Rejecti Rework Segrega ICA PCA

Sr.No. Shop Date Source Part Name Part No Supplier Code Supplier Model Problem Description
on Qty. tion (Immediate Corrective Action)
Agency Resp. Target Date Status RCA (Root Cause Analysis)
(Permanent Corrective Action)
Agency Resp. Cutoff Status PRR NO.
All load body check at customer end and our
end. Miss because opertor not aware about
1 BIW-1B 5/21/2020 Incoming Assy Load Body 553770000126 A68763 Autoline Ace 7.6P Tail skirt spot miss. 1 0 0 VQA Arun 5/21/2020 G Spot Plan display & training given to operator AQ Kuldeep 5/21/2020 G PQ2077650
defected load body rework by 03 plug spot plan (Spot Plan not Display)
welding done.
All Load body checked at TML as well as our
2 BIW-1B 5/22/2020 Incoming Assy Load Body 553770000119 A68763 Autoline Ace 7.6D Tail gate hinge welding miss. 1 0 0 VQA Arun 5/22/2020 G Process Oversight By the operator. OPL display at this station and 100% inspection at PDI Stage. AQ Kuldeep 5/22/2020 G PQ2077652
end.

Parameter not set as per required, New

3 BIW 1C 06.06.2020 TCF Assy Load Body 553770000119 A68763 Autoline Ace 7.6D Cutout plate nut broken & Hole mismatch 0 42 0 Checking marking done VQA Pankaj 06.06.2020 G Parameter chart display on machine and training provide to concern operator. SQ Jaipant 320007345 G PQ2077732
operator at this station

SPOT MISS IN W-BKT .OPERATOR

LEFT BEFORE COMPLETING THE 1. OPL Displayed on line.
OPERATOR DURING ASSEMBLES 2. 100% marking started for next four days.
4 BIW 1C 08.06.2020 BIW Assy Wheel arch 553761600166 M32363 Musco Ace 7.6 W bkt spot miss 0 3 0 ok marking started on part VQA Pankaj 08.06.2020 G SQ Vinayak 320007212 G PQ2077740
PROCESS.OPERATOR WAS NOT 3. Poison test (Competency test) activities started for the operator & inspector
AWARE OF THE BAD IMPACT OF THIS for the alertness check and recorded
MISTAKE

Electrode use of Big Diameter of Now Electrode used of less Diameter in place of 50mm now we are using of
5 BIW 1C 08.06.2020 TCF Assy Load Body 553770000119 A68763 Autoline Ace 7.6D Engine cover insulation mounting bracket weld nut miss  0 1 0 Tic marking started after checking VQA Pankaj 08.06.2020 G SQ Jaipant 320007354 G PQ2077742
50mm. 25mm Dia Electrode.

1- 100% inspection imparted with new handy gauge to ensue Fuel harness
During drilling process hole position clip mounting hole position.
Fuel harness clip not parked on tubular due hole shift up to
6 BIW 1C 10.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 0 5 0 Tic marking started after checking VQA Pankaj 10.06.2020 G disturbed in drilling jig up to 4mm in y 2- Correction done in drilling jig for harness clip mounting hole position as per SQ Vinayak 320007354 G PQ2077828
4mm
axis. drawing.
.
1.100% inspection started at PDI Stage with marking to ensure bracket
availability.
Fixture has not provision to prevent part 2. OPL displayed at Final PDI.
7 BIW 1C 10.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Battery bracket miss 0 1 0 Tic marking started after checking VQA Pankaj 10.06.2020 G SQ Vinayak 320007210 G PQ2077829
miss during production 3. Provision to be made in welding fixture to prevent part miss during
production.

1-100% inspection started at PDI Conveyor with marking to ensure bracket

Weld Template has not provision to
position in Y axis.
8 BIW 1C 15.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Brake pipe 3 way clamp bracket position shifted 0 1 0 Tic marking started after checking VQA Pankaj 10.06.2020 G prevent bracket position shifting in Y axis SQ Vinayak 320007210 G PQ2077830
2- Provision to be added in weld template for bracket welding to prevent
during production
bracket shifting in Y axis during production.

1-100% inspection started at PDI Stage with 6.5 mm gauging pin to ensure
TML Provided Tool has Not Provision to Nox sensor clip hole diameter. (Gauging Pin Go size-6.5mm & No Go Size-
Nox sensor clip hole coming over size ( found 6.8 against
9 BIW 1C 15.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 0 15 0 One addional hole added on part with 6.5mm VQA Pankaj 10.06.2020 G Prevent Wrong Punch Fitted during 6.9mm). SQ Vinayak 320007210 G PQ2077831
drawing 6.5±2mm) and metal burr
production.(M/S Panse) 2- M/S Panse make provision in new tooling

1-100% inspection started at PDI Conveyor with M6 Bolt to ensure nut

position.
No provision available to ensure Nut
10 BIW 1C 10.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Nut offset inside DPS sensor mtg bkt 0 10 0 Tic marking started after checking VQA Pankaj 10.06.2020 G 2- Nut weld Tack template provision provided to prevent nut offset issue. SQ Vinayak 320007354 G PQ2077832
position
3-OPL displayed at respective stage.

1-100% Co2 tack Welding implemented on LCL UCL (Second Cross Member)
Projection M/C parameter not appropriate mtg. nuts to resolve nut broken issue.
11 BIW 1C 15.06.2020 TCF Assy Frame 553731000114 B62160 Badve Ace 7.6 LCL/.UCL mtg nut miss 3 25 0 Inspection started with ok marking VQA Pankaj 13.06.2020 G 2-Every Two Hours Torque Test to be done on parts at sub assembly stage. SQ Vinayak 3200007415 G PQ2077878
to maintain nugget strength
3-Re-Validation of weld parameter carried out.

1-Manual template to be made for panel assembly.

Front panel locating provision not
12 BIW 1C 17.06.2020 TCF Assy Load Body 553770000119 A68763 Autoline Ace 7.6D Heat shied insulation mtg mismatch 0 5 0 Inspection started with ok marking VQA Pankaj 09.06.2020 G 2-Locating provision to be provided in welding fixture. SQ Jaipant 320007354 G PQ2077879
available in welding fixture.

1. OPL Display at Assy fixture & Training provided to operator. 2. 100%

13 BIW 1A 03.06.2020 TCF Load Body 554670000112 S54570 Supreme INTRA V30.6 LH side Stay road mounting bracket miss 0 3 0 Checking marking done VQA Praguman 06.06.2020 G
LH side Stay road mounting bracket miss from Supplier end. AQ Kuldeep 03.06.2020 G PQ2077903
Inspection done at PDI before dispatch

14 BIW 1A 05.06.2020 BIW Load Body 554670000112 S54570 Supreme INTRA V30.6 Plug welding fail in front LHS corner of V30 Load body 1 0 0 Checking & marking done VQA Praguman 06.06.2020 G Co2 welding on uper one part only 100% Inspection done at PDI before dispatch with marking AQ Kuldeep 08.06.2020 G PQ2077722

Two hole of 6.5 Diameter for Temp. sensor routing clip miss
15 BIW 1A 06.06.2020 TCF Frame Assy 554531000211 A76632 ALF INTRA V10.6 in frame. 0 30 0 Checking & marking done VQA Praguman 08.06.2020 G Wrong part used by supplier BSIV All Obselete part covered and stored in specified location AQ Vaibhav 08.06.2020 G PQ2077868

16 BIW 1A 09.06.2020 TCF Frame Assy 554631000112 A76632 ALF INTRA V30.6 Rear RH Leaf spring Mtg Bush Welding miss 0 1 0 Purging done VQA Praguman 09.06.2020 G Welding miss from Supplier end Specified material BIN arranged for all sub assy stage AQ Vaibhav 30.06.2020 G PQ2077810

100% inspection by four pin gauge for Part clamping not proper(slight loose
17 BIW 1A 09.06.2020 TCF Frame Assy 554531000211 A76632 ALF INTRA V10.6 EPG mtg bkt tilled welded 0 25 0 VQA Praguman 10.06.2020 G Fixture correction made by shimming adjustement. AQ Vaibhav 10.06.2020 G PQ2077904
flatness and CD after clamping)

Adequate training not given to Dispatch

18 BIW 1A 11.06.2020 BIW Roof Header Rear 554565700102 A75291 PANSE INTRA V10.6 Roof header rear LHS Bracket miss 0 1 0 Purging done cut off no 120003157 VQA Praguman 12.06.2020 G person. Bkt. miss point added in PDI check sheet. SQ Aditya 12.06.2020 G PQ2077905

FLOOR DAMAGE REAR SIDE. FLOOR

DAMAGE AT MANUAL STAGE. ASSY
All floor assembly done on Robotic fixture & FLOOR DONE ON MANUAL FIXTURE.
19 BIW 1A 11.06.2020 BIW loadbody 10.6 554570000197 S54570 Supreme INTRA V10.6 Floor Heavy Damage 1 VQA Praguman 11.06.2020 G Floor assembly done on manually fixture thats why floor goes bend. AQ Kuldeep 18.06.2020 G PQ2077805
all old floor assy removed. FLOOR ASSEMBLY DONE ON
MANUALLY FIXTURE THAT#S WHY
FLOOR GOES BEND.

20 BIW 1A 16.06.2020 TCF ASSY REAR STRUCTURE 554661600139 A75291 PANSE INTRA V30.6 Splash guard mounting nut niss 0 2 0 Purging Done. VQA Praguman 17.06.2020 G Splash guard mounting nut niss from Supplier 1.0mm shim add in X + direction in welding fixture SQ Aditya 17.06.2020 G PQ2077895

21 BIW 1B 16.06.2020 BIW Assy Load Body 553770000126 A68763 Autoline Ace 7.6 Side panel spot fail 1 0 0 Purging Done, 100% tic marking VQA Arun 16.06.2020 G Gun shunting with side panel. Insulation mounted on gun and in process inspection started for verification. AQ Kuldeep 20.06.2020 G PQ2077875

Locating pin was not available in fixture

22 BIW 1A 17.06.2020 TCF Load Body 554670000112 S54570 Supreme INTRA V30.6 R Pass sensor mounting hole miss observed in V30 Loa 0 1 0 Purging Done VQA Praguman 17.06.2020 G clamp for sensor hole Locating pin provided in LH & RH side for sensor hole at robotic AQ Kuldeep 18.06.2020 G PQ2077896

1- 100% inspection imparted with M8 bolt to ensure nut position (welding

No masking provision available to prevent spatter).
23 BIW 1C 16.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 FCU mtg. bolt not tightening 0 2 0 ok marking started on part VQA Pankaj 16.06.2020 G spatters inside the nut during tack weld 2- Copper masking provision provided to prevent spatters inside the nut during SQ Vinayak 320007523 G PQ2077880
operation. tack weld operation.

1. Main line welding fixture pin replaced with new pin.

2. PM plan update V. Floor and special point added.
24 BIW 1C 16.06.2020 TCF Vertical Floor 553761600184 A75290 Panse Ace 7.6 Hand braek leaver nut offset 0 5 0 ok marking started on part VQA Pankaj 16.06.2020 G Timely PM not done SQ Sandeep 320007523 G PQ2077881
3. All parts dispatch with J marking.

1-100% inspection started at PDI Conveyor With (14.10MM) Pin

2- Pneumatic Copper Masking Provision to be Make Available to Prevent
inspection started with bolt and pk marking Shocker Bush From Weld Spatter
25 BIW 1C 17.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 welding lumps inside shocker mtg bush 0 2 0 VQA Pankaj 17.06.2020 G SQ Sandeep 320007598 G PQ2077968
done on part,biw availabe part fpound ok
Welder skipped copper masking which
leads spatter inside bush.

Purging done and Tic marking started after

26 BIW-1B 17.06.2020 BIW Load Body 553770000119 A68763 Autoline Ace 7.6 Heat shield reinforcement bracket plug fail/Miss. 2 0 0 VQA Arun 17.06.2020 G Pending 8D NOT ATTACHED Y PQ2077877
checking

100% Inspection Imparted With 16/12 MM Gauging Pin to Avoid 70MM Gap
During Inspection Operation Dimension Issue
27 BIW 1C 20.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Less gap found between Leaf spring bkt 0 3 0 48 parts checked with gauge found ok VQA Pankaj 20.06.2020 G SQ Sandeep 320007610 G PQ2077969
70MM Revising Process Skipped
2-OPL displayed at respective stage to enhance awareness.
1- 100% inspection imparted with handy gauge to ensure C mount hole
position.
Long member hole not align with respect 2- Long member hole position rectified by supplier (Ms. Panse).
nut found shifted andf manual rework done by
28 BIW 1C 20.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 C mount mtg mismatch 0 26 0 VQA Pankaj 20.06.2020 G to reinforcement & spring hanger which [Before:- Vertically long member load in horn piercing die which leads hole SQ Sandeep 320007588 G PQ2077967
supplier ,ok marking started
leads to hole mismatch issue. shifted in X and Z direction.
After:- Horizontally long member load in new cam piercing die to avoid hole
position shifted issue
100% Inspection Imparted With Gauging in X and
Pin to Z direction.]
Avoid Fitment Issue. (pin Go
size-10.6mm and No Go size-11mm)
part checked with bush pin found ok infrom to No Provision Available in Welding Fixture 2-Pneumatic arrangement made Regarding Copper Masking
29 BIW 1C 20.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Welding spatter inside ARB bush 0 2 0 VQA Pankaj 20.06.2020 G SQ Sandeep 320007592 G PQ2077970
supplier for 100% marking to Prevent ARB Bush From Weld Spatter

1-100% inspection started at PDI Conveyor With 16/12 mm

16/12mm pin has not interlocking with 2. 16/12mm pin interlocking with clamping done in welding fixture to prevent
LH Front spring hanger bush reverse welded ( inside part reverse fitment during production.
30 BIW 1C 22.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 0 1 0 ok marking started as ICA VQA Pankaj 22.06.2020 G clamping in welding fixture to prevent part SQ Sandeep 320007510 G PQ2077971
bush welded outside and outer side welded inside)
reverse fitment during production.

1-100% Inspection started with M6 bolt & identification marking implemented

to ensure nut availability.
Fixture has not provision to prevent part 2-OPL displayed at respective stage to increase awareness.
31 BIW 1C 22.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Brake Pipe Mtg Weld nut Miss 0 2 0 ok marking started as ICA VQA Pankaj 22.06.2020 G SQ Sandeep 320007523 G PQ2077974
miss during production

1. Hold Mark must be written on the part which has to be rework.

Marking Wasn’t available On That Part
2. 100% part must be inspected after final process.
32 BIW 1C 22.06.2020 TCF Rear Wall assy 553764000108 A75291 Panse Ace 7.6 Air Deflector mtg bkt miss 0 1 0 ok marking started as ICA VQA Pankaj 22.06.2020 G So Dispatch Person Put That Part In FG SQ Sandeep 320007523 G PQ2077976
3. Training given to operator and shift supervisor.
Trolley
1-Welding length increased

2-100% inspection Started at PDI with marking.

Welding length increase and ok marking During welding operation welder did not
33 BIW 1C 22.06.2020 TCF Assy Frame 553731000117 B62160 Badve Ace 7.6 Brake pipe bkt welding broken 0 1 0 VQA Pankaj 22.06.2020 G 3- OPL displayed at ace sub assy. SQ Sandeep 320007523 G PQ2077977
started on part weld it properly.
4- On job training imparted regarding parking bkt co2 tack broken issue.

All load body checked and verified at TML as

well as AIL end for spot fail issue in front post
34 BIW-1B 22.06.2020 BIW Assy Load Body 553770000119 A68763 Autoline Ace 7.6 Front post reinforcement bracket spot fail 4 0 0 VQA Arun 22.06.2020 G 8D NOT ATTACHED Y PQ2077973
reinforcement.TICK MARK STARTED AFTER
CHISEL TEST.

All Cab closure checked and verified at AIL Air filter bracket shift in z direction.
03 mm Shim added in bkt holding clamp to avoid shifting issue of air filter
35 BIW-1B 22.06.2020 TCF bkt assy cab closure mtg 553761600196 A68763 Autoline Magic 2.6 air filter bracket shift in Z direction up to 3mm. 0 5 0 end for Air filter bkt shift in Z direction./Tic VQA Arun 22.06.2020 G bkt holding clamp loose. G PQ2077975
bracket
marking started

36 BIW 1A 20.06.2020 BIW ASSY REAR STRUCTURE 554661600139 A75291 PANSE INTRA V30.6 Wheel guard bracket Miss 0 3 0 Co2 Started at BIW level Till PCA. VQA Praguman 21.06.2020 G spot done on radius profile of bkt Gun guide to be provide SQ Sandeep 20.06.2020 G PQ2078025

1.On Job training provided to operator for

use ok part.
37 BIW 1A 24.06.2020 BIW Frame Assy 554631000112 A76632 ALF INTRA V30.6 Welding shift on inter cooler pipe mounting bracket. 0 1 0 VQA Praguman 24.06.20 G Part flange damage and weld shift Under analysis AQ Vaibhav 24.6.2020 G PQ2078026
2.100% tick mark imparted for weld brun
availability after inspection at PDI stage.

1-Training to operator
Tic marking started after checking/Purging 1- Training not provided to the 2-100% inspection at this area with marking.
38 BIW 1C 23.06.2020 TCF Load body 553770000119 A68763 Autoline Ace 7.6D Mud Guard mtg. Stud Welded or Wrong Position 0 1 0 VQA Pankaj 23.06.2020 G SQ Sandeep 320007523 G PQ2078088
done operator 3-Training Plan sheet checked by Production in charge monthly

1. Sample displayed at respective areas describing the problem.

New Operator who was not aware 2. Training given to the operator the problem.
39 BIW 1C 23.06.2020 incoming Frount floor 553761600189 D66920 Devchaya Ace 7.6D W bracket miss 0 1 0 All parts cheacked found ok VQA Pankaj 23.06.2021 G SQ Sandeep 320007523 G PQ2078101
about process & defects.

At the time of sub-assembly of seat belt &

Magnetic Gauge with step guided pin made to locate seat belt with B-Pillar
During purging 2 parts found at incoming, B pillar , the nut offset occurred due to
40 BIW-1B 6/25/2020 TCF Assy body side inner LH 282963600101 N61722 NEEL METAL Ace 7.6D Seat belt mounting nut offset 0 3 0 VQA Arun 6/25/2020 G panel for spotting to avoid shifting of seat belt. SQ Vinayak 220013549 G PQ2078130
Tick marking started from supplier end improper tightening of nut and bolt

One load body found at incoming, Tick

41 BIW-1B 6/25/2020 Incoming Assy Load Body 553770000126 A68763 Autoline Ace 7.6P Under floor heat shield mounting W bracket nut miss 1 0 0 VQA Arun 6/25/2020 G 8D NOT ATTACHED 6/25/2020 R PQ2078131
marking started from supplier end.

1. After communication of quality issue we 1- Forming tool rectified with hardening and sharpening by supplier.
42 BIW-1B 6/25/2020 BIW Assy CCB 554560600137 M32363 Musco Magic 2.6 Crack at FCM mounting bracket 1 0 0 have checked all parts at TML & MCIE end VQA Arun 6/25/2020 G Punch chip-off in forming die 2- 100% inspection imparted with dot mark at PDI to ensure crack issue. 8D NOT ATTACHED 6/25/2020 G PQ2078132 
both, cracked part reworked.

1.100 % INSPECTION WITH TICK MARKING panel checker report attached, accuracy 86.5%. part is ok as earlier accepted.
FOR CONTAINMENT PURPOSE
43 BIW-1B 6/25/2020 BIW Assy door inner 282972200105 A71724 ASAL Ace/Magic Door beading area bend up to 5mm. 0 10 0 VQA Arun 6/25/2020 G die limitation as per design, 6/25/2020 G PQ2078185
2. All available parts Re- Inspection at TML& Again blue matching to be done and trail taken
ASAL.

44 BIW 1C 6/25/2020 TCF Assy Load Body 553770000126 A68763 Autoline Ace 7.6 P Fuel neck cap welding tack broken 0 1 0 2. Quality Alert display on line VQA Pankaj 6/25/2020 G Only single welding tack at fuel lid cover. Two no’s co2 tack implemented for strength. SQ Jaipant 320008157 G PQ2078221

Poka yoke was not availabe in Templete

Engine insulation cover ( Cutout plate) t clip position
45 BIW 1C 6/26/2020 TCF Assy Load Body 553770000126 A68763 Autoline Ace 7.6 P 1 5 0 Inspection started with TCF Matching part. VQA Pankaj 6/26/2020 G causing reverse using during T clip Poka yoke provide in Templete to avoid bkt orientation wrong SQ Jaipant 320008196 G PQ2078216
mismatch
fitment

1. Load body replaced.

1. Due to fourth load body used instead
46 BIW 1C 25.06.2020 Incoming Frame Assy 553731000117 K65332 KLT Ace 7.6 D NOx sensor clip hole mismatch 2 0 0 ok marking started as ICA from supplier VQA Pankaj 25.06.2020 G 2. Check point added in Quality Gate check sheet. AQ Kuldeep 320007523 G PQ2078217
of tubular load body.

1. New post added for Urea tank reinf. Bkt.

47 BIW 1C 25.06.2020 Incoming Frame Assy 553731000117 K65332 KLT Ace 7.6 D Urea tank hole mismatch 1 0 0 ok marking started as ICA from supplier VQA Pankaj 25.06.2020 G Urea tank bkt welded manually. 2. Check point added in Quality gate check sheet. AQ Kuldeep 320007523 G PQ2078218

Cab support RH & LH plate flange not as

48 BIW 1C 25.06.2020 Incoming Frame Assy 553731000117 K65332 KLT Ace 7.6 D Cab support cut by welding 2 0 0 ok marking started as ICA from supplier VQA Pankaj 25.06.2020 G 1. Correction to be done on die on or before 10.07.2020 AQ Kuldeep 320007523 G PQ2078219
per drawing.

1. Co2 welding nozzle changed.

Poor welding due to CO2 gas trapped in
49 BIW 1C 25.06.2020 Incoming Frame Assy 553731000117 K65332 KLT Ace 7.6 D Poor welding on Front spring hanger 1 0 0 ok marking started as ICA from supplier VQA Pankaj 25.06.2020 G Check point added in Quality Gate Check Sheet. AQ Kuldeep 320007523 G PQ2078220
nozzle.

1. All assembly frames checked at TML end

and rework done.
Forming tool rectified with hardening and sharpening by supplier.
2. 100 % segregation done for all available
50 BIW-1B 6/29/2020 Incoming Frame Assy 553731000117 B62160 Badve Ace 7.6 D Cab support bracket crack 6 0 0 VQA Arun 29.06.2020 G Forming tool damaged 2- 100% inspection imparted with dot mark at PDI to ensure crack issue AQ Kuldeep G PQ2078327
inventory at BEL end and defected part
rework done.
 Date Part Name Part No Supplier Code Supplier

04.07.2020 Assy frame 553731000117 K65332 KLT

7/14/2020 Assy Frame 553731000117 K65332 KLT

7/16/2020 Assy Frame 553731000117 K65332

KLT
7/16/2020 Assy Frame 553731000117 K65332 KLT
 Model Problem Description

Ace 7.6 D ARB bush miss

Ace 7.6D Rear shocker bush taper

Ace 7.6D Front spring hanger alingment not ok

Ace 7.6D Steering gear box mounting mismatch

 ICA
(Immediate Corrective Action) RCA (Root Cause Analysis)

1. All 12 nos frame segregated at TML end &

no frame found defective.
1. ARB bush miss due to WIS not
2. 100% checking & marking started at PDI
displayed at concern stage.
stage.

1. 36 nos frame checked at KLT end & no frame

found defective.
2. 100% checking by gauge & marking on concern 1. Long member hole is over respect
area to ensure it to Shocker bush plate

1. 100% Gauging before Dispatch. 1. Due to Dowel pin not available for post
tightening only tightened by bolt.
100% qualifying gauge before Dispatch. 1. Pin worn out due to pin was without
hardened material.
 PCA
(Permanent Corrective Action) PRR NO.

1. WIS & OPL displayed

2. Training provided to the operator about it.
PQ2078488
3. Check Point added in PDI check sheet.

New Fixture post provided at 30 stage to control

PQ2078860
shocker plate position.

1. Post Tightened & Dowel pin added in fixture. PQ2078888

1. Locating pin replaced with Hardened material. PQ2078890

Sl.No Shop Date Source Part Name Part No
1 BIW-1B 17.06.2020 BIW Load Body 553770000119
2 BIW-1B 22.06.2020 BIW Assy Load Body 553770000119
3 BIW-1B 6/25/2020 Incoming Assy Load Body 553770000126
4 BIW-1B 6/25/2020 BIW Assy CCB 554560600137
Supplier Code Supplier SQ Person Model
A68763 Autoline Kuldeep Sharma Ace 7.6D
A68763 Autoline Kuldeep Sharma Ace 7.6D
A68763 Autoline Kuldeep Sharma Ace 7.6P
M32363 Musco Kuldeep Sharma Magic 2.6
 Problem Description PRR NO. Jun'20 1-Jul
Heat shield reinforcement bracket plug fail/Miss. PQ2077877 #REF!
Front post reinforcement bracket spot fail PQ2077973 #REF!
Under floor heat shield mounting W bracket nut miss PQ2078131 #REF!
Crack at FCM mounting bracket PQ2078132  #REF!
2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 8-Jul 9-Jul 10-Jul 11-Jul
12-Jul 13-Jul 14-Jul 15-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul
22-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 29-Jul 30-Jul 31-Jul