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Tyre Size

:245/65 R16 Elanzo Supra TL

Customer

:Mahindra & Mahindra

Problem Description

:Cut Mark On the Tread End

Quantity Reported

:18 Tyres with week code 4013/4213

Complaint Receipt date

:21.10.2013 Through Mail
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ERA/ICA(Containment Action) 1)On receipt of the complaint.809 tyres 3)All the concerned operatives and others were well informed about the issue and high level of awareness was created.-1500 tyres 2)Screening at JK Tyres .Chennai Plant started. Screening has been started at Mahindra and defect free tyres are feed to the Line . 2 .

Problem Description: Tyres are identified with Trim knife cut mark on the tread portion at Mahindra Customer assembly line. Defect is shown below in the image Defect Tyre Images 3 .

Process Flow of Tyre Manufacturing Mixing Static Balancing Stock preparation Dynamic Balancing Tyre Building Tyre Curing 100% QA Visual Inspection Warehousing Defect occurring process Defect passing process Trimming First Line Inspection by Production Operatives Uniformity Testing Dock Audit Before vehicle loading for OEM dispatch 4 .

Cured Tyre Before Trimming Vents to be trimmed As cured As cured 5 .

Process and Images-Tyre Vent Trimming Trimming M/C front side Tyre Entering to M/C Trimming Trimming Knifes Radial Blade Lateral Blade 6 .

Cause and Effect Flash Trimming Knife cut damage Man Machine Missed to identify damage in First Line and Second Line Fire wall Tire Holder Damage in Trimming Lateral Blade position incorrect Cut Mark On Tread Material Lightness Method Material 7 .

Cause Validation and Analysis 4M Cause Validation Decision (Significant/Non significant) significant Man Missed to identify damage in First Line and Second Line Fire wall Flash Trimming Knife cut damage Tire Holder Damage in Trimming Lateral Blade position incorrect Material Lightness Checked in the Finished Good and tyres are identified Not possible by Flash removing knife .Flash is in the mid of the sidewall circumference Holder surface is smooth and no such issue Simulated and found the cut mark Man Insignificant Machine Insignificant Machine Significant Material No such defect in this tyre size from the start of the production itself and the defect records of Oct 13&Sep 13 also reveals the same Insignificant 8 .

Root Cause Analysis Cause Knife Cut mark on tire Why Why-Why Analysis Lateral Trimming Blade Position incorrect (excess forwarding which caused tire damage) Why Height/Time setting is same as that of other small tires(12 inch to 15 inch) Why End effect was not known and the setting was common for all tires Root Cause Tyre specific height/Time setting not carried in PLC Counter Measure Tire specific Height and Time setting Carried in M/C to tire specific Blade Actual posi Blade Required Po 9 .

Root Cause Analysis Cause Missed to identify damage in First Line and Second Line Fire wall Why Why-Why Analysis Passed to next process due to operator negligence Root Cause Passed to next process due to operator negligence Counter Measure All the persons involved were counselled and high level of alert was created in CTP 10 .

10.Corrective Action Summary 4M Cause Countermeasure Status Man Missed to identify damage in First Line and Second Line Fire wall Awareness created and the tyres are ensured with no such cut marks Completed on 21.2013 Machine Tyre specific height/Time setting not carried in PLC Height and Time setting carried to tire specific.10.2013 11 . The same will be ensured in weekly check by maintenance Completed on 21.

3 Levels Of Inspection First Line Inspection-Production Second Line Inspection-QA Dock Inspection-QA 12 .

Conclusion : JK will ensure the defect free dispatch to M&M by maintaining the tyre specific heights/time setting in PLC and strengthening the Inspection at three levels(First Line Inspection by Production/Second Line Inspection by Quality and Final Dock Inspection by Quality) JKTIL (CTP) will continue to ensure the above points to ensure there is no customer line hindrances henceforth. 13 .

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