S0701-FRHO-F0-010

HONDA MOTORCYCLE & SCOOTER (INDIA) PVT. LTD.

Department or supplier name Date ( Y/M/D ) Date:
Documentation Instruction Analysis record [ Problem Analysis Sheet ]
Responsibility Approved Make Approval Check

HMSI
Made by

THEME
ANGLE OF GUIDE BEND NOT OK 96 degree (Spec.-90± 3 degrre) SNO Probable Cause Ideal Condition Actual Condition Result P. BHAYANA AJAY PAWAR D. MALIK

PART NUMBER 47602-K83A-D000

PART NAME Cover Comp Bracket

[ Situation Event Symptom, Complaints, Number of occurrences, actions ] [ Identified facts result of verification, cause analysis, manufacturing quality status on the applicable date ]
SPECIFICATION: Parts should be as per drg. ACTUAL: parts not as per drg
1. TYPE OF OCCURANCE CABLE CAME OUT DURING ASSY. PROBLEM CONTENTS: Guide bending angle ng

OCCURANCE
2 .PLACE OF OCCURANCE HMSI PROCESS FLOW DIAGRAM OF GUIDE BENDING :-

SUB SUPPLIER BENDING PROCESS NOT ESTABLISHE ( NO PROCESS QAV DONE BY ADVIK)
3. CONDITIONS AND
CIRCUMSTANCES OF SUB ASSY 2 ( SUB ASSY.
PROBLEM WHEN IT
DURING ASSY. 1 + SPRING + LEVER +
OCCURED BOP REC. & TRACEBILITY MARKING SUB ASSY 1 (BRKT L PIN PIVOT + LEVER
INSPECTION HANDLE + SW ASSY.) COMP. + BOLT + CABLE
COMP 1ST
NG GUIDE
4. DATE OF OCCURANCE 1/9/2016
Bending angle not ok(96 degree) OUTFLOW

SUB ASSY 3 & SW NO CHECK POINT AT FINAL "Q" GATE AND ASSY. ( NO POTENTIAL CAUSE ANALYSED & CONSIDERED IN FMEA)
5. NUMBER OF CASES 04/30 NOS. SUB ASSY 4 (BRKT BRK WORKING CHECKING (
+ EQUALIZER + SUB ASSY 2 + NUT
FINAL ASSY & FINAL STOPPER EQUALIZER + MOUNTING SUB ASSY FLANGE + E RING
INSPECTION SPRING DELAY + 3 ON HANDLE
COVER + CABLE COMP
DETAILS :- Material checked at HMSI end & Supplier end as below : 2 FR & 2ND RR + BOLT

Material packed as Finish Good checked again details as below: FACTS VERIFICATION CAUSE ANALYSIS
SR.
S.NO LOCATION QTY. CHECKED NG PARTS Probable Cause Ideal Condition Actual Condition Result
NO Fishbone Diagram

1 1 BOP INSPECTION AS PER SPEC. OK OK

Man Machine
2 2 1st bending AS PER SPEC. OK OK

OPERATOR AWARENESS
3 3 2nd bending AS PER SPEC. OK OK

NO CHECKPOINT
4 3rd bending AS PER SPEC. NG NG
Guide bending angle not ok

TIER 2 PART "Q" GAURANTEE

BENDING PROCESS INPUT MATERIAL

SUB SPLR CONTROL
TIER 2 PROCESS NOT PACKING CONDITION
ESTABLISHED
Method Material

Root Cause of Problem ( How the Problem occurred, duplication test, problem analysis ) Counter Measure Taken ( Measure contents, expected Results) Confirmation of effectiveness ( Actual Results After Counter Measure Taken )

A. OCCURANCE ROOT CAUSE C. OCCURANCE COUNTERMEASURE TARGET DATE

CONFIRMATION RESULTS OF 3 SUBSEQUENT LOTS AFTER COUNTERMEASURE

1 TIER 2 PROCESS NOT ESTABLISHED ( INADEQUATE BENDING PROCESS) 1 SUB SUPPLIER PROCESS ESTABLISHED Done
S.NO DATE LOT QTY RESULT REMARKS

SUB SUPPLIER PROCESS QAV-2 DONE & ALL COUNTERMEASURE CLOSED ( QAV PLAN MADE
2 QAV-2 AT SUB SUPPLIER WAS NOT ENOUGH 2 1
FOR ALL SUB SUPPLIERS)

3 POTENTIAL FAILURE NOT CONSIDERED IN FMEA 3 FMEA UPDATED FOR ALL BOP PARTS FOR POTENTIAL FAILURE 2

B.OUT FLOW ROOT CAUSE D. OUT FLOW COUNTERMEASURE TARGET DATE

1 NO CHECK POINT AT ASSY. & FINAL "Q" GATE 1 100% CHECK POINT ADDED ON ASSY. LINE Done

TRAINING TO OPERATORS/ INSPECTORS & OPL DISPLAYED AT ASSY. & FINAL INSPECTION
2 NO OPERATOR / INSPECTOR AWARENESS 2
STAGE

3 WEAK RECEIVING INSPECTION STANDARD 3 RECEIVING INSPECTION STANDARD REVISED FOR BENDING ANGLE CHECK n

(BENDING IN DIE BY POWER PRESS PROVIDE THE BLOCK TO DETECT THIS ANGLE

Problem analysis Feedback (Contents to be reflected in the systems / procedures )

Step 1 2 3 4 5

).Excess movement of lever in manual bending No any provision to control the lever Man depend process control
C Occurrence Guide a tilt welded Bending angle not ok
fixture stroke length
o
n
t
e
n
t
s Outflow Guide a ng angle flow out No detection in fixture for angle varify