Supplier Veeras

 BRKT WIRING MTG ( 91931-T7120 ) END CUT - 1 NO Issue Date 13.12.23

Problem status Improvement

 New gear was changed in coil feeder avoid for end cut issue
- Completed 14.12.23

New gear

 BRKT WIRING MTG ( 91931-T7120 ) END CUT - 1 NO (@ HMI)

 Machine PM check sheet gear point added for ensure the gear condition
- Completed 14.12.23
Occurrence Cause
1. End cut occurred at OP 10 Blank stage
2. Improper movement of coil in blank stage
3. Coil feeder miss feeding occurred
4. In feeder machine, gear damaged condition

Gear damaged

NG blank width 50.07 mm OK blank width 56 mm

ROOT CAUSE ANALYSIS REPORT(TOOL CONDITION & M/C FEEDER CONDITION )

OP 10 Blanking tool condition M/C coil feeder condition ..

OP 10 Blanking stage all Guide pin are

available die verified no issue

Feeder Gear damage End cut

Observation : OP 10 coil feeder in gear damage condition so during production time

NG blank width OK blank width 56 coil feeder miss feeding occurred
50.07 mm mm
 Supplier Addo tools
 A4006920043-LOCKING HOOK–FORMING NG - 40 NOS Issue Date 12.12.23

Problem status Improvement

 New Die insert to be provided in OHNS material with 56 HV

- Completed 18.12.23

New die insert made

Spec : 2.3 ± 0.2 mm

LOCKING HOOK–
Act : 1.2 mm FORMING NG - 40 NOS (@
DICV)

Occurrence Cause
1. Forming operation not done properly
2. Forming stage insert crack available
3. Insert hardness is high
( 61 HV) Insert crack Awareness given to Line inspectors & final inspectors for to ensure
100% free from forming issue - Completed 12.12.23
 AC3 DUST COVER FORMING ISSUE -2 NO’S

Problem status Improvement

Improvement :
PROBLEM PHOTO: Visual :
Spec :100 % visual ok part with 1. Locating pin provided in tool for arrest the play.
out any problem
Actual – Dent mark problem.
Target date : COMPLETED (31.10.23).

NEW LOCATER IS
PROVIDED

Ok part

Occurrence Cause
1. Operator running part miss located in tool came to forming problem.
2. Checked the tool while running possible for play and able to keep on locater

WhatsApp Video 2023-02-20 at 3.53.09 PM.mp4 Stopper block is

provided

No locating block
Root cause:

BOTTOM TOOL FULL VIEW AND

PROBLEM OCCURANCE AREA SIMILATION PART
(FORMING PROBLEM)

WhatPART
sApp Video LOCATING
2023-02-20 at 3.53.09 PM.mp4
VIDEO

NG PART NG LOADING
OK LOADING

OK PART
 BA COVER INSULATOR SLUG NOT OPEN -1 NO

Problem status Improvement

PROBLEM PHOTO: Improvement :

Visual :
Spec : 100% Visual checking
the part with out slug open.
Actual – slug not open.
 After piercing die insert land reduced to 3mm and
piercing punch height changed to 72 mm.
 slug not hold in tool each stroke piercing slug fall down.
 Awareness given to operator about the issue.
TARGET DATE: completed.
Piercing punch height changed
from 70mm to 72 mm ,land
also increased each stroke
slug fall down from tool

Occurrence Cause
1. BA cover insulator piercing die insert land is 5mm to that of sheet
thickness 2 mm, 2 slug hold in die insert land is more and punch
height is 70 mm.
2. Running time piercing slug got not open, operator did not notice the
slug not open while continues running.

Piercing stage land is

less slug not open in
tool. Piercing die insert land
changed from 5 mm to 3mm
Root cause:
Slug not open

Piercing punch.

Piercing die insert land is

5 mm (2 slug hold in
insert)