MGI-SQE-PRR-001

Problem Reporting & Resolution (Notice)

PR&R#： PRR-032-July-2020

Supplier name： Huizong (Supplier Park)

Lower arm of FCM
Part name：
Recipient name： Mr. Arjun

Position： QA /Plant Head

Part No:
Tel/Email： ArjunM@shac.com.cn

PRR requirements :
1. Supplier shall complete containment actions immediately to ensure no outflow to MGI production line
2. Supplier shall submit intermediate corrective actions within 24 hours
3. Supplier shall submit permanent corrective actions within 7 working days
4. Corrective actions effectiveness shall be monitored for a period of one month and PRR shall be closed if found effective
5. Non conforming qty mentioned in this form subject to change based on segregation results
6. Contact respective SQE engineer for addtional information
7. Evidence of intermediate and permanent actions to be attched in evidence sheet1, sheet2 etc.

Noise of heavy metal to metal contact on vehicle due to lower arm joint bolt torque observed 40 against
Problem Description
required 125 Nm

Problem Image :

Noise of heavy metal to metal contact on vehicle due to lower arm joint bolt torque observed 40 against required 125 Nm

Issue Type： Appearanc performa

e dimension material ✘
nce
Concern
Source： GA- SnR Severity : High 7/24/2020
Date:

Model: HECTOR Variant Affected VIN : 28219

Occurrence time:1
NG Material
Batch code : Quantity : 1
Secon Over 2
✘ First
Segregation Transfer d times
Production line SPS Kitting Area MGI Warehouse Supplier warehouse
Status warehouse

Conformity

Non conformity

Issued by

SQE Name : Vivekanand Shinde

 Author: Mr. Vinod Krishna Phone No: Date: 27.06.2109
Problem Solving Report
Problem Found By:
Mr. Vinod Krishna QG EOL Maintenance Production
Safety Quality Delivery Cost Morale Environment
Other:
Shift: Audit PR#
Issue Number: PRR--032-Jul-2020 Product Model: CN202SR
General 2nd Shift
Mark Sections or Questions that do not apply "N/A" Yard Check: # of Vehicles Checked # Items Found
Problem Description: Photo / Sketch
Noise of heavy metal to metal contact on vehicle on 24/07/2020at
rough roadby S&R line inpectorin one vehicle lower arm joint bolt
torque 40 against required 125 Nm

Problem Definition:(Real Problem)

The LCA mounting bolt was found loose during the test track trial in
MGI, the issue was communicated by Mr. Vinod on mobile on 23-07-
2020 at 19:30pm
Point Of Cause: (where problem is first occurring, not where first detected):

The problem occurred at OP-10 station in huizhong at Front frame production line.

Team Member/Responder Input:

Mr. Arjun Modi Mr. Jignesh Patel

Mr. Ravikant Gupta Mr. Balvantsinh Raulji

Quality Breakdown Other Areas Impacted

Standard: Torque 110 - 140 Nm PPH: 1 Start Time:
Deviation: Torque miss End Time:
23648149 (Petrol Variant)
How Often: 1 time Duration:

Containment: Who Date Status Break Point

CUT OFF Details: Start: Final Line
VIN No. 28282 Prakash &
7/24/2020
CSN No.28988 Divyaraj
Checked similar rework parts available parts at Huizhong & MGI Finish: MG Ware house
Huizhong - 00 Nos.
Start: Transit to MGI
MGI - 00 Nos. Dilip &
Stock: 7/24/2020
Mahendra
Huizhong - 68 Nos. Finish: Huizhong weld line
MGI - 22 Nos.
Start:

Finish:
Process/Part Check: (Quality Problems answer Detailed First 4 Diamond Questions.) Previous/Current Quality Diagnostic sheet available: (optional)
Summarize results below Is there a Diagnostic Sheet available to support solving this problem?
Y N Y N
1 Is correct process followed? √ 4 Do The Parts support quality? √ Yes: No:
2 Is correct tool being used? √
3
Is correct part being used? √ If Yes, which one? Used?

If Yes for all 4 Diamonds proceed to Most Probable Cause Analysis: If answer to Diamond 1-4 is No, complete 5 Why Analysis on page 2.
Determine the Root Cause for the specific "No" answer in the Diamonds 1-4 Questions using the 5 Why Analysis:
Most Probable Cause Analysis: llustrate tool used to determine Most Probable Cause(s) (e.g.: Fishbone, Is/Is Not, Histogram, etc.). Circle most likely direct causes.

Most Probable Cause(s): (test each direct cause and decide: not a cause, possible cause, direct cause)

615618202.xlsx
Root Cause Analysis: In the first Why write down the Most Probable Cause from the front.(use additional sheets if more than one probable cause)

Why? Noise of heavy metal to metal contact on vehicle

Why? The LCA mounting bolt was loose in the vehicle.

Why? The bolt was not tightened by the operator due to offline produced.

Why? The part was run in offline condition due to cut mark on LCA boot cap.

Why? The procedure does not state to prepare part after fully dismental and start from initial station.

Root Cause: The procedure does not state to prepare part after fully dismental and start from initial station.

Proposed Solution: Brainstorm possible solutions. Select the most efficient, effective solution.
The conditon where violation of online process required, it has to be done offline, dismental the CKD parts and reproduce the part again in with new
barcode in online condition.

Trial Run: Confirmation trial to test proposed solution:

The similar situation was created and the part was taken offline, appied hold tag and dismental offline condition and reproduce with new barcode.
Date: Sequence #'s
Team Members Supporting Problem Owner
Date: Name:
Name: Area: Signature:
Area:
7/25/2020 Jignesh Patel Maintenance

7/25/2020 Ravikant Gupta Process

Intermediate Action Plans (not containment) Who Due Date Break Point Status
1). The observation was done continuously by the quality operator to look after the
defect and similar abnormalities at productionline.
Quality 7/24/2020 7/27/2020
2). All the torque was checked to support the regular production and online production
control. Quality 7/24/2020 7/27/2020

Long-Term Corrective Actions Who Due Date Break Point Status

1.The rework procedure changed to stop the rework in similar cases where KD parts are
having issues.( Horizontal deployment in case of rework due to child part quality issues) Process 7/27/2020 Continuous
2. The part to be fully dismentalled and produce the part again in Online method with
new bar-code to ensure traceability. ( Rework method changed and instead of repair all
parts to be made only on line) Quality 7/27/2020 Continuous
3. The part to be checked by the quality person and till completion of the product, it
should be under his supervision. The part to be tagged till it reaches to the production
line in online stage and data will be recorded on the register for the same. 7/27/2020 Continuous
Quality
Verification & Resolution Questions: 1 - Identified 2 - Implemented

Has this problem reoccurred ? Y N N 4 - Closed 3 - Feedback

Has the WIN been updated ? Y N N/A Y

Has the Product Quality Standard been updated ? Y N N/A N Countermeasure Tracking (Days with/without repeat)

Has the Job Instruction Training been updated ? Y N N/A Y 1 2 3 4 5 6 7 8 9 10

Have the Preventative Maintenance/Process Control Plans been updated ? Y N N/A Y 11 12 13 14 15 16 17 18 19 20

Have Prints, Check Sheets or other forms been updated ? Y N N/A Y

Issue Resolved satisfactorily? Yes, Issue closed No, assigned to PRTS+ #

Lessons Learned: "Send Copy of Problem Solving Form to" Regional

Could the communication of this problem and its fixes possibly

prevent other departments from incurring the same problem? Press/Stamping Body Paint TCF Powertrain Supplier Other Global
Yes No

Date/ Signature: Author (required for closure) Group Leader/Shift Leader (info only) Area Manager (info only)

Shift:

Shift:

Shift:

Shift:
 Format No.: FMT/PRD/BDS/O3/A
Purging Report Revision No./Date: A / 13.5.2019

Date: 7/23/2020 Problem Reported: Lower Control Arm Bolt Torque Less

Problem Identified & Informed By : Mr. Vinod Krishna

Sr. No. Area VIN Status Remarks Value

OK / NOT OK ( If Applicable )

1 Low Chassis 28283 OK

2 Low Chassis 28242 OK

3 Low Chassis 28242 OK

4 Low Chassis 28256 OK

5 Low Chassis 28315 OK

6 Low Chassis 28220 OK

7 Low Chassis 28303 OK

8 Low Chassis 28182 OK

9 Low Chassis 28318 OK

10 Low Chassis 27812 OK

11 Low Chassis 28306 OK

12 Low Chassis 28265 OK

13 Low Chassis 28330 OK

14 Low Chassis 28329 OK

15 Low Chassis 28327 OK

16 Low Chassis 28207 OK

17 Low Chassis 28269 OK

18 Low Chassis 28271 OK

19 Low Chassis 28281 OK

20 High Chassis 28249 OK

21 High Chassis 28273 OK

22 High Chassis 28294 OK

23 High Chassis 28260 OK

24 High Chassis 28275 OK

25 High Chassis 28259 OK

26 High Chassis 27457 OK

27 High Chassis 28183 OK

28 High Chassis 28253 OK

29 High Chassis 28286 OK

30 High Chassis 28276 OK

31 High Chassis 28262 OK

32 High Chassis 28274 OK

33 High Chassis 28270 OK

34 High Chassis 28295 OK

35 High Chassis 28241 OK

36 High Chassis 28243 OK

37 High Chassis 28299 OK

38 High Chassis 28258 OK

39 High Chassis 28233 OK

40 High Chassis 28248 OK

41 High Chassis 27257 OK

 42 High Chassis 28297 OK

43 High Chassis 28284 OK

44 High Chassis 28291 OK

45 High Chassis 28306 OK

46 High Chassis 28316 OK

47 High Chassis 28312 OK

48 High Chassis 28135 OK

49 High Chassis 28293 OK

50 High Chassis 28203 OK

51 High Chassis 28298 OK

Total Checked
Qty 51 Checked By : Prakash / Divyaraj

Found OK 51 Submited By : Arjun

Found Not OK 00 Date Submited : 7/25/2020

Trial Run taking similar situation
Operator training re
to acknowledge the team.
Operator training record.
 MEP002

Standardized Operating Sheet（SOS）

Install the rear suspension and control arm vertical

Employee ID 9Y-009 Process name Product type SGM126 Part drawing number 23648149/50 File No CN202SR-23648149/50-SOS-51-Rework
bolt and control arm horizontal bolt.

Workshop/team CN202SR Front Frame Assembly team product name SAIC-GM-Wuling CN202SR Part Name Front Frame Assembly version 002 Release date 2019.6.20

Working order Safety Key process Quality inspection Environmental factor

Element time
M s Mark
JES (second)
a t Mark by process E
Sequence Work content/job elements
r e
number
k p
Machine Manual
Walking around Remarks Dynamic walking road map
operation operation

NC part offline and rework procedure

9 JES -01 900 (Offline)
NC પાર્ટ ને ઓફલાઇન કરી ને રિવર્ક ની પદ્ધતિ (Part Rework)

Other applicable parts：N/A

Total 900
5
Total 900
6

Signature
7 7

Prepared by Review Workshop sign Engineering Branch Quality Assurance Section Production Section legend：

Ravikant Gupta Balvant Raulji Arjun Modi Balvant Raulji

Direction of
materials Workbench device Step Walking route
movement
 MEP002

Product name Part Name Workshop/team version Release date

Job Element Sheet（JES） SAIC-GM-

Front Frame CN202SR Front Frame
Wuling 002 2020.7.25
Assembly Assembly team
CN202SR
Work NC part offline and rework procedure
File No CN202SR-23648149/50-JES-51-30-9
content NC પાર્ટ ને ઓફલાઇન કરી ને રિવર્ક ની પદ્ધતિ
Working Quality Key Mark by Environme
Safety E Symbol Sl No The main steps Key elements Reason
order inspection process process ntal factor

图 The parts has to be move out of the station if any
1 problem occurred in the part and it is not able to
1 produce further online.
જો પાર્ટ માં પ્રોબ્લેમ આવે અને તે ઓફલાઇન ના બની
શકે તો તેને લાઇન માઠી બહાર કાઢવો.
Put yellow tag on the part to hold and
handover to the quality person.
પાર્ટ ને બહાર કાઢવો અને તેના ઉપર યેલ્લો Offline
ટે ગ લગાડવો અંદ ક્વાલિટી ડિપાર્ટમેટં ને
હે ન્ડઓવર કરવો.

Dismental the OP-20 parts Stabilizer

Part should be dismental outside the line. Bar first.
2 Offline
પાર્ટને ખોલી નાખવો પ્રોડક્શન લાઇન ની બહાર. પ્રથમ ઓપી -20 ભાગો સ્ટે બિલાઇઝર
બારને ડિસેન્ટલ કરો.

Dismental the Steering Gear Extension

Dismental the Dust Proof boot & OP-40 parts
part sub assembly (if required).
Steering Gear.
3 સ્ટીઅરિંગ ગિયર એક્સ્ટે શ
ં ન ભાગ સબ Offline
图 ડિસ્ટમેટં લ ડસ્ટ પ્રૂફ બૂટ અને ડિસમેન્ટલ ઓપી -40
એસેમ્બલીને ડિસેન્ટલ (જો જરૂરી હોય
2 ભાગો સ્ટીઅરિંગ ગિયર.
તો).

Dismental the OP-30 parts Fuel

Dismental the OP-30 parts like LCA LH & RH.
Variant Mounting.
4 એલસીએ એલએચ અને આરએચ જેવા ઓપી -30 Offline
ઓએસ -30 ભાગોને ડિસોમેન્ટલ ફ્યુઅલ
ભાગોને ડિસેન્ટલ કરો.
વેરિએન્ટ માઉન્ટિં ગ.

Part should be again offer to production

department for production and new barcode label
Reuse fasterners as defined in the
to be applied on part and run production in
drawing
5 online condition. Online
ડ્ રોઇંગમાં નિર્ધારિત મુજબ ફાસ્ટનર્સનો
પાર્ટ ને પરત પ્રોડક્શન ડિપાર્ટમેટં ને આપવો અને નવા
ફરીથી ઉપયોગ કરો
બાર કોડ સાથે પ્રોડક્શન રન કરવું ઓનલાઈન કંડિશન
માં.

Signature Other applicable parts：N/A

Quality
Engineering
Prepared by Review Workshop sign Assurance Production Section
Branch
Section
Ravikant Balvant Raulji Arjun Modi Balvant Raulji