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  • TPM Rev 24

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    Ankit Ranjan
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    The document analyzes and proposes solutions to address a defect where the C4 circlip was missing from the counter shaft assembly in the Passion 110CC motorcycle. It found that without the C4 circlip, the C4 freely moved upward. To fix this, a spring lifter was installed at the gear poka-yoke gate to prevent the C4 from moving up. A separate kaizen addressed improper storage of the fuel injector assembly, which was replaced by a wagon wheel that could hold 20 assemblies inclined at 30 degrees to eliminate o-ring and insulator pad misses.

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    tpm Rev 24

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    The document analyzes and proposes solutions to address a defect where the C4 circlip was missing from the counter shaft assembly in the Passion 110CC motorcycle. It found that without the C4 circlip, the C4 freely moved upward. To fix this, a spring lifter was installed at the gear poka-yoke gate to prevent the C4 from moving up. A separate kaizen addressed improper storage of the fuel injector assembly, which was replaced by a wagon wheel that could hold 20 assemblies inclined at 30 degrees to eliminate o-ring and insulator pad misses.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    35 views2 pages

    TPM Rev 24

    Uploaded by

    Ankit Ranjan
    The document analyzes and proposes solutions to address a defect where the C4 circlip was missing from the counter shaft assembly in the Passion 110CC motorcycle. It found that without the C4 circlip, the C4 freely moved upward. To fix this, a spring lifter was installed at the gear poka-yoke gate to prevent the C4 from moving up. A separate kaizen addressed improper storage of the fuel injector assembly, which was replaced by a wagon wheel that could hold 20 assemblies inclined at 30 degrees to eliminate o-ring and insulator pad misses.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 2

    Defect Analysis: To Eliminate C4 Circlip Miss in Passion 110CC

    Counter Shaft Assembly

    BEFORE ANALYSIS AFTER


    C1
    Uplift stopper

    C3
    Poka-yoke
    stopper
    Circlip
    Miss
    C4
    Spring lifter

    C2

    When C4 circlip miss, C4 freely moves


    upward.
    Master Sample

    Spring lifter
    Gear Movement Hard at Quality Gate 2
    installed at gear
    due to C4 Circlip Miss
    poka-yoke gate

    Watch Video

    Team Details :

    Be the Future of Mobility Create | Collaborate | Inspire 1


    Kaizen – Engine Assembly 1 & 2
    Model:
    Passion 110cc
    Karakuri Kaizen for the storage of Passion 110cc Fuel Injector Assembly
    Before Condition After Condition

    Background: Action:
    There were no standard Bin to keep the Fuel Injector assembly. Storage Bin replaced by a wagon wheel of capacity of 20 Fuel
    As a result , O-ring miss and Insulator pad miss issue occurring Injector assy storage capacity inclined at an angle of 30 degree.
    due to inappropriate storage of assembly.
    Benefits:
    1. O-ring miss issue due to mishandling eliminated.
    2. Motion loss is reduced due to Karakuri wheel motion.

    Be the Future of Mobility Create | Collaborate | Inspire 2

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