S.

No 1 2 3

DEFECTS

Critical & Major PQR Defects & Corrective Action April Responsi NATURE Date Of Defect bility CR CR CR TCF Line 8-Apr-11 3/VQA TCF LINE18-Apr-11 3 VQA 21-Apr-11

R/H/S rear axle hub cover mtg. one bolt missing & oil leakage. Air leakage from LHS front Brake hose pipe socket joint at LM end. Air leakage from rear RHS brake hose pipe crimping joint.

4

Turbo charger inlet hose & Air filter outlet hose pipe clip loose .

MA

TCF LINE9,12, 25 Apr 11 3

5

Exhaust brake pull rod ball joint fouling with long member.

MA

TCF LINE9 & 12 Apr 11 3

6 7

Exhaust brake pull rod ball joint fouling with long member. L/H/S P/Stg. Pipe fouling with engine cross member & clamp orientation wrong (Inter change).

MA MA

R2 Line 3 13 & 14 Apr11 TCF LINE16-Apr-11 3

8

Silencer muffler welding joint blow hole & exhaust gas leakage (Muffler to be changed) Water ingress from driver door top beading side & left window. Cab inside welding joint poor & blow hole Cab inside sheet joint one screw broken,two screw loose & sheet not seated proper & gap. Rear both side tyre inflator fouling with rim & compress. Rear axle propeller shaft dent.

MA

VQA

22 & 30 Apr 11

9 10 11 12 13

MA MA MA MA MA

Trim CAB 11 &22 Apr 11 BIW BIW 26-Apr-11 26-Apr-11

TCF Line 8-Apr-11 3 VQA 9-Apr-11

Cab inside all hole black sticker missing. Clutch paddle rod fouling with CAB. Speedo meter sensor hand loose.D. Engine to inter cooler hose pipe clip shifted at engine side.U. MA Line-3 11-Apr-11 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Brake nylon pipe came out from sleeve & fouling with Fuel line clamp bkt mtg. Front R/H/S brake hose pipe socket check nut loose. R2 VQA TCF LINE-3 Trim Line-2 TCF LINE-3 R2 TCF LINE-3 VQA TCF LINE-3 16-Apr-11 16-Apr-11 18-Apr-11 18-Apr-11 18-Apr-11 19-Apr-11 19-Apr-11 19-Apr-11 19-Apr-11 Assy Line 23-Apr-11 Line 28-Apr-11 Assy Line 22-Apr-11 R2 VQA PAINT SHOP 23-Apr-11 20-Apr-11 28-Apr-11 . all bolt hand loose. RHS door hinge lock pin came out. Fuel tank neck rusty. Front R/S centre panel stopper rubber crack. one bolt hand loose. Front RHS Inter cooler fouling with long member. Inside cab both side silent proper not pest & hole. R/H/S rear axle "S" cam shaft grease nipple loose. bolt at 4th cross member. shroud damage. A/C outlet pipe socket joint loose near upon muffler. Front LHS engine arm mtg. Front RHS noise shield mtg. D. Drag link rod fouling with slack adjuster during turning posing. Wiper motor link rod fouling with clutch fluid oil container. nylon pipe fouling with A/C outlet pipe. 1st air tank Voss connecter fouling with 2nd air tank SPV Voss connecter. Drag link rod clamp bolt fouling with slack adjuster during turning. Fuel tank neck rusty. MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA Line 21-Apr-11 Trim line 20-Apr-11 VQA 13-Apr-11 TCF Line13-Apr-11 3 & R2 R2 VQA Trim Line 14-Apr-11 14-Apr-11 14-Apr-11 14-Apr-11 TCF LINE-3 & 15-Apr-11 R2.14 L/S door air wind glass lock lever rusty. Front RHS kin pin grease nipple hand loose. one bolt not seated proper with Engine. L/S rear leaf spring both "U" clamp loose. MA VQA 9-Apr-11 15 ABC bkt mtg. Fan shroud fouling with fan.

Front RHS cab badly bend near stay rod R/H/S brake hose pipe fouling with noise shield. Rear side brake hose pipe "T" socket mtg. hand loose. bkt loose fitment. Wiper motor mtg. Air filter outlet hose pipe clip shifted.40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 L/H/S P/Stg. Rear side brake hose pipe "T" socket check nut loose at axle. Reveres horn badly paint over spray . Oil leakage from inter axle deferential. Front RHS wheel arch mud guard supporter rod mtg. RHS fuel line fouling with AC out let pipe near fuel tank (Fuel line loose due to clamp over size) MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA VQA Line R2 VQA R2 Line Line VQA BIW R2 R2 Assy Line Line Line R2 Assy Line/ VQA 20-Apr-11 25-Apr-11 25-Apr-11 26-Apr-11 26-Apr-11 26-Apr-11 27-Apr-11 27-Apr-11 27-Apr-11 11-Apr-11 23-Apr-11 30-Apr-11 29-Apr-11 29-Apr-11 29-Apr-11 30-Apr-11 . bkt loose at rear axle. Hose pipe fouling with noise shield. Rear LHS leaf spring U" clamp bolt hand loose. Ac head inlet pipe elbow loose. Front side cover bolt. Rear LHS cab dent Rear LHS tyre inflator fouling with rim. 6 dia clutch pipe fouling with long member.

LPK 2518 3 2. first operator fit the Air intake hose onto the air filter hole and then fit the another end onto the aluminium pipe. Feedback given to the Trim line to shift the air filter towards right hand side so that the shorten length of the hose can be compainsated. Request to ERC and TS to increase the length of the Air intake hose by 20 mm. 3. LPK 2518 2 Under analysis till feedback given to the inspection area to check the Exhaust brake pull rod and 100% rework done in R2 area LPK 1618 LPT 2518 2 2 100% inspectino leakage test to be performed. improvement at No PDC supplier end is under process Given 2 LPS 3518 LPS 3518 LPK 2518 LPK 2518 LPS 4018 LPK 2518 2 2 2 1 1 .& Corrective Action April 11 Model LPS 4018 LPT 2518 LPS 3518 Occurren ce 1 1 1 Action Taken Id mark for fitment of all the bolts and leakage PDC Status 1.e. Process sequence is modified i.

LPK 2518 1 LPS 3518 1 Feedback and training given to the operator & Yellow marking is introduced on regular basis LPS 3518 LPS 3518 LPK 1618 LPK 1618 LPK 1618 LPK 1618 LPK 1618 LPK 1618 LPT 2518 LPT 2518 LPT 2518 LPT 2518 LPT 2518 LPT 2518 LPK 2518 LPK 2518 LPK 2518 LPK 2518 LPS 3518 LPS 3518 LPS 3518 LPS 3518 LPS 3518 LPS 3518 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Feedback and training given to the operator Feedback and training given to the operator Feedback and training given to the operator .

LPS 3518 LPK 2518 LPK 2518 LPK 2518 LPK 2518 LPK 2518 LPK 2518 LPK 2518 LPK 2518 LPS 3518 LPS 3518 LPS 3518 LPK 1618 LPK 1618 LPK 1618 LPS 3518 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Feedback and training given to the operator 1 .

one bolt hand loose. L/S rear cab inside rear wall sheet dent & gap between sheet joint. oil leakage from stg.Critical & Major PQR Defects & Corrective Action May . Both side cab shocker mtg. Drag link rod fouling with slack adjuster. Stg. Air leakage from clutch booster body joint. 6 dia nylon pipe sleeve missing near 3rd cross member. 30 May 12.No 1 2 3 4 5 6 7 DEFECTS Air leakage from rear modulator valve socket joint & exhaust post. 25 May Line Line 3 R2 Line 3 / VQA Assy Line VQA Omax Trim CAB Line 3 R2 Assy Line BIW Line 3 R2 BIW BIW Assy Line Trim CAB Trim CAB VQA VQA Line 3 / VQA Line 3 R2 Paint shop VQA BIW Line 3 R2 13-May-11 17-May-11 23-May-11 30-May-11 26. Cab inside roof lining cover stitching cut. R/S welding blow hole inside cab near wind shield top corner & near inside sliding window.. pump socket joint ( O ring damage ). Water leakage from driver door top side. bkt paint scratch & rusty. Wiper motor noisy. Both side sealant missing near top side sliding window. Coolant leakage from thermostat top side gasket joint. Clutch paddle free play more 25 mm. 20 May 18.11 S. 27 . Rear RHS long member reinforcement mtg.25 May 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA 13 & 21 May 14. 26 May 23. Wiper motor link rod fouling with harness cluster pipe. NATURE CR CR CR CR CR MA MA Responsi Date Of Defect bility Assy 12. two screw hand loose. Return fuel line bend & fouling with main fuel line near silencer muffler. Cab inside sheet mtg. 31 May 8 MA 5. Air filter dust collector rubber boot clip hand loose. 28 may 13-May-11 11-May-11 29-May-11 16-May-11 4-May-11 11-May-11 24-May-11 27-May-11 . 25 May 21. 5th Coupling (Trailer couping) reinforcement mtg four hex screw projection nil Air intake hose pipe clip loose & shifted Cab inside welding missing near instrument panel / co-driver door. Air filter to turbo charger intake hose pipe cut mark. 23 May 4-May-11 5-May-11 6. Engine hood one lock not working.

R/S front wheel inflator compress between rim & drum. & inter axle rusty. R/S wiper motor blade mtg box welding crack.14 May 20-May-11 9-May-11 20-May-11 6-May-11 26-May-11 30-May-11 29-May-11 24-May-11 29-May-11 . bkt. Engine sump dent & paint scratch. Rear LHS fender mtg. Front RHS radiator to inter cooler mtg. Front RHS wheel arch supporting rod mtg. Harness hanging near silencer muffler. Rear RHS 5th cross member mtg. bkt bend. Main fuel line hose compress. Gear lever knob threaded bush crack . Plane washer & split pin not fitted in Spare wheel carrier lock. P/stg hose fouling with engine noise shield sharp edge & long member sharp edge near oil filter. MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MI MA MA MA MA MA MA MA MA MA MA Line 3 R2 VQA Assy Line Line 3 R2 SQIG/ Line 3 R2 VQA VQA Line 3 R2 Assy Line VQA Line 3 R2 VQA Line 3 / VQA VQA BIW Assy Line Line 3 R2 VQA Assy Line Omax Trim CAB Line 3 / VQA Line 3 R2 VQA Assy Line Omax 18-May-11 4-May-11 30-May-11 17-May-11 18-May-11 19-May-11 29-May-11 28-May-11 28-May-11 28-May-11 19-May-11 20-May-11 11-May-11 16-May-11 10-May-11 4-May-11 11. Exhaust 1st pipe dent.25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Engine oil indicter continuous working. bolt hand loose. R/S rear end cross member mtg one bolt hand loose. Exhaust brake pull rod ball joint fouling with long member. Rear RHS leaf spring shackle pine grease nipple hand loose. Fuel tank neck inside heavy rusty . bkt & air filter strap mtg. Front brake hose fouling with engine noise shield. Front LHS leaf spring supporting bkt not seated proper & bend. bkt & mud flap mtg. Rear LHS "S" came shaft circlip not seated proper. Front RHS bumper reflector crack. Front LHS noise shield mtg. two bolt hand loose. L/S inside welding material more & not clean near wind shield top corner. Rear LHS inter axle brake shoe inspection cover missing. one bolt hand loose. Front LHS cab mtg. bolt hand loose.

51 52 53 54 55 56 57 58 Rear RHS ramp bkt. RHS tie rod ball joint grease nipple hand loose. Wiper motor link rod fouling with ABS harness . MA MA MA MA MA MA MA MA Assy Line Assy Line Line 3 R2 VQA Assy Line Line 3 R2 Trim CAB Assy Line 16-May-11 31-May-11 16-May-11 17-May-11 21-May-11 23-May-11 14-May-11 27-May-11 . one bolt loose. Water in fuel indicator continue glowing. RHS return fuel pipe fouling with AC outlet pipe clamp mtg. Water ingrease in both side indicator lamp. mtg. bkt. RHS pneumatic cluster sleeve missing near ABC bracket. Silencer muffler hanger bkt rubber buffer spacer not fitted & rubber compress.

LPS3518 LPK 2518 LPS 4018 LPK 2518 LPS 3518 LPS 4018 LPS 4018 LPK 2518 LPS 3518 Occurren Action Taken PDC Status ce 2 1 1 1 1 3 3 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 . LPK 2518 LPS 3518 LPK 2518. 3518 LPK 2518.ve Action May . LPS 3518 LPK 2518 LPS 4018 LPS 4018 LPS 4018. 3518 LPS 3518. LPk 2518 LPS 4018. 4018 LPS 3518.11 Model LPS 3518 LPK 2518 LPK 2518 LPK 2518 LPS 4018 LPS 3518.

LPK 2518 LPS 4018 LPS 4018 LPK 2518 LPK 2518 LPS 4018 LPK 2518 LPS 3518 LPS 3518 LPS 3518 LPS 4018 LPS 4018 LPS 4018 LPS 3518 LPS 4018 LPS 4018 LPS 3518. 4018 LPS 4018 LPS 4018 LPS 4018 LPS 3518 LPS 3518 LPS 4018 LPK 2518 LPK 2518 LPK 2518 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 .

LPS 3518 LPK 2518 LPS 3518 LPK 2518 LPS 3518 LPK 2518 LPS 3518 LPS 3518 1 1 1 1 1 1 1 1 .

Coolant leakage from thermostat top side gasket joint. Return fuel line bend & fouling with main fuel line near silencer muffler. Stg. Water leakage from driver door top side. Drag link rod fouling with slack adjuster.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DEFECTS Air leakage from rear modulator valve socket joint & exhaust post. oil leakage from stg. R/S welding blow hole inside cab near wind shield top corner & near inside sliding window. Wiper motor link rod fouling with harness cluster pipe. L/S rear cab inside rear wall sheet dent & gap between sheet joint. NATURE CR CR CR CR CR MA MA MA MA MA MA MA MA MA Responsi bility TCF Line 3 TCF Line 3 TCF Line 3 TCF Line 3 VQA Omax Trim CAB TCF Line 3 BIW TCF Line 3 BIW BIW TCF Line 3 Trim CAB . Rear RHS long member reinforcement mtg. Air intake hose pipe clip loose & shifted Cab inside welding missing near instrument panel / co-driver door. Air leakage from clutch booster body joint. Engine hood one lock not working.11 S.Critical & Major PQR Defects & Corrective Action May . bolt hand loose. pump socket joint ( 'O' ring damage ).

25 May 13-May-11 17-May-11 Model LPS 3518 LPK 2518 LPK 2518 Occurren ce 2 1 1 1 1 3 3 2 2 2 2 2 2 2 Action Taken PDC Status 23-MayLPK 2518 11 30-MayLPS 4018 11 26. 25 May 21. LPS May 3518 14.Corrective Action May . LPS 3518. 30 May 4018 12. 23 LPK 2518 May 4-May-11 5-May-11 6. 3518 LPS 3518.11 Date Of Defect 12. 20 May 18. LPk May 2518 13 & 21 LPK 2518. 27 . LPK 2518 LPS 3518 . 26 May LPS 4018 LPS 4018 LPS 4018. 31 LPS 3518.

73 ABC bkt mtg. 68 Cab inside welding joint poor & blow hole Cab inside sheet joint one screw broken. Rear both side tyre inflator fouling with rim & compress. bkt & air filter strap mtg. Engine oil indicter continuous working. 60 Air leakage from LHS front Brake hose pipe socket joint at LM end. Return fuel line bend & fouling with main fuel line near silencer muffler. 67 11 Engine hood one lock not working. bkt & mud flap mtg. Wiper motor link rod fouling with clutch fluid oil container. Exhaust 1st pipe dent. Cab inside roof lining cover stitching cut. Exhaust brake pull rod ball joint fouling with long member. Front RHS kin pin grease nipple hand loose. Engine sump dent & paint scratch. shroud damage. R/H/S rear axle "S" cam shaft grease nipple loose.1 Air leakage from rear modulator valve socket joint & exhaust post. . Front LHS cab mtg. Front RHS bumper reflector crack. 62 Turbo charger inlet hose & Air filter outlet hose pipe clip loose . Clutch paddle free play more 25 mm. Cab inside sheet mtg. 15 Wiper motor link rod fouling with harness cluster pipe. 2 Coolant leakage from thermostat top side gasket joint. L/H/S P/Stg.two screw loose & sheet not seated proper & gap. one bolt hand loose. 58 Wiper motor link rod fouling with ABS harness . nylon pipe fouling with A/C outlet pipe. Front R/S centre panel stopper rubber crack. bkt. 3 Stg. 75 19 Air filter to turbo charger intake hose pipe cut mark. 64 Exhaust brake pull rod ball joint fouling with long member. 16 Wiper motor noisy. 74 18 Air filter dust collector rubber boot clip hand loose. Fan shroud fouling with fan. oil leakage from stg. 7 Water leakage from driver door top side. RHS door hinge lock pin came out. Front brake hose fouling with engine noise shield. Brake nylon pipe came out from sleeve & fouling with Fuel line clamp bkt mtg. Drag link rod clamp bolt fouling with slack adjuster during turning.U. 77 78 79 80 81 82 83 84 85 86 87 88 89 90 A/C outlet pipe socket joint loose near upon muffler. & inter axle rusty. Speedo meter sensor hand loose. Cab inside all hole black sticker missing. Drag link rod fouling with slack adjuster during turning posing.D.. 61 Air leakage from rear RHS brake hose pipe crimping joint. Front LHS leaf spring supporting bkt not seated proper & bend. Fuel tank neck rusty. 5 Air leakage from clutch booster body joint. Pipe fouling with engine cross member & clamp orientation wrong (Inter change). 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Both side cab shocker mtg. one bolt hand loose. 6 Rear RHS long member reinforcement mtg. one bolt hand loose. 69 13 70 14 71 Rear axle propeller shaft dent. bolt at 4th cross member. R/S welding blow hole inside cab near wind shield top corner & near inside sliding window. 76 L/S rear leaf spring both "U" clamp loose. two screw hand loose. 8 5th Coupling (Trailer couping) reinforcement mtg four hex screw projection nil 65 9 Air intake hose pipe clip loose & shifted 66 10 Cab inside welding missing near instrument panel / co-driver door. Silencer muffler welding joint blow hole & exhaust gas leakage (Muffler to be changed) Water ingress from driver door top beading side & left window. 72 L/S door air wind glass lock lever rusty. Both side sealant missing near top side sliding window. 4 Drag link rod fouling with slack adjuster. 63 Exhaust brake pull rod ball joint fouling with long member. pump socket joint ( O ring damage ). bkt paint scratch & rusty. Front RHS Inter cooler fouling with long member. Front R/H/S brake hose pipe socket check nut loose. one bolt missing & oil leakage. 59 R/H/S rear axle hub cover mtg. 17 6 dia nylon pipe sleeve missing near 3rd cross member. D. Front LHS noise shield mtg. 12 L/S rear cab inside rear wall sheet dent & gap between sheet joint.

45 R/S wiper motor blade mtg box welding crack. 102 Front RHS wheel arch mud guard supporter rod mtg. Engine to inter cooler hose pipe clip shifted at engine side. bkt bend. Plane washer & split pin not fitted in Spare wheel carrier lock. 46 Rear LHS "S" came shaft circlip not seated proper. 55 Silencer muffler hanger bkt rubber buffer spacer not fitted & rubber compress. 101 Oil leakage from inter axle deferential. 109 Rear LHS tyre inflator fouling with rim. bkt loose at rear axle. 43 R/S front wheel inflator compress between rim & drum. Fuel tank neck rusty. 48 Rear LHS inter axle brake shoe inspection cover missing. 110 Air filter outlet hose pipe clip shifted. 91 92 93 94 95 96 1st air tank Voss connecter fouling with 2nd air tank SPV Voss connecter. Front RHS wheel arch supporting rod mtg. 112 Reveres horn badly paint over spray . Gear lever knob threaded bush crack . 106 Front RHS cab badly bend near stay rod 50 Rear RHS 5th cross member mtg. 105 Rear LHS leaf spring U" clamp bolt hand loose. bkt loose fitment. P/stg hose fouling with engine noise shield sharp edge & long member sharp edge near oil filter. 111 6 dia clutch pipe fouling with long member. Front side cover bolt. 53 RHS return fuel pipe fouling with AC outlet pipe clamp mtg. bolt hand loose. L/S inside welding material more & not clean near wind shield top corner. two bolt hand loose. 49 Rear RHS leaf spring shackle pine grease nipple hand loose. . 42 99 Rear side brake hose pipe "T" socket mtg. Hose pipe fouling with noise shield. 47 Rear LHS fender mtg. 51 Rear RHS ramp bkt. RHS fuel line fouling with AC out let pipe near fuel tank (Fuel line loose due to clamp over size) 56 Water in fuel indicator continue glowing. 97 Inside cab both side silent proper not pest & hole. one bolt not seated proper with Engine. 54 RHS tie rod ball joint grease nipple hand loose. Front RHS noise shield mtg. Clutch paddle rod fouling with CAB. one bolt loose. 108 Rear LHS cab dent 52 RHS pneumatic cluster sleeve missing near ABC bracket. Harness hanging near silencer muffler. 113 57 Water ingrease in both side indicator lamp. Fuel tank neck inside heavy rusty . mtg. 40 Main fuel line hose compress.34 35 36 37 38 39 Front RHS radiator to inter cooler mtg. 104 Rear side brake hose pipe "T" socket check nut loose at axle. hand loose. 41 98 L/H/S P/Stg. all bolt hand loose. bkt. 107 R/H/S brake hose pipe fouling with noise shield. 44 R/S rear end cross member mtg one bolt hand loose. 100 Wiper motor mtg. 103 Ac head inlet pipe elbow loose. Front LHS engine arm mtg. bolt hand loose.

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