Quality Report - Week # 35 ( 29.08.2022-04.09.

2022)

1.Field failure

Attribute to AIL /
Customer Model Failure Details QTY Corrective Action Customer/Unknown

NIL _ _ _ _ _ _

2.Customer returned Housings to AIL

Reason for return Attribute to AIL /
Customer Model (To be filled by concern Dept head)
QTY Corrective Action Customer/Unknown

Part number: 10164535

Nylon boss M10X1.5 thread NO GO answering 4
Housing No: H31550G22,H37299H22,H7316H22,H37296H22,
1. 1.6mm weld wire replaced by 1.2mm weld wire for the nylon boss welding to reduce the heat
input to boss
2.During welding tapper pin provided in the thread hole to avoid thread shrinkage
3.During trolley inspection M10X1.5 thread plug gauge 100% inspection implemented ans added AIL
in trolley check sheet.
(Deatiled 8D report submitted to customer)
Part no: 992954
Housing No: H26712G22 Nylon boss M10X1.5 thread NO GO answering 1

Part No: 10051164 Breather hole thread NO GO answering 2 1.During final inspection 100 % thread plug gauge inspection ensured to avoid customer complaint AIL

DIPL(Oragadam)

1.After welding identification mark will be done by welding operator at process and instruction
Part no: 10353191 given to operator thru OPL.
Housing No: E20722H22
Inner plate missing 1
2.Final inspector will be check and ensure the inner plate available and make line mark over the AIL
inner plate and added in control plan

1.Drill bit size changed from 19.10mm to 19.00mm to avoid over size during drilling (Spec:
18.92/19.20)
Part no: 990963
Housing No:E20050H22 ABS Hole NO-GO Answering 1 2.Operator instructed to check 100% gauge inspection at brake flange drilling operation thru OPL AIL
and included in the control plan
3.ABS hole 100% inspection included in final inspection & PDI report .

Part no: 990963 1.Centralizing of the housing to be done instead of bore budding.(Centralizer to be provided.
Housing No: H30575G22
B/F to SS Over size 1
Feasibility under study. AIL

3.Customer End Rejection/Rework

 Rejection Details Disciplinary
Customer (Reported in Portal and considered in PPM)
Corrective Action taken Customer Concerns(Not considered in PPM) Corrective Action  Action

Problem: Shock Absorber bracket Inner width undersize. 1. Weld sequence changed.( i)Welding done on outside of the bracket ii) Welding done on inside
DANA,USA NIL Part no: 10166412; Model: S110 of the bracket. _
Reported Qty: 15No's 2.Bracket width to be maintained in max spec. before welding.(i.e. 46.2mm instead of 45.5mm)

1.Robo oil application machine will be used for Japan Tag to ensure Anti –rust oil applications in
Problem: Rust in V stay bracket all machined surfaces at uniform level
Volvo truck-Thailand/ Part no:23168116 ; Model: Japan Tag 2.Between centers need to be modified in Robo rust preventive oil application machine to load
Japan NIL Reported Qty: 3no's housings with end cups - Pending _
Reported Date: 31.08.2022
Thus we get rid of the situation of depending on man in this process

DICV/AAM NIL NIL

TML DL,
Jamshedpur NIL NIL

TML DL Pune NIL NIL

Problem: TOE ISSUE.

Part no: ISK7361 ; Model: VE3500 1) Initial Containment action taken by providing 100% gauge inspection for checking the SS hole
VECV NIL symmetricity. _
Reported Qty: 6No's
Reported date: 03.09.2022 Root cause analysis under process; Corrective action to be provided.

SML NIL NIL

Mahindra NIL NIL

Problem: ABS hole oversize plug Gauge NOGO Gauge answering (ABS Hole 1.Drill bit size changed from 19.10mm to 19.00mm to avoid over size during drilling (Spec:
oversize by 0.1mm)
Part No: 992954 18.92/19.20).
2.Operator instructed to check 100% gauge inspection at brake flange drilling operation _
Rejected Qty: 1No's thru OPL and included in the control plan.
Reported date: 03.09.2022
3.ABS hole 100% inspection included in final inspection & PDI report .

Problem: Slinger Plate Not welded in one side 1.After welding identification mark will be done by welding operator at process and
Part no: 10353191- E20722H22 instruction given to operator thru OPL.
Rejected Qty: 1No's 2.Final inspector will be check and ensure the inner plate available and make line mark _
Reported date: 03.09.2022 over the inner plate and added in control plan

DIPL-Oragadam NIL

1. 1.6mm weld wire replaced by 1.2mm weld wire for the nylon boss welding to reduce
Problem: Nylon top boss bracket TPG NOGO Gauge answering
Part no: 10164535-H31550G22, Part No: 992954 the heat input to boss
2.During welding tapper pin provided in the thread hole to avoid thread shrinkage
Rejected Qty: 5 3.During trolley inspection M10X1.5 thread plug gauge 100% inspection implemented ans _
Reported date: 03.09.2022
added in trolley check sheet
Dated: 05.09.2022

Problem: Weld Metal Slag burr

Part No: 001000-E19813H22,992954 1.Additional air cleaning check provided at trolley insppection area. _
Rejection Qty: 2
Reported date: 03.09.2022

DIPL-
Pant Nagar NIL NIL