Sr. no.

Process

Contributing sub-process

Activity

Body

Eng. Room Line

Respot line

ELPO

Before and after check by

passing bolt on 25 vehicles

Body Sealer

applied some sealer to child

part's nut and tightened on
bench wise using wrench

Assembly

SOS followed; DC tool

calibrated; Happy tool ok;
Torque ok- QCOS sheet

Paint

GA

Observation

ok

not ok

ok

Sr. no.

Part

Engine mount

Bolt

Longi with M10 nut-Body

Activity

Observation

Found 1 part which washed out 1 vehicle

Not ok

Visual check and hand tightened random

20 bolts on good child part

ok

check by passing bolt at Body shop (Out

of 433, 13 part not ok)

Not ok

Month
April

May

June

July

Aug

Sept

Oct

No. of washouts

2
0
0
0
1
0
2
3
3
0
2
2
4
0
0
1
1
1
4
2
5
2
0
1
1
7

No. fwashouts(Def ctsBo kedinGSIP)

8
7

Stared
workingon
theis ue

6
5

No. f
washou
ts

4
3
2
1
0
123456789 10 1 1213 14 15 1617 18 19 20 21 2 23 24 25 26 27 28

No. fwashouts(Def ctsBo kedinGSIP)

8
7
6
5

Stared
workingon
theis ue
No. f
washou
ts

4
3
2
1
0
123456789 10 1 12 13 14 15 16 17 18 19 20 21 2 23 24 25 26 27 28

ts
3
2
1
0
123456789 10 1 12 13 14 15 16 17 18 19 20 21 2 23 24 25 26 27 28

Sr no

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Date
Shift

9/24/2013
B

Supplier
Manpower

Mr. Swapnil
Jadhav

Total checked

106

Found Not ok and

reworked

9/25/2013
A

9/26/2013
A

Mr. Roshan

10/2/2013
A

10/3/2013
B

Mr. Roshan

Mr. Swapnil
Jadhav

Mr. Roshan

Mr. Roshan

51

81

62

83

51

434

13

Total

Observation
Sr. no.

Model

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

M300
M300
M300
M300
SGM
M300
M300
SGM
M300
SGM
M300
M300
M300
SGM
SGM
SGM
SGM
M300
M300
SGM
M300
SGM
M300
SGM
M300
SGM
M300
M300
M300
M300
SGM
SGM
M300
M300
M300
SGM
M300
M300
SGM
M300
SGM

Hand pre-tight (before)

ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok

42
43
44
45
46
47
48

SGM
M300
SGM
SGM
SGM
SGM
M300

ok
ok
ok
ok
ok
ok
ok

Observation: Since nut were visually checked as well as hand pre-tightened before assembly and f
incoming material at GA is ok

Observation
Assembly (After)
ok
ok
ok
ok
ok
ok
ok
NOT ok (RH RR)
ok
ok
ok
ok
NOT ok (RH FRT)
ok
ok
ok
ok
ok
ok
ok
ok
ok
Finally ok (but CROSS initially RH FRT)
ok
ok
ok
ok
Finally ok (but CROSS initially RH FRT)
ok
ok
ok
ok
ok (Vishal Took considerable time)
ok
ok
ok
ok
ok
ok
ok
ok

AGV no.
9
7
6
4
1
9
7
6
4
1
9
7
6
4
1
9
7
6
4
1
9
7
6
4
1
9
7
6
4
1
9
7
6
4

operator
LH
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj

RH
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal

ok
ok
ok
ok
ok
ok
ok

1
9
7
6
4
1
9

Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj

Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal

checked as well as hand pre-tightened before assembly and found ok conclusion is that
incoming material at GA is ok

Observation
Sr. no.

Model

8
9
10
11
12
13
23
28
33
43
44
45
46
47
48

SGM
M300
SGM
M300
M300
M300
M300
M300
M300
M300
SGM
SGM
SGM
SGM
M300

Hand pre-tight (before)

ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok

Observation: Since nut were visually checked as well as hand pre-tightened before assembly and f
incoming material at GA is ok

Observation
Assembly (After)
NOT ok (RH RR)
ok
ok
ok
ok
NOT ok (RH FRT)
Finally ok (but CROSS initially RH FRT)
Finally ok (but CROSS initially RH FRT)
ok (Vishal Took considerable time)
ok
ok
ok
ok
ok
ok

AGV no.
9
7
6
4
1
9
9
9
9
9
7
6
4
1
9

operator
LH
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Dhananjay
Vishal
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj
Vanraj

RH
Prashant
Prashant
Prashant
Prashant
Prashant
Prashant
Vanraj
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal
Vishal

checked as well as hand pre-tightened before assembly and found ok conclusion is that
incoming material at GA is ok