SL.

Notification
Month Date CPI/RMN CUSTOMER NAME PRODUCT PART NO COPQ
NO No.

1 January 04.01.2019 RMN 200707432 AL-ALWAR RELAY VALVE FVA00200

15 LTR AIR TANK -TWO PORT

2 January 08.01.2019 RMN 200708072 AL-PANTNAGAR F1J00500 998.03
NG120

3 January 21.01.2019 CPI/RMN 700028121 AL-ALWAR 7062CM CLUTCH BOOSTER F4C01900 7000

4 January 29.01.2019 RMN 200713272 AL-ALWAR SBA Type 12/12 FZ2602900

5 February 01.02.2019 CPI 700028282 AL-ALWAR SBA TYPE 24/24 RH F3R04600 7000

6 February 07.02.2019 CPI 700028330 AL-PANTNAGAR SRGHCV FJT00100 7000

700028409
7 February 13.02.2019 CPI/RMN AL-ALWAR SBA TYPE 24/24 RH F3R04500 7000
200714383
SL. Notification
Month Date CPI/RMN CUSTOMER NAME PRODUCT PART NO COPQ
NO No.

Compressor 230 cc Water

8 February 20.02.2019 RMN 200720377 AL - Pantnagar X7493400 4586.99
cooled

9 February 21.02.2019 CPI 700028520 AL - Pantnagar IPU X6M00700 7000

10 February 25.02.2019 RMN 200722163 AL - Pantnagar INTEGRATED PEDAL UNIT X6M00400

11 February 28.02.2019 RMN 200722849 AL - Pantnagar Air Compressor X3979000

12 March 06.03.2019 RMN 200724386 AL - Pantnagar SRGHCV FJT00100

13 March 08.03.2019 CPI 700028735 AL - Pantnagar Air Compressor F7474000 7000

14

47585.02

WINU PARTS
SL. Notification
Month Date CPI/RMN CUSTOMER NAME PRODUCT PART NO COPQ
NO No.
WINL PARTS
WINC PARTS

PROBLEM DESCRIPTION
Leakage from joint
Leakage through drain valve
Continous air leakage from breather
Continous air leakage from Clamp ring joint
Continous air leakage from Clamp ring joint
Lever movement hard
Continous air leakage from Clamp ring joint
PORTAL
QTY ROOT CAUSE
STATUS
During retesting at Customer end there is no leakage observed in the
1 OPEN
part.
Loose chips stuck in between the sealing area .
Reason of re-taping of the threads:-
1- Re-tapping operations chips getting inside tank.
2 - Re-tapping done to clear paint inside boss thread & qualify the TPG
go gauge
1 Close
1.Defective part opened for analysis and observed bonded valve tear in sealing
surface with the impression mark of some foreign particle - Possibly ferrous
1 burr from the pipeline. Close
2.Defective part observed with Tested Ok punch mark, this defect may
happened after Wabco Process.
1 Diphragm pulled in is the root cause of clampring joint leak. OPEN
1 Diphragm pulled in is the root cause of clampring joint leak. Close
Boring operation tool wear out in VMC machine at supplier end (Jainidhi
1 automotive) due to Tool change frequency inadequate
Close
1 Diphragm pulled in is the root cause of clampring joint leak. Close
 PORTAL
PROBLEM DESCRIPTION QTY ROOT CAUSE
STATUS

Dent on the MTG mounting face due handling at customer end resulting
Leakage from head mounting face 1 leakage. - NON PPM
Close

CMC Cylinder body bore found over size by 0.41mm due to New Combination
CMC Leak 1 Reamer tool's finish diameter Ø26.125mm found excess run out and two trial OPEN
samples mix-up to series production parts.

Coupler Housing found damage 1 OPEN

Coolant leakage from delivery port 1 Close

Wrong mounting plate 1 OPEN

Abnormal noise from 1 OPEN

 ACTION PLAN January February March April

Claim rejected.

1. Quality alert displayed in line and operator awareness created.

2. All the Air tanks available in the plant checked 100% for the loose chips and identified with tick mark on
the air tanks.
3. Re-Tapping Process started after end cover adapter welding so that chips could get cleared during in
the pre-treatment process.
4. Ensure proper masking of the boss threads so that paint not gets inside thread during painting process.
5. Thread masking cleaning frequency as well as self life to be freezed and monitoring.
6. Prepare the rewok procedure for the re-tapping and linked with control plan

Since Wabco Process have control for cleaning, this impression may be due to some foreign particle entered from
pipeline at vehicle level. This defect may occurred after Wabco process since Test ok punch mark observed in
defective part.
So This claim is considered as No Fault Found.

Under analysis

Training provided to line operator for proper assembly of diaphragm.

2. 100% Additional visual check on available parts
3. Awareness provide to operator through Quality alert at WINU.
4. After retesting identification mark (Testing operator identification) will be put on the Cylinder as shown below
5. Till the time permanent corrective action taken, parts will be tested at firewall station with 5 times manually
cycling and identification mark will be provide
6. Dowel hole provided on the cylinder mounting plate to avoid excess play of the plate.
7. Added same point in the fixture varification sheet.

Supplier end Actions:

1. Tool change frequency reduced from 5000 nos to 3500 nos. Implemented
2. Tool life monitoring (3500 nos) system interlinked with VMC machine- 27.02.2019
3. Mechanical poka yoke at next operation (Slot milling) to detect ID undersize parts. Target: 28.02.2019
Wabco Action:
4. Lever movement check point to be added in PDI check point

1.Ensure clamp ring torque value - 26 ~ 28 N-m. ( every part)

2. Equal visibility of diaphragm each side ( Top and bottom) to ensue least miss match of NPP and Flange.
3. Cycling of Ram - 5 times by apply air in port 12.
4. Cycling of Push rod by apply air in port 12 and port 11.
5. Double punch mark on the flange ensuring dry leak testing and and re tightening done properly.
6. More than 6 threads of clamp ring bolt out from the Nut.
7. RC marking with Date and month coding ( 12B - 12 is date and B for Feb.)
6. Dowel hole provided on the cylinder mounting plate to avoid excess play of the plate.
7. Added same point in the fixture varification sheet.
 ACTION PLAN January February March April

Claim rejected.

1) 100% Air gauge Inspection for cylinder body bore at machine shop. Resp.: Mahendran - MC Shop Leader, Target :
28.02.19 , Status : Completed.
2) Quality Alert displayed & Training given to PED / VS members for EOJ process (New Trials / Process changes).
Resp.: E Satishkumar - VS Q, Status : Completed
3) Cylinder Body machining traceability to be introduced for serial number and date/shift. Resp. : Vijayakumar-PED,
Target : 15.04.2019

1) CMC - Cylinder bore 100% checking frequency updated in control plan (QCPC) / Operating Standard (OS) from 4
no's/hours with air gauge. Resp.: Vijayakumar-PED / Satish -VS Q - 28.02.19 - Status : Completed
2) Instruction given to PED team for follow EOJ process (New Trials / Process changes) and any new trial jobs to be
identified with Blue paint # (Hatch) marks to avoid mix-up to line. Resp.: Mahendran - MC Shop / Satish -VS Q, Target
- 28.02.19, Status : Completed
3) Exploring the possibility of cylinder body bore over size detection at CMC EOL test Rig. Resp.: R.Sivaguru-PD,
Status: Under experiments Target : 15.03.2019

Claim rejected.
May June July August September October November December
May June July August September October November December
Sr. Date Material Material Description Criticality
No. Number
1 1/21/2019 F4C01900 7062 CM CLUTCH BOOSTER MEDIUM
2 01.02.2019 F3R04600 SBA TYPE 24/24 RH MEDIUM
3 07.02.2019 FJT00100 GHCV MEDIUM
4 13.02.2019 F3R04500 SBA TYPE 24/24 RH MEDIUM
5
6
Date Value Issue Status Notification No Date Month 7202746

1/21/2019 7,000 OPEN 700028121 January 7,000

01.02.2019 7,000 February 21,000
07.02.2019 7,000 March 0
13.02.2019 7,000 700028409 April 0
May 0
June 0
July 0
August 0
September 0
October 0
November 0
December 0

28,000

28,000
7203694 Total

0 7,000
0 21,000
0 0
0
0
0
0
0 0
0 0
0
0
0 0

0 28,000
Sr. Type Reason User Name Date Time Material Number
No.
1 CPI
3 CPI
2 CPI
4 CPI
5 CPI
6 CPI
7 CPI
Material Description Comments Criticality
Date Value Issue Status Notification No Notification Date
Type

0
Document number Document
Type
 JANUARY FEBRUARY MARCH APRIL MAY JUNE
Sr. No. Part No. Part Name ALA PNR ALA PNR ALA PNR ALA PNR ALA PNR ALA PNR
1 FVA00200 RELAY VALVE 1 0 0 0 0 0 0 0 0 0 0 0
15 LTR AIR TANK -TWO
F1J00500
2 PORT NG120 0 1 0 0 0 0 0 0 0 0 0 0
F4C01900 7062CM CLUTCH
3 BOOSTER 1 0 0 0 0 0 0 0 0 0 0 0
4 FZ2602900 SBA Type 12/12 1 0 0 0 0 0 0 0 0 0 0 0
5 F3R04600 SBA TYPE 24/24 RH 0 0 1 0 0 0 0 0 0 0 0 0
6 F3R04500 SBA TYPE 24/24 RH 0 0 1 0 0 0 0 0 0 0 0 0
7 FJT00100 SRGHCV 0 0 0 1 0 1 0 0 0 0 0 0
8 X7493400 Compressor 0 0 0 1 0 0 0 0 0 0 0 0
9 X6M00400 IPU 0 0 0 1 0 0 0 0 0 0 0 0
10 X6M00700 IPU 0 0 0 1 0 0 0 0 0 0 0 0
11 X3979000 Air Compressor 0 0 0 1 0 0 0 0 0 0 0 0
12 F7474000 Air Compressor 0 0 0 0 0 1 0 0 0 0 0 0
13 0 0 0 0 0 0 0 0 0 0 0 0
14 0 0 0 0 0 0 0 0 0 0 0 0
15
16
17
18
Total 3 1 2 5 0 2 0 0 0 0 0 0
Grand Total 4 7 2 0 0 0
Incidents 0 0 0 0 0 0

RMN
RMN/CPI
 JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER
ALA PNR ALA PNR ALA PNR ALA PNR ALA PNR ALA PNR Total
0 0 0 0 0 0 0 0 0 0 0 0 1

0 0 0 0 0 0 0 0 0 0 0 0 1

0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 2
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0

0
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 13
0 0 0 0 0 0 0