0 0 0 0 0 0 43 2.24
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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 3 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 7 14 9 0 0 0 0 26 11 13 12 11 16 119 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 3 3 5 0 0 0 0 12 5 8 2 2 3 43 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 3 0 0 0 0 4 4 2 3 0 0 16 0
7 Vespa (MY15) 45 0 0 45 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 47 0 0 47 25 0 0 25 53.19 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 1 0 0 0 0 0 0 0 0 0 0 8 0 9 0
11 DT Front 92 0 0 92 21 0 0 21 22.83 0 0 0 0 0.00 10 Gapnotok 0 0 0 6 0 0 0 0 0 0 23 0 4 0 0 0 33 0
12 DT Rear 129 0 0 129 18 0 0 18 13.95 0 0 0 0 0.00 11 Fitment Nok 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 2 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 343 0 0 343 65 0 0 65 18.95 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 2 1 8 0 0 0 0 0 0 0 0 0 0 11 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Tuesday, February 07, 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 150 329 374 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 33 0 0 0 0 0 0 4 0 2 0 0 13 11 0 0 7 8 78 3.49

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 3 0 0 0 0 0 0 0 0 3 0 0 5 3 0 0 2 0 16 0.72
4 Ktm Front 0 18 0 18 0 0 0 0 0.00 0 16 0 16 88.89 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 9 0 0 0 0 0 0 0 0 10 0 0 10 4 0 0 4 0 37 1.66
5 Ktm Rear 22 21 0 43 0 0 0 0 0.00 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
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 11 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 14 0.63

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

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 4 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 6 0.27
17 MY17 Front 59 53 0 112 20 15 0 35 31.25 0 0 0 0 0.00 226 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 58 53 0 111 12 45 0 57 51.35 0 0 0 0 0.00 378 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 7 0 0 0 0 1 0 1 0 0 0 0 2 0 0 0 0 0 11 0.49

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 10 1 0 0 0 0 0 0 0 0 0 0 0 11 0.49

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 1 0 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 2 0 0 0 0 0 0 0 0 0 0 0 0 2 0.09
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 15 0 30 15 0 0 0 0 0 0 0 0 0 0 0 60 2.69
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 1,112 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 3 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 6 8 23 0 11 0 0 4 16 25 24 7 3 127 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 3 3 5 0 0 0 0 6 3 8 10 3 2 43 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 59 0 0 59 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 0 0 0 3 0 0 0 0 6 4 2 0 15 0
7 Vespa (MY15) 132 0 0 132 22 0 0 22 16.67 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0
8 JY (MY 16) 234 0 0 234 28 0 0 28 11.97 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 2 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 2 0
11 DT Front 100 0 0 100 21 0 0 21 21.00 0 0 0 0 0.00 10 Gapnotok 0 0 0 12 0 0 0 0 0 0 5 1 12 0 0 0 30 0
12 DT Rear 93 0 0 93 11 0 0 11 11.83 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 2 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 22 0 0 22 15 0 0 15 68.18 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 1 2 2 1 6 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 52 0 0 52 23 0 0 23 44.23 0 0 0 0 0.00 13 Rexine Cut 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 PU 20.42 25.4974 4.52 2.95815

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Wednesday, February 08, 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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 46 0 0 0 0 0 0 0 12 10 0 0 22 12 63 61 17 21 264 9.44

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 0 0 0 0 0 0 0 0 1 1 0 0 1 4 18 1 2 6 34 1.22
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 27 0 0.00 0 0.00 3 Tearing 24 0 0 0 0 0 0 0 2 15 0 0 8 0 0 0 10 1 60 2.15
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 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

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 0 123 0 123 0 0 0 0 0.00 25 27 0 52 42.28 110 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 0 118 0 118 0 0 0 0 0.00 6 26 0 32 27.12 166 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 0 185 187 372 49 42 43 134 36.02 5 0 0 5 1.34 184 0 0.00 0 0.00 1 Vent trap 2 0 0 0 0 5 2 1 0 0 0 0 3 0 0 0 1 9 23 0.82
14 K4 Rear 0 182 177 359 31 15 16 62 17.27 1 0 3 4 1.11 466 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 0.04

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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 7 26 15 0 0 0 0 26 16 18 5 9 13 135 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 3 6 4 0 0 0 0 2 5 7 3 7 3 40 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 5 0
6 Vespa R 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 1 5 0 0 0 0 0 0 0 2 2 2 2 14 0
7 Vespa (MY15) 3 0 0 3 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 2 0 3 0 0 0 0 0 0 1 0 0 0 6 0
8 JY (MY 16) 252 0 0 252 29 0 0 29 11.51 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0 6 0
11 DT Front 169 0 0 169 21 0 0 21 12.43 0 0 0 0 0.00 10 Gapnotok 0 0 0 6 0 0 0 0 0 0 14 13 16 0 0 0 49 0
12 DT Rear 186 0 0 186 39 0 0 39 20.97 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 2 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 839 0 0 839 47 0 0 47 5.60 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 2 2 0 0 0 0 0 5 0 3 0 0 2 14 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Thursday, February 09, 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 150 500 470 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 36 0 0 0 0 0 0 2 0 5 0 0 11 14 26 22 9 8 133 4.33

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 0 0 0 0 0 0 0 0 0 2 0 0 5 5 0 3 10 2 27 0.88
4 Ktm Front 0 15 0 15 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 20 0 0 0 0 0 0 17 0 6 0 0 5 10 5 2 10 0 75 2.44
5 Ktm Rear 0 57 0 57 0 0 0 0 0.00 1 0 0 1 1.75 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 0 0 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 6 0.20
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) 54 15 0 69 33 6 0 39 56.52 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 6 Voids 81 0 0 0 0 0 0 17 0 20 0 0 88 20 30 47 43 74 420 13.66

8 JY (MY 16) 54 58 0 112 28 8 0 36 32.14 0 1 0 1 0.89 345 0 0.00 0 0.00 7 Loose Skin 17 0 0 0 0 0 0 0 0 6 0 0 17 3 4 0 0 0 47 1.53
9 KHI F 23 12 0 35 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! Total 154 0 0 0 0 0 0 36 0 39 0 0 132 52 65 74 72 84 708 23.03

10 KHI R 4 0 0 4 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0!

11 DT Front 104 117 0 221 0 0 0 0 0.00 6 14 0 20 9.05 102 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 99 119 0 218 0 0 0 0 0.00 17 23 0 40 18.35 212 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 174 170 0 344 73 59 0 132 38.37 2 1 0 3 0.87 390 0 0.00 0 0.00 1 Vent trap 0 0 0 0 1 0 1 1 0 0 0 0 3 0 0 0 1 1 8 0.26
14 K4 Rear 170 176 0 346 39 13 0 52 15.03 0 0 0 0 0.00 64 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 5 0 0 0 8 0 0 0 0 13 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 3 13 20 0 1 0 0 15 16 11 11 12 10 112 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 2 3 5 0 0 0 0 3 8 3 4 3 4 35 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 8 0 0 0 0 0 2 0 0 10 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 1 3 4 0 0 0 0 0 0 4 3 3 2 20 0
7 Vespa (MY15) 34 0 0 34 14 0 0 14 41.18 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 4 0 0 0 4 0
8 JY (MY 16) 111 0 0 111 32 0 0 32 28.83 3 0 0 3 2.70 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 0
11 DT Front 31 0 0 31 7 0 0 7 22.58 0 0 0 0 0.00 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 6 0 14 0 0 0 20 0
12 DT Rear 56 0 0 56 20 0 0 20 35.71 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 183 0 0 183 28 0 0 28 15.30 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 1 1 0 0 0 0 0 4 0 1 0 2 3 12 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 77 0 0 77 32 0 0 32 41.56 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 23.03 25.4974 2.24 2.95815

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Friday, February 10, 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 150 292 378 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 19 0 0 6 0 0 0 2 0 0 0 0 15 3 13 11 4 11 84 3.37

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 1 0 0 0 0 0 0 6 0 0 0 0 3 2 0 0 2 3 17 0.68
4 Ktm Front 0 55 0 55 0 29 0 29 52.73 0 0 0 0 0.00 35 0 0.00 0 0.00 3 Tearing 33 0 0 0 0 0 0 15 0 0 0 0 18 5 8 3 18 0 100 4.01
5 Ktm Rear 0 55 0 55 0 0 0 0 0.00 3 0 0 3 5.45 36 0 0.00 0 0.00 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) 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

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 84 114 0 198 0 0 0 0 0.00 8 15 0 23 11.62 245 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 90 109 0 199 0 0 0 0 0.00 14 19 0 33 16.58 242 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 122 167 0 289 62 63 0 125 43.25 1 0 0 1 0.35 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 4 0 0 0 3 1 13 0 0 0 0 0 1 3 0 0 3 0 28 1.12
14 K4 Rear 133 167 0 300 14 16 0 30 10.00 2 0 0 2 0.67 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

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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 8 0 0 0 0 0 8 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 15 9 25 0 0 0 0 11 10 11 0 8 10 99 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 7 3 13 0 0 0 0 4 6 3 0 4 3 43 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 3 0 4 0 0 0 0 0 0 0 0 0 0 7 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 2 0 0 0 0 0 0 0 2 0 3 0 7 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 1 0 3 0 0 0 0 0 0 0 0 1 1 6 0
8 JY (MY 16) 250 0 0 250 45 0 0 45 18.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 198 0 0 198 36 0 0 36 18.18 0 0 0 0 0.00 10 Gapnotok 0 0 0 10 0 0 0 0 0 0 16 0 0 0 11 0 37 0
12 DT Rear 144 0 0 144 14 0 0 14 9.72 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 423 0 0 423 39 0 0 39 9.22 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 5 0 0 0 2 7 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 1 0 0 1 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 124 0 0 124 27 0 0 27 21.77 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 118 0 0 118 18 0 0 18 15.25 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 31 24 0 19
TOTAL 1,825 0 0 1,825 216 0 0 216 11.84 0 0 0 0 0.00 Total 0 0 0 36 14 45 0 0 0 0 39 21 16 0 27 18 216 0 % 1.24 0.96 0.00 0.76

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Saturday, February 11, 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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 35 0 0 0 0 0 0 1 0 0 0 0 14 21 18 30 10 23 152 8.84

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 2 0 0 0 0 0 0 1 0 0 0 0 0 4 0 0 0 1 8 0.47
4 Ktm Front 0 58 0 58 0 0 0 0 0.00 0 0 0 0 0.00 106 0 0.00 0 0.00 3 Tearing 25 0 0 0 0 0 0 0 0 0 0 0 17 0 11 0 5 3 61 3.55
5 Ktm Rear 0 58 0 58 0 0 0 0 0.00 0 0 0 0 0.00 144 0 0.00 0 0.00 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! 129 0 0.00 0 0.00 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! 73 0 0.00 0 0.00 6 Voids 61 0 0 0 0 0 0 7 0 0 0 0 36 8 21 14 30 43 220 12.79

8 JY (MY 16) 0 58 0 58 5 4 0 9 15.52 0 0 0 0 0.00 65 0 0.00 0 0.00 7 Loose Skin 6 0 0 0 0 0 0 0 0 0 0 0 19 0 2 0 2 0 29 1.69
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 129 0 0 0 0 0 0 9 0 0 0 0 86 33 52 44 47 70 470 27.33

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 0 113 0 113 0 0 0 0 0.00 27 12 0 39 34.51 142 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 0 115 0 115 0 0 0 0 0.00 10 16 0 26 22.61 86 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 0 174 0 174 43 43 0 86 49.43 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 1 9 0 0 0 0 0 1 2 0 0 0 0 13 0.76
14 K4 Rear 0 173 0 173 13 20 0 33 19.08 0 1 0 1 0.58 195 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 2 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 3 5 0 4 0 0 0 0 0 8 3 2 4 0 0 29 0
4 Ktm Front 0 0 0 0 7 0 0 7 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 1 2 0 1 0 0 0 0 0 2 2 0 1 0 0 9 0
5 Ktm Rear 0 0 0 0 8 0 0 8 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 2 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 1 0 1 0 0 0 0 0 0 0 0 2 0 0 4 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0
8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 3 0 0 0 0 0 0 0 0 12 0 6 0 0 0 21 0
12 DT Rear 0 0 0 0 8 0 0 8 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 0 0 0 0 22 0 0 22 #DIV/0! 0 0 0 0 #DIV/0! 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 7 0 0 7 #DIV/0! 0 0 0 0 #DIV/0! 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 27.33 25.4974 4.59 2.95815

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

16 K 10 Rear 0 0 0 0 8 0 0 8 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 14 28 0 35
TOTAL 0 0 0 0 69 0 0 69 #DIV/0! 0 0 0 0 #DIV/0! Total 0 7 8 0 8 0 0 0 0 0 22 7 9 8 0 0 69 0 % 0.81 1.63 0.00 2.03

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Sunday, February 12, 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 150 714 495 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 31 0 0 0 0 0 0 3 0 0 0 0 6 33 32 53 0 23 181 5.47

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 1 0 0 1 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 2 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 1 4 0.12
4 Ktm Front 36 46 0 82 0 0 0 0 0.00 0 0 0 0 0.00 57 0 0.00 0 0.00 3 Tearing 16 0 0 0 0 0 0 9 0 0 0 0 29 2 7 2 0 3 68 2.06
5 Ktm Rear 44 47 0 91 0 0 0 0 0.00 2 0 0 2 2.20 70 0 0.00 0 0.00 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 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.03

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

10 KHI R 17 46 0 63 0 0 0 0 0.00 0 3 0 3 4.76 0 0 #DIV/0! 0 #DIV/0!

11 DT Front 129 98 0 227 0 0 0 0 0.00 10 19 0 29 12.78 219 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 131 98 0 229 0 0 0 0 0.00 14 7 0 21 9.17 268 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 198 139 0 337 65 44 0 109 32.34 0 0 0 0 0.00 38 0 0.00 0 0.00 1 Vent trap 1 0 0 0 1 1 5 1 0 0 0 0 0 0 0 0 1 1 11 0.33
14 K4 Rear 198 134 0 332 31 24 0 55 16.57 0 0 0 0 0.00 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

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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 10 2 0 29 0 0 41 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 7 15 4 6 0 0 0 0 0 13 24 2 8 9 19 107 0
4 Ktm Front 0 0 0 0 20 0 0 20 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 5 6 3 2 0 0 0 0 0 14 11 3 7 3 4 58 0
5 Ktm Rear 0 0 0 0 25 0 0 25 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 3 0 0 0 0 0 0 0 0 0 1 3 4 1 12 0
7 Vespa (MY15) 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 20 0 0 20 0 0 0 0 0.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 50 0 0 50 12 0 0 12 24.00 0 0 0 0 0.00 10 Gapnotok 0 8 0 4 0 0 0 0 0 0 9 0 0 0 0 0 21 0
12 DT Rear 71 0 0 71 10 0 0 10 14.08 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 176 0 0 176 47 0 0 47 26.70 1 0 0 1 0.57 12 Pu Pad Problem 0 0 1 1 2 0 0 0 0 0 0 2 0 0 3 4 13 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Monday, February 13, 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 150 758 707 343 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

10 KHI R 14 21 0 35 0 0 0 0 0.00 2 3 0 5 14.29 0 0 #DIV/0! 0 #DIV/0!

11 DT Front 128 121 0 249 0 0 0 0 0.00 15 7 0 22 8.84 34 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 126 113 0 239 0 0 0 0 0.00 7 0 0 7 2.93 23 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 192 178 210 580 61 30 47 138 23.79 0 1 0 1 0.17 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 3 0 0 0 2 0 0 0 0 0 3 8 0.17
14 K4 Rear 189 171 209 569 19 24 12 55 9.67 0 0 0 0 0.00 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

15 K10 Front 30 0 0 30 10 0 0 10 33.33 0 0 0 0 0.00 330 0 0.00 0 0.00 3 Tearing 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0.02

16 K 10 Rear 31 0 0 31 8 0 0 8 25.81 0 0 0 0 0.00 535 0 0.00 0 0.00 4 Collapse 5 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0.13
17 MY17 Front 63 59 69 191 33 25 25 83 43.46 1 2 2 5 2.62 199 0 0.00 0 0.00 5 Soft 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 9 #DIV/0!
18 MY17 Rear 64 61 72 197 56 39 37 132 67.01 1 1 2 4 2.03 190 0 0.00 0 0.00 6 Hard 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 #DIV/0!
19 Diwali (Front) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 61 0 0.00 0 0.00 7 Deforme 0 0 0 0 0 1 1 0 0 0 0 2 0 0 0 0 0 1 5 0.11
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 100 0 0.00 0 0.00 8 Voids 0 0 0 1 0 6 0 0 0 0 0 0 0 0 0 0 2 0 9 0.19
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 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 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 2 0 0 0 0 0 0 0 0 0 0 0 0 2 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 5 4 0 0 0 0 0 0 0 0 0 0 0 9 0.19
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 2 0 0 0 0 0 0 0 0 0 0 0 10 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 1,843 1,663 1,112 4,618 287 188 205 680 14.72 32 20 10 62 1.34 2,933 0 0.00 0 0.00 Total 13 0 0 1 1 22 7 3 0 0 0 5 0 0 0 0 6 4 62 1.34
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 2 2 0 0 0 0 4 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 4 2 7 5 12 0 6 0 0 8 33 11 16 0 0 104 0
4 Ktm Front 40 0 0 40 14 0 0 14 35.00 0 0 0 0 0.00 3 Staple Mis 0 5 1 7 6 3 0 0 0 0 2 5 4 6 0 0 39 0
5 Ktm Rear 50 0 0 50 4 0 0 4 8.00 0 0 0 0 0.00 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 3 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 1 0 3 0 0 2 0 0 0 0 2 0 0 0 8 0
7 Vespa (MY15) 0 0 0 0 11 0 0 11 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 108 0 0 108 17 0 0 17 15.74 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 119 0 0 119 22 0 0 22 18.49 0 0 0 0 0.00 10 Gapnotok 0 5 0 8 0 0 0 0 0 0 4 0 16 0 0 0 33 0
12 DT Rear 108 0 0 108 16 0 0 16 14.81 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 3 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 118 0 0 118 16 0 0 16 13.56 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 2 2 0 0 0 0 0 2 0 0 0 0 6 1 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 45 0 0 45 #DIV/0! 0 0 0 0 #DIV/0! 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 14.72 25.4974 1.34 2.95815

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Tuesday, February 14, 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 150 783 286 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 23 0 0 7 0 0 0 9 0 0 0 0 8 9 17 13 9 32 127 3.58

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 2 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 7 0.20
4 Ktm Front 64 57 68 189 34 29 28 91 48.15 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 28 0 0 5 0 0 0 10 0 0 0 0 27 10 11 2 38 6 137 3.86
5 Ktm Rear 66 56 70 192 0 0 0 0 0.00 1 0 0 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! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 92 0 0 71 0 0 0 21 0 0 0 0 60 11 4 8 72 90 429 12.08

8 JY (MY 16) 64 59 91 214 19 14 12 45 21.03 2 0 0 2 0.93 110 0 0.00 0 0.00 7 Loose Skin 0 0 0 8 0 0 0 0 0 0 0 0 34 2 0 0 0 0 44 1.24
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 145 0 0 91 0 0 0 45 0 0 0 0 129 32 32 23 119 128 744 20.96

10 KHI R 3 21 0 24 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0!

11 DT Front 129 110 0 239 0 0 0 0 0.00 6 7 0 13 5.44 0 0 #DIV/0! 0 #DIV/0! Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 123 104 0 227 0 0 0 0 0.00 9 18 0 27 11.89 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 198 169 0 367 73 56 0 129 35.15 0 1 0 1 0.27 329 0 0.00 0 0.00 1 Vent trap 0 0 0 0 1 0 8 1 0 0 0 0 0 0 0 0 0 0 10 0.28
14 K4 Rear 199 167 0 366 21 11 0 32 8.74 1 0 0 1 0.27 265 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 6 4 0 0 0 0 10 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 4 5 9 11 13 0 0 0 0 11 24 17 0 5 6 105 0
4 Ktm Front 0 0 0 0 9 0 0 9 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 2 1 7 4 4 0 0 0 0 12 6 8 0 2 2 48 0
5 Ktm Rear 0 0 0 0 8 0 0 8 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 2 2 5 0 0 0 0 0 0 0 8 0 0 0 17 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 2 0 0 0 0 0 0 0 0 6 0 0 0 8 0
8 JY (MY 16) 184 0 0 184 20 0 0 20 10.87 1 0 0 1 0.54 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0
11 DT Front 122 0 0 122 34 0 0 34 27.87 0 0 0 0 0.00 10 Gapnotok 0 3 0 12 0 0 0 0 0 0 4 2 14 0 0 0 35 0
12 DT Rear 76 0 0 76 20 0 0 20 26.32 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 550 0 0 550 35 0 0 35 6.36 2 0 0 2 0.36 12 Pu Pad Problem 0 0 0 2 0 2 0 0 0 0 0 0 0 0 3 0 7 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 113 0 0 113 12 0 0 12 10.62 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 98 0 0 98 8 0 0 8 8.16 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 80 0 0 80 0 0 0 0 0.00 0 0 0 0 0.00 Qty 20 12 0 18
TOTAL 1,917 0 0 1,917 242 0 0 242 12.62 10 0 0 10 0.52 Total 0 9 8 34 20 20 0 0 0 0 35 43 53 0 12 8 242 10 % 0.56 0.34 0.00 0.51

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Wednesday, February 15, 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 150 293 272 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 10 0 0 11 18 0 0 9 0 0 0 0 14 10 0 0 3 11 86 4.14

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 2 0 0 0 0 0 0 0 0 0 0 0 0 5 0 0 4 0 11 0.53
4 Ktm Front 69 70 0 139 21 34 0 55 39.57 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 6 0 0 0 0 0 0 1 0 0 0 0 12 7 0 0 0 3 29 1.40
5 Ktm Rear 69 70 0 139 48 48 0 96 69.06 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
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! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 33 0 0 43 78 0 0 15 0 0 0 0 44 10 0 0 28 49 300 14.44

8 JY (MY 16) 69 0 0 69 11 14 0 25 36.23 0 0 0 0 0.00 153 0 0.00 0 0.00 7 Loose Skin 12 0 0 1 0 0 0 0 0 0 0 0 41 0 0 0 0 0 54 2.60
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 63 0 0 55 96 0 0 25 0 0 0 0 111 32 0 0 35 63 480 23.10

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 37 0 0 37 0 0 0 0 0.00 8 0 0 8 21.62 238 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 37 0 0 37 0 0 0 0 0.00 2 0 0 2 5.41 202 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 202 210 0 412 49 62 0 111 26.94 0 0 0 0 0.00 771 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0.05
14 K4 Rear 198 205 0 403 15 17 0 32 7.94 0 0 0 0 0.00 500 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 68 71 0 139 18 23 0 41 29.50 0 0 0 0 0.00 27 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 68 70 0 138 27 36 0 63 45.65 0 0 0 0 0.00 30 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! 33 0 0.00 0 0.00 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! 29 0 0.00 0 0.00 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 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0.05
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 4 0 0 0 0 0 0 0 0 0 0 0 0 4 0.19
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 2 2 0 0 0 0 0 0 0 0 0 0 0 4 0.19
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 1,110 968 0 2,078 220 263 0 483 23.24 10 0 0 10 0.48 2,901 0 0.00 0 0.00 Total 0 0 0 0 0 8 2 0 0 0 0 0 0 0 0 0 0 0 10 0.48
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 147 0 0 147 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 Vespa (MY15) 18 0 0 18 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 110 0 0 110 0 0 0 0 0.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 76 0 0 76 0 0 0 0 0.00 0 0 0 0 0.00 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
12 DT Rear 54 0 0 54 0 0 0 0 0.00 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 572 0 0 572 0 0 0 0 0.00 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Thursday, February 16, 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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 410 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 #DIV/0!
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 120 0 0.00 0 0.00 7 Loose Skin 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 365 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
14 K4 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 408 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 #DIV/0!

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 140 0 0.00 0 0.00 4 Collapse 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 166 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! 42 0 0.00 0 0.00 7 Deforme 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
20 Diwali (Rear) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 88 0 0.00 0 0.00 8 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
TOTAL 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2,686 0 0.00 0 0.00 Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 11 0 0 11 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 Vespa (MY15) 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 154 0 0 154 0 0 0 0 0.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 105 0 0 105 0 0 0 0 0.00 0 0 0 0 0.00 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
12 DT Rear 40 0 0 40 0 0 0 0 0.00 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 431 0 0 431 0 0 0 0 0.00 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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!

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Friday, February 17, 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 150 300 292 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

2 JD Front 35 40 0 75 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 14 0 0 13 7 0 0 2 0 0 0 0 3 3 28 25 4 11 110 5.38

3 Jd Rear 33 39 0 72 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 4 0 0 0 0 0 0 0 0 0 0 0 0 6 3 1 0 0 14 0.68
4 Ktm Front 52 41 0 93 22 17 0 39 41.94 1 0 0 1 1.08 238 0 0.00 0 0.00 3 Tearing 14 0 0 0 1 0 0 2 0 2 0 0 7 4 13 2 7 3 55 2.69
5 Ktm Rear 47 41 0 88 23 26 0 49 55.68 3 5 0 8 9.09 128 0 0.00 0 0.00 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 29 0 29 0 4 0 4 13.79 0 0 0 0 0.00 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 1 0 1 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 46 0 0 26 41 0 0 20 0 2 0 0 12 9 21 31 29 47 284 13.89

8 JY (MY 16) 56 40 0 96 24 0 0 24 25.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 7 Loose Skin 2 0 0 0 0 0 0 0 0 0 0 0 16 1 0 0 0 0 19 0.93
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 80 0 0 39 49 0 0 24 0 4 0 0 38 23 65 59 40 61 482 23.58

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 96 76 0 172 0 0 0 0 0.00 3 5 0 8 4.65 0 0 #DIV/0! 0 #DIV/0! Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 49 37 0 86 0 0 0 0 0.00 3 4 0 7 8.14 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 45 3 0 48 38 0 0 38 79.17 0 0 0 0 0.00 103 0 0.00 0 0.00 1 Vent trap 1 0 0 1 8 0 2 0 0 0 0 0 0 0 2 0 0 3 17 0.83
14 K4 Rear 133 19 0 152 10 13 0 23 15.13 1 0 0 1 0.66 485 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 84 85 0 169 31 34 0 65 38.46 1 1 0 2 1.18 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 102 84 0 186 26 33 0 59 31.72 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 2 0 0 0 0 0 0 0 1 0 0 0 0 1 0 0 0 0 4 0.20
17 MY17 Front 51 42 0 93 22 18 0 40 43.01 0 0 0 0 0.00 200 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 51 42 0 93 29 32 0 61 65.59 0 3 0 3 3.23 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 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.05
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 6 1 0 0 0 0 0 0 0 0 0 0 0 7 0.34
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 2 4 0 0 0 0 0 0 0 0 0 0 0 6 0.29
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 1,134 910 0 2,044 268 214 0 482 23.58 13 22 0 35 1.71 2,004 0 0.00 0 0.00 Total 4 0 0 1 8 8 7 0 1 0 0 0 0 1 2 0 0 3 35 1.71
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 8 0 0 0 0 0 8 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 10 8 0 5 0 0 8 0 21 5 14 7 78 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 3 0 1 0 0 5 0 6 2 2 2 21 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 72 0 0 72 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 2 2 0 3 0 0 0 0 6 1 2 2 18 0
7 Vespa (MY15) 40 0 0 40 11 0 0 11 27.50 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 3 0
8 JY (MY 16) 135 0 0 135 13 0 0 13 9.63 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 2 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 20 0 0 20 0 0 0 0 0.00 0 0 0 0 0.00 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 7 0 10 0 0 0 17 0
12 DT Rear 46 0 0 46 15 0 0 15 32.61 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 2 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 296 0 0 296 32 0 0 32 10.81 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 1 0 0 0 0 0 4 0 0 0 1 2 8 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 61 0 0 61 8 0 0 8 13.11 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 148 0 0 148 19 0 0 19 12.84 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 42 0 0 42 13 0 0 13 30.95 0 0 0 0 0.00 Man Machine Method Material
19 Diwali 3 0 0 3 0 0 0 0 0.00 0 0 0 0 0.00 Qty 17 12 0 6
TOTAL 1,473 0 0 1,473 157 0 0 157 10.66 0 0 0 0 0.00 Total 0 0 0 0 15 13 0 11 0 0 32 0 46 8 19 13 157 0 % 0.83 0.59 0.00 0.29

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Saturday, February 18, 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 150 201 377 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

2 JD Front 25 0 0 25 7 0 0 7 28.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 29 0 2 2 0 0 0 0 0 1 0 0 0 7 0 8 7 12 68 6.49

3 Jd Rear 21 0 0 21 10 0 0 10 47.62 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 2 Release Mark 0 0 3 0 0 0 0 0 0 0 0 0 0 9 0 0 3 0 15 1.43
4 Ktm Front 24 5 0 29 12 0 0 12 41.38 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 38 0 5 0 0 0 0 0 5 0 0 0 0 10 0 0 1 0 59 5.64
5 Ktm Rear 24 5 0 29 9 0 0 9 31.03 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
6 Vespa R 17 0 0 17 11 0 0 11 64.71 1 0 0 1 5.88 0 0 #DIV/0! 0 #DIV/0! 5 Deforme 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.10

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 27 2 0 10 9 0 0 0 2 6 0 0 0 0 0 13 16 22 107 10.22

8 JY (MY 16) 0 97 0 97 7 0 0 7 7.22 0 0 0 0 0.00 55 0 0.00 0 0.00 7 Loose Skin 15 5 0 0 0 0 0 0 4 0 0 0 0 0 0 0 0 0 24 2.29
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 110 7 10 12 9 0 0 0 11 7 0 0 0 26 0 21 27 34 274 26.17

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 30 0 0 30 0 0 0 0 0.00 5 0 0 5 16.67 102 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 27 0 0 27 0 0 0 0 0.00 2 0 0 2 7.41 100 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 356 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0.19
14 K4 Rear 53 0 0 53 10 16 0 26 49.06 0 0 0 0 0.00 175 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 29 0 0 29 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 3 Tearing 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0.10

16 K 10 Rear 30 0 0 30 21 0 0 21 70.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 4 Collapse 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 2 0.19
17 MY17 Front 0 48 0 48 13 14 0 27 56.25 1 1 0 2 4.17 150 0 0.00 0 0.00 5 Soft 2 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 3 #DIV/0!
18 MY17 Rear 0 34 0 34 20 14 0 34 100.00 0 0 0 0 0.00 135 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 0.19
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 0.19
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 1 1 0 0 0 0 0 0 0 0 0 0 0 2 0.19
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 481 566 0 1,047 149 125 0 274 26.17 10 4 0 14 1.34 2,048 0 0.00 0 0.00 Total 4 0 0 0 0 5 2 0 1 0 0 0 0 0 0 0 2 0 14 1.34
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 10 8 0 3 10 0 0 0 0 0 29 5 7 8 0 80 0
4 Ktm Front 0 0 0 0 20 0 0 20 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 3 4 0 1 4 0 0 0 0 0 5 3 3 2 0 25 0
5 Ktm Rear 0 0 0 0 12 0 0 12 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 0 0 0 0 14 0 0 14 #DIV/0! 0 0 0 0 #DIV/0! 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 7 0 0 0 0 0 0 0 0 0 0 5 0 0 0 12 0
12 DT Rear 0 0 0 0 4 0 0 4 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 2 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 34 0 0 34 #DIV/0! 0 0 0 0 #DIV/0! 13 Rexine Cut 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PU 26.17 25.4974 1.34 2.95815

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

16 K 10 Rear 0 0 0 0 10 0 0 10 #DIV/0! 0 0 0 0 #DIV/0! 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 13 0 0 13 #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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Man Machine Method Material
19 Diwali 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Qty 6 6 0 2
TOTAL 0 0 0 0 121 0 0 121 #DIV/0! 0 0 0 0 #DIV/0! Total 0 20 12 0 4 14 0 0 0 0 0 34 14 10 13 0 121 0 % 0.57 0.57 0.00 0.19

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Sunday, February 19, 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 150 792 734 758 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

2 JD Front 39 61 63 163 0 0 0 0 0.00 2 2 1 5 3.07 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 40 59 62 161 0 0 0 0 0.00 0 0 1 1 0.62 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
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 1 0 1 #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 57 64 121 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 66 62 66 194 0 0 0 0 0.00 0 0 0 0 0.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1139 23.08

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 46 180 191 417 0 0 0 0 0.00 1 2 0 3 0.72 307 0 0.00 0 0.00 1 Vent trap 4 1 1 0 0 0 0 0 0 0 0 0 0 0 1 0 6 3 16 0.32
14 K4 Rear 155 182 196 533 0 0 0 0 0.00 4 2 0 6 1.13 388 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 8 0 0 0 0 8 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 5 8 0 0 14 0 0 0 0 11 15 3 7 8 9 80 0
4 Ktm Front 74 0 0 74 15 0 0 15 20.27 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 80 0 0 80 14 0 0 14 17.50 0 0 0 0 0.00 4 loose staple 0 3 4 0 0 4 0 0 0 0 8 8 0 4 2 2 35 0
6 Vespa R 39 0 0 39 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 1 2 0 0 2 0 0 0 0 0 0 0 4 3 2 14 0
7 Vespa (MY15) 63 0 0 63 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 111 0 0 111 23 0 0 23 20.72 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 3 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 54 0 0 54 0 0 0 0 0.00 0 0 0 0 0.00 10 Gapnotok 0 6 0 0 0 0 0 0 0 0 10 0 7 0 0 0 23 0
12 DT Rear 67 0 0 67 0 0 0 0 0.00 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 213 0 0 213 32 0 0 32 15.02 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 3 0 0 1 0 4 8 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Friday, January 20, 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 150 442 415 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

2 JD Front 38 60 0 98 0 0 0 0 0.00 1 0 0 1 1.02 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 39 60 0 99 0 0 0 0 0.00 0 0 0 0 0.00 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
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 6 61 0 67 0 0 0 0 0.00 0 1 0 1 1.49 65 0 0.00 0 0.00 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) 37 60 0 97 0 0 0 0 0.00 0 0 0 0 0.00 27 0 0.00 0 0.00 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 41 65 0 106 0 0 0 0 0.00 1 0 0 1 0.94 32 0 0.00 0 0.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2060 83.43

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! 1 0 0 1 #DIV/0! 275 0 0.00 0 0.00 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! 1 0 0 1 #DIV/0! 267 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 105 183 0 288 0 0 0 0 0.00 1 3 0 4 1.39 490 0 0.00 0 0.00 1 Vent trap 8 0 0 0 0 0 0 0 1 0 0 0 3 0 0 0 0 0 12 0.49
14 K4 Rear 108 181 0 289 0 0 0 0 0.00 0 1 0 1 0.35 202 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 35 27 0 0 0 0 62 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 5 8 0 8 0 0 0 0 0 13 16 0 12 4 6 72 0
4 Ktm Front 66 0 0 66 15 0 0 15 22.73 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 80 0 0 80 15 0 0 15 18.75 0 0 0 0 0.00 4 loose staple 0 2 3 0 2 0 0 0 0 0 6 7 0 5 3 3 31 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 2 0 6 0 0 0 0 0 0 0 0 1 1 2 12 0
7 Vespa (MY15) 47 0 0 47 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 184 0 0 184 0 0 0 0 0.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 2 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 8 0 0 0 0 0 0 0 0 13 0 0 0 0 0 21 0
12 DT Rear 104 0 0 104 16 0 0 16 15.38 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 204 0 0 204 72 0 0 72 35.29 0 0 0 0 0.00 12 Pu Pad Problem 0 0 2 0 0 0 0 0 0 0 5 2 0 0 0 0 9 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Tuesday, February 21, 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 150 415 364 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

2 JD Front 66 62 0 128 0 0 0 0 0.00 2 1 0 3 2.34 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 65 58 0 123 0 0 0 0 0.00 0 0 0 0 0.00 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
4 Ktm Front 62 70 0 132 0 0 0 0 0.00 1 2 0 3 2.27 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
5 Ktm Rear 59 59 0 118 0 0 0 0 0.00 2 0 0 2 1.69 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 30 63 0 93 0 0 0 0 0.00 1 0 0 1 1.08 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) 66 63 0 129 0 0 0 0 0.00 2 0 0 2 1.55 0 0 #DIV/0! 0 #DIV/0! 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 66 59 0 125 0 0 0 0 0.00 0 0 0 0 0.00 302 0 0.00 0 0.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2440 78.43

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 63 0 63 0 0 0 0 0.00 0 0 0 0 0.00 169 0 0.00 0 0.00 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! 87 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 191 185 0 376 0 0 0 0 0.00 4 2 0 6 1.60 485 0 0.00 0 0.00 1 Vent trap 4 0 0 0 0 0 0 0 1 0 0 0 3 0 0 0 1 0 9 0.29
14 K4 Rear 197 183 0 380 0 0 0 0 0.00 1 1 0 2 0.53 490 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 19 11 0 0 0 0 30 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 10 7 0 0 0 0 0 0 0 66 42 10 5 6 5 151 0
4 Ktm Front 67 0 0 67 25 0 0 25 37.31 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 0
5 Ktm Rear 47 0 0 47 11 0 0 11 23.40 0 0 0 0 0.00 4 loose staple 0 6 4 0 0 0 0 0 0 0 11 9 5 3 3 2 43 0
6 Vespa R 16 0 0 16 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 7 3 0 2 12 0
7 Vespa (MY15) 88 0 0 88 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 100 0 0 100 0 0 0 0 0.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 90 0 0 90 0 0 0 0 0.00 0 0 0 0 0.00 10 Gapnotok 0 9 0 0 0 0 0 0 0 0 12 0 20 0 0 0 41 0
12 DT Rear 146 0 0 146 0 0 0 0 0.00 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 204 0 0 204 114 0 0 114 55.88 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 6 4 3 0 0 0 13 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 67 0 0 67 11 0 0 11 16.42 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 120 0 0 120 13 0 0 13 10.83 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 40 0 0 40 9 0 0 9 22.50 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 39 14 0 0
TOTAL 1,478 0 0 1,478 294 0 0 294 19.89 0 0 0 0 0.00 Total 0 25 11 0 0 0 0 0 0 0 114 66 45 11 13 9 294 0 % 1.25 0.45 0.00 0.00

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Sunday, January 22, 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 150 135 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

2 JD Front 24 0 0 24 0 0 0 0 0.00 13 0 0 13 54.17 155 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 22 0 0 22 0 0 0 0 0.00 0 0 0 0 0.00 597 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
4 Ktm Front 23 0 0 23 0 0 0 0 0.00 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
5 Ktm Rear 23 0 0 23 0 0 0 0 0.00 2 0 0 2 8.70 60 0 0.00 0 0.00 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! 2 0 0 2 #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) 23 0 0 23 0 0 0 0 0.00 2 0 0 2 8.70 0 0 #DIV/0! 0 #DIV/0! 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 22 0 0 22 0 0 0 0 0.00 0 0 0 0 0.00 286 0 0.00 0 0.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

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! 1 0 0 1 #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 69 0 0 69 0 0 0 0 0.00 2 0 0 2 2.90 365 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
14 K4 Rear 66 0 0 66 0 0 0 0 0.00 3 0 0 3 4.55 270 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 47 0 0 47 0 0 0 0 0.00 1 0 0 1 2.13 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 23 0 0 23 0 0 0 0 0.00 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 24 0 0 24 0 0 0 0 0.00 2 0 0 2 8.33 0 0 #DIV/0! 0 #DIV/0! 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 23 0 0 23 0 0 0 0 0.00 1 0 0 1 4.35 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) 23 0 0 23 0 0 0 0 0.00 1 0 0 1 4.35 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 547 0 0 547 0 0 0 0 0.00 51 0 0 51 9.32 2,783 0 0.00 0 0.00 Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 8 10 3 0 4 0 25 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 8 5 4 17 11 0 0 0 0 55 45 6 15 14 15 195 0
4 Ktm Front 65 0 0 65 18 0 0 18 27.69 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 30 0 0 30 8 0 0 8 26.67 0 0 0 0 0.00 4 loose staple 0 3 2 3 4 3 0 0 0 0 6 0 2 8 3 6 40 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 1 1 0 4 2 0 0 0 0 0 0 3 3 2 1 17 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 1 0 1 0 0 0 0 0 0 0 0 2 0 0 0 4 0
8 JY (MY 16) 63 0 0 63 16 0 0 16 25.40 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 115 0 0 115 16 0 0 16 13.91 0 0 0 0 0.00 10 Gapnotok 0 5 0 8 0 0 0 0 0 0 7 0 0 0 0 0 20 0
12 DT Rear 176 0 0 176 25 0 0 25 14.20 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 241 0 0 241 81 0 0 81 33.61 0 0 0 0 0.00 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 5 10 0 6 1 6 28 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Thursday, February 23, 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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
14 K4 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 148 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
TOTAL 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1,133 0 0.00 0 0.00 Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 5 7 3 0 5 0 20 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 5 10 8 11 5 0 0 0 0 8 11 8 4 8 8 86 0
4 Ktm Front 100 0 0 100 17 0 0 17 17.00 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 139 0 0 139 24 0 0 24 17.27 0 0 0 0 0.00 4 loose staple 0 2 7 5 4 3 0 0 0 0 5 6 4 2 4 3 45 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 3 3 1 11 0 0 0 0 0 0 0 4 2 3 3 30 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 2 0
8 JY (MY 16) 32 0 0 32 8 0 0 8 25.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 173 0 0 173 26 0 0 26 15.03 0 0 0 0 0.00 10 Gapnotok 0 6 0 11 0 0 0 0 0 0 6 0 0 0 0 0 23 0
12 DT Rear 72 0 0 72 26 0 0 26 36.11 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 56 0 0 56 24 0 0 24 42.86 0 0 0 0 0.00 12 Pu Pad Problem 0 0 4 0 0 0 0 0 0 0 0 0 0 0 0 4 8 0 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 50 0 0 50 8 0 0 8 16.00 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 288 0 0 288 20 0 0 20 6.94 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 19 0 0 19 18.63 1 0 0 1 0.98 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 1,290 0 0 1,290 215 0 0 215 16.67 1 0 0 1 0.08 Total 0 17 24 26 26 8 0 0 0 0 24 24 19 8 20 19 215 0 % #DIV/0! #DIV/0! #DIV/0! #DIV/0!

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Friday, February 24, 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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 36 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
4 Ktm Front 39 79 0 118 0 0 0 0 0.00 0 0 0 0 0.00 50 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
5 Ktm Rear 40 76 0 116 0 0 0 0 0.00 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
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! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

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 1 0 0 1 0 0 0 0 0.00 0 10 0 10 1,000.00 620 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
14 K4 Rear 1 0 0 1 0 0 0 0 0.00 0 0 0 0 0.00 530 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 1 0 0 1 0 0 0 0 0.00 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 0 0 0 0 0 0 0 0 #DIV/0! 0 1 0 1 #DIV/0! 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 50 79 0 129 0 0 0 0 0.00 0 10 0 10 7.75 250 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 49 79 0 128 0 0 0 0 0.00 0 3 0 3 2.34 255 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! 24 0 0.00 0 0.00 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 189 1,178 0 1,367 0 0 0 0 0.00 0 126 0 126 9.22 3,001 0 0.00 0 0.00 Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 3 0 0 0 0 0 0 0 11 10 0 0 4 0 28 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 5 0 4 9 7 0 0 0 0 17 38 9 10 6 20 125 0
4 Ktm Front 45 0 0 45 11 0 0 11 24.44 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 4 0 0 0 0 4 0
5 Ktm Rear 23 0 0 23 5 0 0 5 21.74 0 0 0 0 0.00 4 loose staple 0 2 1 8 2 4 0 0 0 0 8 8 3 4 2 5 47 0
6 Vespa R 3 0 0 3 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 1 2 3 1 0 0 0 0 0 0 1 6 0 1 15 0
7 Vespa (MY15) 13 0 0 13 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 1 0 0 0 0 0 0 8 0 0 0 0 0 9 0
8 JY (MY 16) 100 0 0 100 16 0 0 16 16.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
11 DT Front 59 0 0 59 20 0 0 20 33.90 1 0 0 1 1.69 10 Gapnotok 0 4 0 5 0 0 0 0 0 0 32 0 4 0 0 0 45 0
12 DT Rear 115 0 0 115 16 0 0 16 13.91 2 0 0 2 1.74 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 19 0 0 19 76 0 0 76 400.00 3 0 0 3 15.79 12 Pu Pad Problem 0 0 0 0 2 4 0 0 0 0 0 7 0 0 0 22 35 2 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Saturday, February 25, 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 150 462 359 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

2 JD Front 30 33 0 63 0 0 0 0 0.00 9 10 0 19 30.16 355 0 0.00 0 0.00 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 17 27 0 44 0 0 0 0 0.00 1 2 0 3 6.82 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
4 Ktm Front 42 33 0 75 0 0 0 0 0.00 2 1 0 3 4.00 290 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
5 Ktm Rear 47 31 0 78 0 0 0 0 0.00 2 2 0 4 5.13 83 0 0.00 0 0.00 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! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 4 0 0 4 0 0 0 0 0.00 0 0 0 0 0.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

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! 4 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 8 33 0 41 0 0 0 0 0.00 2 8 0 10 24.39 10 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 132 101 0 233 0 0 0 0 0.00 5 4 0 9 3.86 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00
14 K4 Rear 87 6 0 93 0 0 0 0 0.00 5 1 0 6 6.45 254 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 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

JY Vespa Vespa K4 K4 K10 K10RE MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front AR Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 1 7 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 9 13 5 8 4 0 0 0 0 28 0 15 13 8 10 113 0
4 Ktm Front 65 0 0 65 17 0 0 17 26.15 0 0 0 0 0.00 3 Staple Mis 0 0 1 0 0 0 0 0 0 0 0 0 0 3 0 0 4 0
5 Ktm Rear 75 0 0 75 19 0 0 19 25.33 0 0 0 0 0.00 4 loose staple 0 0 7 5 3 0 0 0 0 0 9 0 7 5 3 4 43 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 1 0 0 0 0 0 0 0 0 0 7 5 2 2 17 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 2 0 0 0 0 0 0 0 0 1 0 0 0 3 0
8 JY (MY 16) 20 0 0 20 6 0 0 6 30.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 62 0 0 62 21 0 0 21 33.87 0 0 0 0 0.00 10 Gapnotok 0 6 0 8 0 0 0 0 0 0 21 0 10 0 0 0 45 0
12 DT Rear 47 0 0 47 11 0 0 11 23.40 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 296 0 0 296 69 0 0 69 23.31 1 0 0 1 0.34 12 Pu Pad Problem 0 2 3 1 0 2 0 0 0 0 5 0 2 0 4 4 23 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 10.80 2.95815

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

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Sunday, February 26, 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 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

2 JD Front 3 0 0 3 0 0 0 0 0.00 0 0 0 0 0.00 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 9 0 0 9 0 0 0 0 0.00 0 0 0 0 0.00 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
4 Ktm Front 10 45 0 55 0 0 0 0 0.00 0 4 0 4 7.27 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
5 Ktm Rear 9 44 0 53 0 0 0 0 0.00 0 3 0 3 5.66 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! 0 0 #DIV/0! 0 #DIV/0! 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 4 0 0 4 0 0 0 0 0.00 0 3 0 3 75.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

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 26 50 0 76 0 0 0 0 0.00 0 5 0 5 6.58 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 4 3 0 0 0 0 0 0 0 0 0 0 0 0 0 7 0.73
14 K4 Rear 11 45 0 56 0 0 0 0 0.00 0 8 0 8 14.29 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

15 K10 Front 6 0 0 6 0 0 0 0 0.00 0 2 0 2 33.33 434 0 0.00 0 0.00 3 Tearing 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 0.73

16 K 10 Rear 4 0 0 4 0 0 0 0 0.00 0 3 0 3 75.00 277 0 0.00 0 0.00 4 Collapse 16 0 0 0 0 0 0 0 0 0 0 0 5 8 2 3 0 0 34 3.54
17 MY17 Front 4 18 0 22 0 0 0 0 0.00 0 4 0 4 18.18 0 0 #DIV/0! 0 #DIV/0! 5 Soft 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 #DIV/0!
18 MY17 Rear 3 20 0 23 0 0 0 0 0.00 0 10 0 10 43.48 27 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 12 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 4 10 29 3.02
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 172 789 0 961 0 0 0 0 0.00 0 78 0 78 8.12 1,688 0 0.00 0 0.00 Total 36 0 0 4 3 0 0 3 0 0 0 0 5 8 2 3 4 10 78 8.12
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 9 2 0 0 0 0 11 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 9 5 4 0 4 0 0 0 0 17 8 17 8 5 8 85 0
4 Ktm Front 53 0 0 53 21 0 0 21 39.62 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 15 0 0 15 7 0 0 7 46.67 0 0 0 0 0.00 4 loose staple 0 0 2 5 0 2 0 0 0 0 4 2 4 3 3 3 28 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 6 2 2 0 10 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 2 0 2 0 0 0 0 0 0 0 0 1 0 0 0 5 0
8 JY (MY 16) 20 0 0 20 7 0 0 7 35.00 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 105 0 0 105 24 0 0 24 22.86 1 0 0 1 0.95 10 Gapnotok 0 10 0 13 0 0 0 0 0 0 11 0 6 0 0 0 40 0
12 DT Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 124 0 0 124 44 0 0 44 35.48 1 0 0 1 0.81 12 Pu Pad Problem 0 0 0 0 0 1 0 0 0 0 3 2 0 2 1 7 16 4 DAY% AVG% DAY% AVG% Rework % Rejection %

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

16 K 10 Rear 44 0 0 44 15 0 0 15 34.09 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 67 0 0 67 11 0 0 11 16.42 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 57 0 0 57 18 0 0 18 31.58 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 44 34 0 0
TOTAL 759 0 0 759 195 0 0 195 25.69 7 0 0 7 0.92 Total 0 21 7 24 0 7 0 0 0 0 44 14 34 15 11 18 195 7 % 4.58 3.54 0.00 0.00

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Monday, February 27, 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 150 426 328 239 993 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

2 JD Front 22 96 27 145 0 0 0 0 0.00 5 0 0 5 3.45 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

3 Jd Rear 35 102 37 174 0 0 0 0 0.00 4 0 0 4 2.30 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
4 Ktm Front 33 51 29 113 0 0 0 0 0.00 3 0 0 3 2.65 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
5 Ktm Rear 34 44 33 111 0 0 0 0 0.00 3 0 0 3 2.70 288 0 0.00 0 0.00 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! 43 0 0.00 0 0.00 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! 30 0 0.00 0 0.00 6 Voids 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

8 JY (MY 16) 34 48 37 119 0 0 0 0 0.00 1 0 0 1 0.84 175 0 0.00 0 0.00 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00

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 17 2 35 54 0 0 0 0 0.00 10 0 0 10 18.52 1 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 11 3 22 36 0 0 0 0 0.00 15 0 0 15 41.67 30 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 111 98 0 209 0 0 0 0 0.00 12 0 0 12 5.74 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0.13
14 K4 Rear 82 98 105 285 0 0 0 0 0.00 4 0 0 4 1.40 170 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 3 1 0 0 3 0 7 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 12 11 7 6 5 0 0 0 0 24 6 11 7 9 8 106 0
4 Ktm Front 50 0 0 50 27 0 0 27 54.00 1 0 0 1 2.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 98 0 0 98 15 0 0 15 15.31 0 0 0 0 0.00 4 loose staple 0 6 2 4 2 1 0 0 0 0 12 3 8 2 4 0 44 0
6 Vespa R 22 0 0 22 0 0 0 0 0.00 0 0 0 0 0.00 5 Rubber Missing 0 0 1 0 0 0 0 0 0 0 0 0 7 0 3 0 11 0
7 Vespa (MY15) 40 0 0 40 0 0 0 0 0.00 0 0 0 0 0.00 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 2 0
8 JY (MY 16) 17 0 0 17 6 0 0 6 35.29 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 0
11 DT Front 110 0 0 110 16 0 0 16 14.55 0 0 0 0 0.00 10 Gapnotok 0 9 0 5 0 0 0 0 0 0 27 0 0 0 0 0 41 0
12 DT Rear 39 0 0 39 11 0 0 11 28.21 2 0 0 2 5.13 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 114 0 0 114 67 0 0 67 58.77 0 0 0 0 0.00 12 Pu Pad Problem 0 0 1 0 3 0 0 0 0 0 1 0 0 3 3 5 16 2 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 41 0 0 41 10 0 0 10 24.39 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 3.52 2.95815

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

16 K 10 Rear 44 0 0 44 12 0 0 12 27.27 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 88 0 0 88 22 0 0 22 25.00 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 46 0 0 46 15 0 0 15 32.61 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 43 67 0 0
TOTAL 861 0 0 861 229 0 0 229 26.60 3 0 0 3 0.35 Total 0 27 15 16 11 6 0 0 0 0 67 10 28 12 22 15 229 3 % 1.38 2.15 0.00 0.00

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Tuesday, February 28, 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 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

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 65 110 103 278 0 0 0 0 0.00 31 30 13 74 26.62 75 0 0.00 0 0.00 Scrap Qty
S.
DEFECTS KTM- JY Vespa Vespa K10 K10 MY17 MY17
12 DT Rear 45 42 55 142 0 0 0 0 0.00 11 7 6 24 16.90 57 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 133 167 114 414 50 60 32 142 34.30 1 0 0 1 0.24 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 29 4 0 0 0 0 0 0 0 0 0 0 4 37 0.69
14 K4 Rear 138 173 159 470 15 35 18 68 14.47 0 0 0 0 0.00 160 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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 7 0 0 0 0 7 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 19 8 0 11 15 0 0 0 0 28 24 0 10 0 0 115 0
4 Ktm Front 121 0 0 121 34 0 0 34 28.10 0 0 0 0 0.00 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 115 0 0 115 13 0 0 13 11.30 0 0 0 0 0.00 4 loose staple 0 0 0 3 0 2 0 0 0 0 4 6 0 2 0 0 17 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 2 0 0 0 0 0 0 0 0 3 0 0 5 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 78 0 0 78 22 0 0 22 28.21 0 0 0 0 0.00 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 26 0 0 26 10 0 0 10 38.46 0 0 0 0 0.00 10 Gapnotok 0 9 0 5 0 0 0 0 0 0 20 0 0 0 0 0 34 0
12 DT Rear 92 0 0 92 16 0 0 16 17.39 0 0 0 0 0.00 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 175 0 0 175 59 0 0 59 33.71 0 0 0 0 0.00 12 Pu Pad Problem 0 6 5 2 3 5 0 0 0 0 7 1 0 2 0 0 31 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 92 0 0 92 38 0 0 38 41.30 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 23.15 25.4974 2.63 2.95815

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

16 K 10 Rear 90 0 0 90 17 0 0 17 18.89 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 119 0 0 119 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 87 0 0 87 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 58 71 0 12
TOTAL 1,048 0 0 1,048 209 0 0 209 19.94 0 0 0 0 0.00 Total 0 34 13 10 16 22 0 0 0 0 59 38 0 17 0 0 209 0 % 1.08 1.33 0.00 0.22

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY
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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
14 K4 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
TOTAL 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
12 DT Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 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!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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!

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY
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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
14 K4 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
TOTAL 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
12 DT Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 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!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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!

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY
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 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

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 1 Vent trap 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
14 K4 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!

15 K10 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
17 MY17 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
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 #DIV/0!
TOTAL 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 0 0 #DIV/0! 0 #DIV/0! Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 #DIV/0!
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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
4 Ktm Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 3 Staple Mis 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Ktm Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 4 loose staple 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Vespa R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 5 Rubber Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
7 Vespa (MY15) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 6 Collar Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 JY (MY 16) 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11 DT Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 10 Gapnotok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
12 DT Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 11 Fitment Nok 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 12 Pu Pad Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DAY% AVG% DAY% AVG% Rework % Rejection %

14 K4 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 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!

16 K 10 Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 15 Rexene Defect 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Stitching #DIV/0! 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 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!

PU Assly Stitching QA Plant Head

 DATE UNDER REVIEW
PRODUCT WISE REWORK AND REJECTION SUMMARY Feb/17
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 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

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 0.00

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 6 8 0 0 0 0 0 0 0 0 0 0 0 14 0.02

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 92 57 0 0 0 0 0 0 0 0 0 0 0 149 0.24
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 15 0 170 150 0 0 0 0 0 0 0 0 0 0 0 335 0.53
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 4 11 0 0 0 0 0 0 0 0 0 0 0 15 0.02

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 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

JY Vespa Vespa K4 K4 K10 K10 MY17 MY 17 Total Model

1 Pulsar 150 0 0 0 126,210 0 0 0 0 0.00 0 0 0 0 0.00 Sr.No DEFECTS Pulsar KTM-MY-F KTM-R DT F DT R KHI-F KHI-R Total R.W Prod. Rej. Prod. Rej. Prod. Rej.
(MY16) R (MY 15) Front Rear Front Rear Front Rear Scrap

2 JD Front 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 1 Pre Assly N.ok 0 0 3 0 0 0 0 5 0 0 135 128 6 32 16 1 326 0

3 Jd Rear 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 2 Wrinkle 0 115 110 113 201 321 5 49 0 0 512 466 241 203 181 230 2747 0
4 Ktm Front 746 0 0 746 270 0 0 270 36.19 1 0 0 1 0.13 3 Staple Mis 0 16 15 38 40 64 2 4 0 0 83 88 61 45 40 39 535 0
5 Ktm Rear 752 0 0 752 188 0 0 188 25.00 0 0 0 0 0.00 4 loose staple 0 24 32 36 19 29 0 8 0 0 76 55 33 40 27 28 407 0
6 Vespa R 524 0 0 524 15 0 0 15 2.86 0 0 0 0 0.00 5 Rubber Missing 0 5 18 7 50 14 3 8 0 0 4 10 83 51 36 29 318 0
7 Vespa (MY15) 624 0 0 624 89 0 0 89 14.26 1 0 0 1 0.16 6 Collar Missing 0 4 0 16 0 6 0 0 0 0 8 0 22 0 1 1 58 0
8 JY (MY 16) 2,933 0 0 2,933 468 0 0 468 15.96 4 0 0 4 0.14 7 Parts Missing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
9 KHI F 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 8 Loose Threds 0 0 0 0 2 3 0 2 0 0 0 1 0 2 0 0 10 0 Total 0 0 0 0 0 0
10 KHI R 0 0 0 0 0 0 0 0 #DIV/0! 0 0 0 0 #DIV/0! 9 Stitiching not ok 0 0 0 1 0 0 0 2 0 0 0 0 0 0 30 2 35 1
11 DT Front 2,203 0 0 2,203 381 0 0 381 17.29 2 0 0 2 0.09 10 Gapnotok 0 98 0 145 0 0 0 0 0 0 298 16 166 1 13 4 741 0
12 DT Rear 2,187 0 0 2,187 330 0 0 330 15.09 4 0 0 4 0.18 11 Fitment Nok 0 0 0 9 0 0 4 7 0 0 0 2 0 0 0 0 22 0 Rework % Scrap % Overall Overall
Cell
13 K4 Front 6,611 0 0 6,611 1,169 0 0 1,169 17.68 8 0 0 8 0.12 12 Pu Pad Problem 0 8 16 16 18 25 1 1 0 0 50 39 11 21 28 69 303 9 DAY% AVG% DAY% AVG% Rework % Rejection %

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

PU Assly Stitching QA Plant Head

 PU (FIP Model)Rejection Details
Production Qty. 1,540 1,607 2,491 2,173
S NO DEFECTS KTM-MY-F KTM-R DT F DT R
1 Pit Mark 15 0.97 0 0.00 170 6.82 150
2 De- Lamination 0 0.00 0 0.00 92 3.69 57
3 Vent trap 5 0.32 17 1.06 41 1.65 59
4 Voids 1 0.06 0 0.00 75 3.01 9
5 Deforme 3 0.19 4 0.25 7 0.28 5
6 Collapse 3 0.19 6 0.37 5 0.20 3
7 Power Fail 0 0.00 0 0.00 4 0.16 11
8 Wrinkle 0 0.00 0 0.00 6 0.24 8
9 Soft 1 0.06 1 0.06 2 0.08 3
10 Tearing 3 0.19 1 0.06 0 0.00 0
11 Hard 0 0.00 0 0.00 0 0.00 1
12 Rexine cut 0 0.00 0 0.00 1 0.04 0
13 Release Mark 0 0.00 0 0.00 0 0.00 0
TOTAL 31 2.01 29 1.80 403 16.18 306

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

99.74 99.87 100.00 100.00

100.00

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

99.40 99.88 100.00 100.00 100.0

98.44
96.65

64

15
8
4 1

Soft Hard Deforme Voids Loose Skin 0 cut

Rexine 0
Wrinkle
 15
8
4 1

Soft Hard Deforme Voids Loose Skin 0 cut

Rexine 0
Wrinkle
etails
6,601 3,254 3,079 2,854 2,615
K4 R K10 F K10 R MY17 F MY17 R
0.106 6 0.184 0 0.000 14 0.491 7 0.268
0.364 9 0.277 14 0.455 12 0.420 5 0.191
0.121 3 0.092 0 0.000 20 0.701 31 1.185
0.045 1 0.031 15 0.487 6 0.210 1 0.038
0.000 2 0.061 0 0.000 6 0.210 11 0.421
0.000 0 0.000 0 0.000 4 0.140 1 0.038
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.000 0 0.000 0 0.000 1 0.035 1 0.038
0.000 0 0.000 1 0.032 0 0.000 0 0.000
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.000 0 0.000 0 0.000 0 0.000 0 0.000
0.636 21 0.645 30 0.974 63 2.207 57 2.180

120.00

100.00 100.00 100.00 100.00 100.00 100.00

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

Tearing Loose Skin Deforme

 6,601 3,254 3,079 2,854 2,615
K4 R K10 F K10 R MY17 F MY17 R
3.666 0 0.000 220 7.145 540 18.921 861 32.925
3.060 0 0.000 297 9.646 112 3.924 276 10.554
1.379 0 0.000 20 0.650 167 5.851 22 0.841
0.454 0 0.000 16 0.520 9 0.315 12 0.459
0.606 0 0.000 85 2.761 47 1.647 67 2.562
0.833 0 0.000 6 0.195 29 1.016 16 0.612
0.000 0 0.000 0 0.000 0 0.000 0 0.000
9.998 0 0.000 644 20.916 904 31.675 1254 47.954

120.00

99.93 100.00 100.00

97.18

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

S NO DEFECTS Pulsar KTM-F KTM -R

1 Wrinkle 0 0.000 115 0.154 110 0.146
2 Gapnotok 0 0.000 98 0.131 0 0.000
3 Staple Mis 0 0.000 16 0.021 15 0.020
4 loose staple 0 0.000 24 0.032 32 0.043
5 Pre Assly N.ok 0 0.000 0 0.000 3 0.004
6 Rubber Missing 0 0.000 5 0.007 18 0.024
7 Pu Pad Problem 0 0.000 8 0.011 16 0.021
8 Collar Missing 0 0.000 4 0.005 0 0.000
9 Stitiching not ok 0 0.000 0 0.000 0 0.000
10 Fitment Nok 0 0.000 0 0.000 0 0.000
11 Rexine Over Heat 0 0.000 0 0.000 0 0.000

12 Loose Threds 0 0.000 0 0.000 0 0.000

13 Rexine Cut 0 0.000 0 0.000 0 0.000
14 Parts Missing 0 0.000 0 0.000 0 0.000
15 Rexene Defect 0 0.000 0 0.000 0 0.000
16 Seat Base N. OK 0 0.000 0 0.000 0 0.000

TOTAL 0 0.000 270 0.362 194 0.258

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

DT-F DT -R KHI F KHI R Vespa

113 0.150 201 0.267 0 #DIV/0! 0 #DIV/0! 54 4.704
145 0.193 0 0.000 0 #DIV/0! 0 #DIV/0! 0 0.000
38 0.051 40 0.053 0 #DIV/0! 0 #DIV/0! 6 0.523
36 0.048 19 0.025 0 #DIV/0! 0 #DIV/0! 8 0.697
0 0.000 0 0.000 0 #DIV/0! 0 #DIV/0! 5 0.436
7 0.009 50 0.066 0 #DIV/0! 0 #DIV/0! 11 0.958
16 0.021 18 0.024 0 #DIV/0! 0 #DIV/0! 2 0.174
16 0.021 0 0.000 0 #DIV/0! 0 #DIV/0! 0 0.000
1 0.001 0 0.000 0 #DIV/0! 0 #DIV/0! 2 0.174
9 0.012 0 0.000 0 #DIV/0! 0 #DIV/0! 11 0.958
0 0.000 0 0.000 0 #DIV/0! 0 #DIV/0! 2 0.174

0 0.000 2 0.003 0 #DIV/0! 0 #DIV/0! 2 0.174

0 0.000 0 0.000 0 #DIV/0! 0 #DIV/0! 1 0.087
0 0.000 0 0.000 0 #DIV/0! 0 #DIV/0! 0 0.000
0 0.000 0 0.000 0 #DIV/0! 0 #DIV/0! 0 0.000
0 0.000 0 0.000 0 #DIV/0! 0 #DIV/0! 0 0.000
381 0.507 330 0.439 12 #DIV/0! 0 #DIV/0! 383 33.362

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

3 0.102 0 0.000 1 0.016 0 0.000 2 0.060

0 0.000 0 0.000 7 0.113 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
402 13.706 1169 17.683 818 13.211 625 18.404 395 11.876

98.88 99.28 99.67 99.86 100.00 100.00 100

5 22 22 10 8

g not ok Fitment Nok Rexine Over Heat Loose Threds Rexine Cut 0
Parts Missing Rexene0Def
 Feb/17

3,073 2,887 161,664

% Rej Contribution % Cum %
MY17 F MY17 R Total
181 5.890 230 7.967 2747 1.70 49.66 49.66

13 0.423 4 0.139 741 0.46 13.39 63.05

40 1.302 39 1.351 535 0.33 9.67 72.72

27 0.879 28 0.970 407 0.25 7.36 80.08

16 0.521 1 0.035 326 0.20 5.89 85.97

36 1.171 29 1.005 318 0.20 5.75 91.72

28 0.911 69 2.390 303 0.19 5.48 97.20

1 0.033 1 0.035 58 0.04 1.05 98.25

30 0.976 2 0.069 35 0.02 0.63 98.88

0 0.000 0 0.000 22 0.01 0.40 99.28

0 0.000 4 0.139 22 0.01 0.40 99.67

0 0.000 0 0.000 10 0.01 0.18 99.86

0 0.000 0 0.000 8 0.00 0.14 100.00

0 0.000 0 0.000 0 0.00 0.00 100.00

0 0.000 0 0.000 0 0.00 0.00 100.00

0 0.000 0 0.000 0 0.00 0.00 100.00

372 12.105 407 14.098 5532 3.14

120.00

100.00 100.00 100.00 100.00

80.00

60.00
 60.00

40.00

20.00

0.00
Missing Rexene0Defect 0 N. OK
Seat Base