KJFPL

CUSTOMER COMPLAINT
DETAILS & ACTION PLAN
MONTH OF SEP’20
 KJFPL

CUSTOMER OVERALL QUALITY RATING FOR 2019 -2020

94
100 100 100 100 100 100
98 98 98
92.06
92 90 90 90 90
91.17
QUALITY RATING %

Packing
80

QUALITY RATING %
Damaged in
90 KJ Hosur to
TVSM HP RUST ISSUE
70 70 IN TVSM HP
NEW ‘Q’
RATING
60 JUPITER CS
88 ASSY TAPER
DIAMETER O/S
50
Rust issue KJ
86 Hosur to TVSM
86 40 HP In transit
During time

30
84
20

82 10
7

9
01
01

01
-2
-2

-2
16

17

18
20

20

20

YEAR MONTH
 KJFPL

CUSTOMER OVERALL QUALITY RATING FOR 2020-2021

96
95
100 100 100
94
90 88 88
92
92
QUALITY RATING %

91

QUALITY RATING %
80

90 NEW ‘Q’
RATING 70 70
SYSTEM
88 60

86 50
86
40
38
84
30
82
20

80 10
7

0
01

01

01

02
-2

-2

-2

-2
16

17

18

19
20

20

20

20

YEAR MONTH
 KJFPL
MONTH OF SEP ’20
TARGET SCORE : F1 20% + F2 30% +F3 30% + F4 10% + F5 10% = 100%

ACTUAL SCORE : F1 0% + F2 0% +F3 30% + F4 4 % + F5 4% = 38 %

F1 : LOT REJECTION QUALITY RATING

F2: LINE REJECTION QUALITY RATING

F3: WARRANTY REJECTION QUALITY RATING

F4 : QDH QUALITY RATING

F5: RESONSE QUALITY RATING

 CUSTOMER COMPLAINT DETAILS MONTH OF SEP ’20 KJFPL

MONTH OF SEP ’20

CUSTOMER QUALITY RATING : 38%

CUSTOMER QUALITY RATING GRADE : BRONZE

NO CUSTOMER COMPLAINT : 09 NO’S

LINE REJECTION PPM : 1918 PPM (QTY:323)

LOT REJECTION PPM : 4242 PPM (Reje 114 nos + 603 nos Rework Accepted)

NO OF LOT REJECTION : 0

NO OF LOT CA : 0

NO OF LOT RTSG : 25 lots

 CUSTOMER COMPLAINT DETAILS FOR MONTH OF SEP ’20 KJFPL

LOT LINE REJ  

COMPLAINT
SL.NO MODEL PART NAME DEFECT DESC QDH
IN TVSM RTSG QTY QTY Remarks
1
HOS JUPITER CRANKSHAFT ASSY FILTER PLATE RUBBING TO CRANK 1 6
CASE DUE TO FILTER PLATE HEIGHT _ _
MORE
CON ROD SMALL END INNER
2 DIAMTER OVER SIZE 2 10
HOS XL100/STAR CITY + CRANKSHAFT ASSY SPEC: 14.003-14.009 , 3+9 4+ 32
Act : 14.019 mm
JUPITER / XL100/STAR
3 HOS CITY + CRANKSHAFT ASSY GOPD PIN MISSING 1 _ _ 4

4 HOS XL100/ JUPITER CRANKSHAFT ASSY NOISE 3 _ _ 24

5 HOS STAR CITY + CRANKSHAFT ASSY BURR PROJECTION- KEY WAY 1 8 16 21

DAMAGE

6 HOS JUPITER CRANKSHAFT ASSY KEY WAY WIDTH O/S - _ _ 1

7 HOS STAR CITY + CRANKSHAFT ASSY OUTER DIA OVER SIZE - _ _ 5

8 HOS XL100 CRANKSHAFT ASSY THREAD DAMAGE 1 _ _ 1

1
9 HP JUPITER CRANKSHAFT ASSY RUST 5 80 +603 247
Our Assembly
10 HP STAR CITY + CRANKSHAFT ASSY FITMENT NOT OK – WOODREFFT KET 1 _ _ 0 found ok (wrong
NOT ENTER QDH Raised )
CAM CHIAN NOT SEATING –
11 HOS XL100 CRANKSHAFT ASSY SPROCKET TEETH 1 _ _ 1

Total 12 25 717 324

 KJFPL
CUSTOMER COMPLAINT DETAILS & ACTION PLAN FOR MONTH OF SEP ’20
Sl.no PART NAME /MODEL PROBLEM Root Cause Action Plan Responsibility Target Status

Improper Seating of Nylon hammer Provided to

FILTER PLATE Operator to Tap the Filter
CRANKSHAFT ASSY – RUBBING TO CRANK Filter Plate in
1 Component and Filter Plate on all sides for Proper J. Prakash 26.09.20 Completed
JUPITER CASE DUE TO FILTER Seating and Training on the Foxit Reader PDF
PLATE HEIGHT MORE Plate Pressing Same by OPL
Document

CRANKSHAFT ASSY- CON ROD SMALL END

2 XL100/STAR CITY+ INNER DIAMTER Refer attached 8D Report
OVER SIZE Microsoft Excel
Worksheet

PART MISSING -GOPD 1.Training provided to Line

PIN MISSING Inspector, Supervisors &
CRANKSHAFT ASSY – Setting Piece Mix-up due Operators on the defect
JUPITER /XL100/STAR to improper phenomena & Setting Piece
3 26.09.20
CITY + Identification of Setting identification to avoid Mix-
Piece up.
Microsoft
2. Clearance fit b/w Pin &
Hole at Extreme limits PowerPoint Presentation

CRANKSHAFT ASSY-
4 XL100/JUPITER NOISE Refer Attached PPT

Microsoft
1. Key Way Top Edge 1. Pin Pressing Fixture PowerPoint Presentation
Damage during Modified by Providing Nylon
CRANKSHAFT ASSY- BURR PROJECTION- loading of Part at Pin Bush
5 STAR CITY + Pressing Fixture
KEY WAY DAMAGE 2. Damage may occur at 2. Proposal for Masking of
Multi-stage Thread dia to avoid damage
of Key way Top Edge after Microsoft
Grinding operation PowerPoint Presentation
 KJFPL
CUSTOMER COMPLAINT DETAILS & ACTION PLAN FOR MONTH OF SEP ’20

Sl.no PART NAME /MODEL PROBLEM Root Cause Action Plan Responsibility Target Status

1.Training provided to Line

CRANKSHAFT ASSY – KEY WAY WIDTH Inspector, Supervisors &
JUPITER O/S Setting Piece Mix-up Operators on the defect
due to improper phenomena & Setting Piece Microsoft
6
Identification of identification to avoid Mix-up. PowerPoint Presentation
Setting Piece 2. Additional gate introduced at
Final PDI stage to check 100%
Key Way Go & No-Go Gauge

7 CRANKSHAFT ASSY- OUTER DIA OVER

STAR SIZE
CITY +

CRANKSHAFT ASSY THREAD DAMAGE

8 -XL100

CRANKSHAFT ASSY-
9 RUST Refer Attached 8D Report & QC Story
JUPITER
Microsoft Excel
Microsoft
Worksheet
PowerPoint Presentation

CRANKSHAFT ASSY- CAM CHIAN NOT Dismantled Sprocket

pressed into
10 XL100 SEATING –SPROCKET
Crankshaft due to
TEETH
Sprocket Shortage
 KJFPL

INHOUSE INPROCESS REJECTION PPM

FOR THE MONTH OF SEP’2020
 KJFPL
ALL MODEL INPROCESS REJ PPM FOR MONTH OF SEP’2020

120000 OVERALL PPM = 26043

100000

80000

60000
PPM

105012

40000
60548
20000 37013
23655 20643 19412
16058 10644
9856 8364 5702 5169
0
H

LH
LH

RH
H
CR

SY

SY

Y
R

SS
2C

3C

SL
SR

AS

AS
CS

CS
5

CS

CS

SA
5C
6

N1

2C

CS

CS
U1

U2

93
62
5

93

5C
N1
N1

U1

U2

62

93
U1

U2

N1
U1

U2
MODEL WISE
 KJFPL
ALL MODEL INPROCESS REWORK SCRAP PPM FOR MONTH OF SEP’2020

60000

REWORK SCRAP PPM - 12640 PPM

50000

40000

30000
PPM

47641
20000

29185 29032

10000
15551 14901
10883
7773 7010 6109 5961 5405 5356 4397 4104 3016 3008
0 772 49

MODEL WISE
 KJFPL
U262 CONNECTING ROD
800 120

700 98 98 99 99 99 99 99 100 100 100 100

95 96 97 100
94
89
600
82
74 80
500
66

400 56 60
720 47
300
QTY

37 40
480 472 459
200 26 425 421
378 372
16 283 20
242
100
60 44 40
0 26 24 19 14 10 10 9 7 6 5 3 0
k NC per k NC per O/S ess O/S ess ess ess U/S e NC e NC lem sing age UST U/S gth me ARK age tion sing
lac & Ta lac & Ta dia ickn dia ickn ickn ickn dth hit Fac prob mis dam & R S & len le ti L M am ejec mis
B B r h r h h h i w r k / g b O D
ID lity ID lity nne all t nne all t all t all t ft w ID DD fer mfe od ar ID O alin Duo TO ole ng R ing
nd Ova end Ova d i W d i w w W So end r n
e l n E n d d E h am cha on ol M &B nne ole ST / il H etti fte
g l l c o A lH U O S o
Bi end ma end ig e B S all e ll en g en B B m
al nd end C T
E
D i R n
s
S l B & i & e B O o
Bi
g al D Sm ma B D S
all Bi
g cti
Sm S du
Sm In
DEFECT
 KJFPL
N15 CONNECTING ROD
1000 120
900
97 98 98 99 99 99 99 100 100 100 100 100 100
94 96 100
800 92
89
83
700 77 80
600 69
59
500 60
918
47
400
34 603 40
300 611 561
200 20 449
376 20
278 260
100
131 108 91
0 43 34 19 14 14 11 9 7 6 4 4 3 1 0
NC /S NC /S er er ss ss ss ss NC ST /S /S RK ge ing m ng e ing NC th NG
O O e e U U e i
l
k k p p e e
ac dia lac dia Ta Ta ickn ickn ickn ickn Fac
e R h
t
U & M
A
am
a is rob iss e ti iss ite leng ADI
s l m
B er B er y & y & th th th th D id O/S IN E m
d er r p g m obl /m wh ng LO
D D w L e i
d
I inn I inn lit lit all all all all
d a a D
oft I D d / rod amf mfe nin Du ag d ID eal NG
n d n d v v W w w W S &B en on ch ha fte ole am en nn RO
ig e ll en all e g en nd O nd O SE end end BE D B C d d c so H e D ig A W
B a m Bi e e B ll g B e n n on il ol B
&
ll D ma B D& i e ti O
Sm S g
Bi ma S
g
Bi all duc il H
S O
Sm In
 Bi
Sm g en
all d I
en D B

100
200
300
400
500
600

0
Bi d in lac
ge n kN
n e r

27
D& d

528
i di C
B n a
SE ner O/

45
D& W d S

353
B all ia O
BE th /

58

250
Sm Wa ick S
Sm al ll t nes
l

67
all en hic s

169
en d I kn
d D e

74
Ov Bl ss
ali ack
Sm ty N
80

134 123
all Soft & T C
en ap
d wid er
w
85

92
all th U
Bi Co thi /S
88

g e n r ck
nd od ne
90

Ov da ss
ali m
ty ag
& e
92

61 52 35
T
Be D a
nd D F per
94

/R ac
Sm E e
all Oi WO NC
95

en l H
d ol RK R
e
c
96

Bi ham Da EJ
ge m
nd fer age
97

Oi wa prob
l H ll l
ol thi em
e
98

Du kn c
An ob ess
U293 CONNECTING ROD

98

ne le
a ti
Se ling me
tti
99

28 24 20 19 17 13 10

In ng len
du g
9
99

cti Oi Rej th
on l H ec
so ole tion
7

fte m
ni i
ng ssin
m g
2

iss
in
g
1

RU
ST
1
100 100 100 100

0
KJFPL

20
40
60
80
100
120
 KJFPL
N15 CRANKSHAFT RH

700 120

600 97 97 98 98 98 99 99 99 99
93 94 95 96 100
91 92
86 89
84
500 79
71 80
400
664 635 60
300
36 40
200

100 20
137
92
50 45 35 23 22 18 17 16
0 12 10 8 7 5 5 5 4 3 0
t k e n /S r e g N e t e S k t t r c K e t
Ou mar r siz ctio & O ape r siz ssin OKE ag tigh r siz u/ mar ffse Rus ape ss n RAC ag ffse
T i m / & T m
t /ID tep nde eje /S & o ve y m BR Da ge nde o/s lack er
O
& Bo / C Da ay o
R U it y ER ole ma t y & g e g
ou a S u g ia l ia a u h /B Cen t
ali lem ma illin ey w
ir ll r Di r dia ttin r d Ova er d ey W UTT n h Da idth lent NC v
D
pe t e S e n e u t K / C pi
ad w g ce
O ob
r D a ss m & k
Ta Ou In O e D e ss in Fa g p OB
D
Bo ole
rok OP Thr Bo den in h
li B G ar & r g D
l C o
Dr
H
D
N F
G OP
O PD O
G
 KJFPL
U262 CRANKSHAFT RH
250 120

97 98 98 99 99 99 100 100
95 96 100
200 89 92
84 87
81
77
73 80
150 69
64
58
52 60
100 212 44
33 40
22 104
50 103
75 20
64 56
43 43 40 32 28 27 27 27 26
13 8 7 6 4 3 3 3
0 2 0
U/S ut GE ark ize set /S /S /S /S /S gle per ght lem ing ark age ing per ark /S /S ing
A
D ia rill O M k m er s Off & U th U ia O & O th O An Ta /ti rob den e m am iss Ta e m th U ia U den
g D DA c v er S id D S id & & ge p r in D M & lin id r D ar
r in ID ing Bla ID O ent O/ s w eer h U/ y w try lity ma ing h ha Id l y
KW alit ID ay w Inne gh h
ea li
l e C CD s In t a e a a rg i g i
B M Fac bo ep W m Ov d D fo H
m e & Ov
y w H
y
o ss e & a y D Ke Sy re
a
m
ag ID ke
B a g h
m eyw T Da
a K &
eD s et
c
Fa y Off
a
y W
Ke
 KJFPL
U262 CRANKSHAFT LH
300 120

99 99 99
250 93 94 95 96 96 97 97 98 98 100
91 92
86 88 89 90
82 84
79
200 73 80
66
59
150 60
268 50

100 204 40
29

50 84
20
66 58 57
27 21 18 16 14 11 11 10 10 8 7 6
0 5 5 5 4 4 3 3 2 0
/S ut per NC ken size /S ark Size /S ken /S ken ken /S ted age O/S ken set O/S ark ing /S age U/S
U O a / U r U U c o O n ff O
ia rill T GE Bro ver S & k m de th Bro S & bro l Br ia cou am Dia bro e O s & ne m den & am pth
D D y & A ll O / ac n id ll r S d
n g it M r i O Bl U w r i O/ rill ril er D nac t /D ing rill Hol t u/ D li ha U/ ole De
i ID al A D ID le e ia oss D D d D n e u g h ar r
ear v D m o ac D b b C ep m I / ti e m D ler eigh I igh LE er h me
B O g m
in 0 er h & F 12 St
u
de .5 m l em line
B m ng H
8 A
H HO gl ea
n R
l
il 2 . . N
M e am age ia
2
r ob Sp a 3 PI P IN A
p i
oss R m
a
D
ng D PD PD
B D g i GO O
ace for G
F
 KJFPL

600 N15 CRANKSHAFT LH 120

99 99 100 100 100 100 100

500 94 95 95 96 97 98 98 99 100
91 92 93
88 89
83 84 86
80
400 74 80
66

300 57 60
566
47

200 40

100 20
127 106 105
66
32 23 21 20 19 14 14 13 12 10 10 9 9 9 7 6
0 4 3 3 2 2 1 1 0
t S n er h /S e ze rk E ze ze G g t et e S c S K er h S S S g RK
Ou a U/ ctio ap ouc & O mag r si ma AG r si r si IN issin tigh ffs mag O/ ss n O/ AR ap atc U/ u/ U/ issin A
T M / e T h & M
t /ID r di eje & ne t /S /Da Ove ack DAM nde nde CO e m ge er O Da /S & Bo anc P M & ism ngt /s nce g m EP
R y i U l a t g & E y m o a T
l ou ut e ng alit spl ia ght ID /B OD th u ID u D/IN plin am Cen llin ce U em Dist /ST alit ne d le th ist nin D S
l O tti v & d i i n D e
i
Dr ing Se O /s ner ne
ti N C E S / w id TE S D
d s m t a n o b l t r e a r k O v S p l r e a l e t r e ar d O
i c e G s N a s i s r n h g
T in en H
ar th
o In pl
Fa MA Bos OU hr
e
Bo er D ng
p Ce e m
n C
Be n g S
& A CC T t rg i l i n de
le D A n p r
d NC EB U N Ce Fo S te Ha
a D
re O /W ee
l
Th st h
Ru W
 KJFPL

180 U293 CRANKSHAFT RH 120

160
97 98 98 99 99
95 96 97 100
93 94
90 92
140 87 89
83 85
80
120 77 80
73
67
100 61
60
80 157
45

60 114 40
26 93
40
20
20 38 36
23 17
14 13 12 11 10 8 7 7 6
0 5 5 4 3 3 2 2 0
 KJFPL

140
U293 CRANKSHAFT LH 120

120 98 99 99 99 100 100

95 97 100
92 94
88 90
85
100 82
79
80
72
80 62
60
128
60 117
45
95 40
40
23
56
20 20
36
17 17 16 12 12 11 7 7 5 5 3 2 2 1
0 0
 KJFPL

250 U262 CRANK SHAFT ASSY 120

98 98 99 99 99 99 100 100
95 96 97 97 100
92 94
200 91
88
84
80
80
150 69

238
60
100
40

50
20
37
15 11 11 6 5 4
0 3 2 2 2 2 1 1 1 1 1 1 0
 KJFPL

U293 CRANKSHAFT ASSY

140 120

120 98 99 100
95 97 100
94
91

100 79
80

80 65
60
132
60 46

40
40
55
20 41 20
34
9 4 4 4 3
0 2 0
ok e s g
T OK oise t s ed in
g
ag lem u/ ix up s in
n o o ad m b t is
NO u p/ ry n Cl lo da pro e igh d
m m
G t m g o e
IN uc
k m ble ron ay lin
g gh n
r
hol
U st m o w il in o l
TR d sy pr w
key m e ar C
s oi
R o in at s s B s
kp lo Bo o
Con
an F g t o
/Cr
cr r
arin u la
g
Be An
 KJFPL
N15 CRANKSHAFT ASSY
300 120

98 98 98 99 99 99 99 100 100
250 95 96 96 97 97 100
93 94 95
91
88
81
200 73 80

150 60
284

100 40

50 20

30 26
0 11 9 3 3 2 2 2 2 2 2 2 1 1 1 1 1 1 1 0
ok ing oise urr ing o/s wn u/s o... age ing ack urr nd RH
age N C LH ise U/S ight
t b r s r e / o
no load p/n te/ iss dia do gth D P am Pres C / B d B g LH dam OD H & g N S & in T
g M in llin g n D e ro in R rin
uin ng
rcku ota le/ P i le OB
O D t e le t
o n s ay le a O/ on P
r o R o D e / e p is w b e h
T w
r
d
st / il h
OP s m lin
p ge pl om c
M e y ou B idt Pist
Ro
e
ag le o G bos S m
a
co
m
in
c ad K D
y W
n m b a I n e re a
Co Da dou D ov Th yw
e R H ro e
/ K
P lat Rod LH G
er Con d
Fit rea
Th