APQP

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1 Sourcing Decision
2 Customer Input Requirements
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3 Design FMEA
4 Design Reviews
5 Design Verification Plan
6 Sub-Contractor APQP Status
7 Facilities, Toolings & Gauges
8 Prototype Build Control Plan
9 Prototype Builds
10 Drawings & Specifications
11 Team Feasibility Commitment
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12 Manufacturing Flow chart
13 Process FMEA
14 Measurement System Evaluation
15 Pre-Launch Control Plan
16 Operator Process Instructions
17 Packaging specifications
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18 Production Trial Run
19 Production Control Plan
20 Preliminary Process Capability Study
21 Production Validation Testing
22 PPAP
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23 PSW Part Delivery
SPICER INDIA QF/TSG/003,
3-4-14441-1 - TURNER ENDYOKE DEVELOPMENT PLAN Date:01/02-4-2004
LIMITED -JODALLI
Part Description : END YOKE Drawing Number:: 3-4-14441-1
Customer : UK DANA Revision Level:F
End Customer : TURNER POWER TRAIN SYSTEMS Revision date : 27.08.08
Status Revieved on Schedule Remarks

Sl# Activity Responsibility
01.06.09 30/4/2009 5/4/2009 05/28/09 05/29/09 05/30/09 06/01/09 06/02/09 06/03/09 06/04/09 06/05/09 06/06/09 15/06/09
Volumes PPAP Approved, Line Started for Regular supplies from Jodalli
1 KSR
End Yole Line Shifted , Facilities , Personnel and Training Completed as

Completed
Project Start
per Plan, PPAP For other customer Parts completed and 60 % of High
Completed
2 Drawing Issue Walikar
Completed
3 Project Review Meetings W-ly
Completed
4 TFC MDT
5 APQP Walikar
Completed
6 PFMEA MDT
Completed
7 PFC & Control Plan Walikar
for all PPAP Approved Parts.

8 Testing NA
Completed
9 Production Tooling Lokesh
Completed
10 Production Gauging Ezhil
Completed
11 Floor Plan Layout Varaprasad
Completed
12 Production Facilities Varaprasad
13 Bought out part submission NA
14 Part Manufacture Walikar
15 Standard Operation Sheets Walikar
16 Packaging Harish
Completed
17 Recruitment and Training KSR
18 Capability Studies Walikar

19 Part Submission Walikar
20 PPAP Approval Customer / Walikar 38

On Time
Delayed but End Result may be achieved.,Jodalli to provide more details
End Result Delayed
Indicates changes/new dates
AREAS OF CONCERN IDENTIFIED BY TURNER POWERTRAIN
Part Number : CKB 69208
Rust on all surfaces
Porosity in the casting
Scratches and marks on the Oil Seal Diameter
68 mm slinger diameter undersize
Tapped holes not parallel to each other
Dents to surfaces of End Yoke
Transport damage either @ Jodalli or during shipment to our plant
AREAS OF CONCERN FOR OTHER END YOKES

As identified on the CKB69208 End Yokes
Marks on Oil Seal Diameter
Dinks & other damage
Damage to Oil Seal Diameter End Face ( Swarf in Broaching Pot not cleaned out)
Undersize Grinding length
Oversize Threads in tapped Holes
Holes not tapped
Chatter marks on Oil Seal Diameter
Chamfers chipped
Oil Seal Diameter scored
Customer Complaints 2007 - LDEY /HDEY
Customer complaint register - 2007
NCMR Number
Sr How
Customer Part Number Complaint When Root cause Action plan
No Many
1.Replace the faulty filtering Membrane 2.Maintain water hardness below 50 TDS and
PPM below 20, Portable TDS meter to Monitor the results on daily basis 3.Existing
coolant soluble oil replace to blaser swiss lube 4.Packing By Zee rust with axxnol de
watering agent and RP oil 5.De-coolanting parts by air blow in the manifacturing
Dana 1.One of the filtering mambrane at RO plant got burst]2.Mix up of Hard
Staining On Hub process 6.Auto filtering of Rust Preventive oil at packing 7.Stop keeping packed boxes
6 Wellingboroug 42043 CKB 69208 1-19-2007 water for coolant preperation 3.Wet boxes due to water entry to the 23
Diameter at material corridor ( Avoid possibility of rain sprinkling) 8.Ensure leak proof container /
h container
Vissual check 9.Avoid wooden corner support logs 10.Introduce plastic covers
between the wooden pallets and corrigate box 11.Cover the top layer of the boxes at
container 12.Introduce the de-humidifier bags in the container 13.Dispatch parts
without protective caps 14.Stretch wrapping of the boxes
1.Replace the faulty filtering Membrane 2.Maintain water hardness below 50 TDS and
PPM below 20, Portable TDS meter to Monitor the results on daily basis 3.Existing
coolant soluble oil replace to blaser swiss lube 4.Packing By Zee rust with axxnol de
watering agent and RP oil 5.Packing By Zee rust with axxnol de watering agent and
Dana 1.One of the filtering mambrane at RO plant got burst 2.Mix up of Hard
RP oil 6.Auto filtering of Rust Preventive oil at packing 7.Stop keeping packed boxes a
7 Wellingboroug 42042 CKB 69208 Rusty & Pitting 1-19-2007 water for coolant preperation 3.Wet boxes due to water entry to the 25
material corridor ( Avoid possibility of rain sprinkling) 8.Ensure leak proof container /
h container
Vissual check 9.Avoid wooden corner support logs 10.Introduce plastic covers
between the wooden pallets and corrigate box 11.Cover the top layer of the boxes at
container 12.Introduce the de-humidifier bags in the container 13.Stretch wrapping of
the boxes
Dana 1.Chamfer diameter less in First operation. Spec : 40.0±0.20 20.

Burr on Blind 1.Setting piece will be checked by variable method ( Vernier ) 2.During process part to
9 Wellingboroug CKB 69208 10/18/2007 2.During finish turning hub face will be further reducded by 0.20mm 17
Spline area. be checked by flush pin
h 3.Deburring missed after chamfer rework.
1.Pre broach bore & OD Turning : Stool not available at work station .
Parts are kept on the Bin for checking where scratches/ Dents are
observed. (2) Dents are observed on the Half Round Diameter because
of non cleaning up of the holding locator. 2.Counter Boring Opn : Parts are
1.(A) Provide stools with rubber mat to keep the part while inspecting so as to avoid
kept on the Edge of the bins for checking the Counter bore Diameter , due
keeping on ribs of the bin .& avoid dragging of parts at turning Opn on Churchil .
to which the parts are getting Damaged on Hub Face. 3.Counter Boring
B) Remove Bins & shall implement trolleys. 2. (a) In put & Out put bins will be removed
Opn : Parts are kept on the Edge of the bins for checking the Counter bore
Dana Scratches & trolleys shall be implimented (b) Stool having rubber mat shall be provided for keeping
Diameter , due to which the parts are getting Damaged on Hub Face. 4.
13 Wellingboroug 42039 CKB 69208 Damages on Hub 1/19/2007 single part for inspection immediate after processing. (CNC 500) 3.Remove Bins & 73
Opn : Nib milling , Drilling & Tapping M/C Hass : : Cleaning of the locator
h Face & on Radius . provide Trolleys & Stool of keeping & checking the processed part.(ODIN Broaching
after machining was improper Chips remained at the bottom face of the
M/C) 4.Awarness to be given to OE'S regarding cleaning of locator . 5.Rubber sheet
locator. 5.Parts received for deburring are deburred on the table which is
shall be provided on deburring table 6.Rubber sheet / Thick plastic sheet to be
of metal sheet , metal to metal contact occures during deburring &
provided on Final inspection table
scratches are formed on the hub face. 6.At final inspection parts are
inspected on the table which is with metal sheet , parts are dragged during
inspection due to which dents , damages, scratches occurs because of
metal to metal contact.
Parts are kept on the Bin for checking where scratches/ Dents are
observed. (2) Dents are observed on the Half Round Diameter because 1.(A) Provide stools with rubber mat to keep the part while inspecting so as to avoid
of non cleaning up of the holding locator. 2.Counter Boring Opn : Parts arekeeping on ribs of the bin .& avoid dragging of parts at turning Opn on Churchil .
kept on the Edge of the bins for checking the Counter bore Diameter , dueB) Remove Bins & shall implement trolleys. 2. (a) In put & Out put bins will be removed
Dana to which the parts are getting Damaged on Hub Face. 3.Parts kept in bins trolleys shall be implimented (b) Stool having rubber mat shall be provided for keeping
Hub Dia Chamfer
14 Wellingboroug 42041 CKB 69208 1/19/2007 at Broaching Stage , Stool not available at Broaching M/C to check the single part for inspection immediate after processing. (CNC 500) 3.Remove Bins & 18
Chipped
h operation completed part.Parts are checked on the M/C Table where provide Trolleys & Stool of keeping & checking the processed part.(ODIN Broaching
dinks are observed, 4.Opn : Nib milling , Drilling & Tapping M/C Hass : : M/C) 4.Awarness to be given to OE'S regarding cleaning of locator . 5.Rubber sheet
Cleaning of the locator after machining was improper Chips remained at shall be provided on deburring table 6.Rubber sheet / Thick plastic sheet to be
the bottom face of the locator. 5.Parts received for deburring are deburred provided on Final inspection table
on the table which is of metal sheet , metal to metal contact occures
during deburring & scratches are formed on the hub face. 6.At final
inspection parts are inspected on the table which is with metal sheet ,
parts are dragged during inspection due to which dents , damages,
scratches occurs because of metal to metal contact.
Parts are kept on the Bin for checking where scratches/ Dents are 1.(A) Provide stools with rubber mat to keep the part while inspecting so as to avoid
observed. (2) Dents are observed on the Half Round Diameter because keeping on ribs of the bin .& avoid dragging of parts at turning Opn on Churchil .
of non cleaning up of the holding locator. 2.Counter Boring Opn : Parts areB) Remove Bins & shall implement trolleys. 2. (a) In put & Out put bins will be removed
Dana kept on the Edge of the bins for checking the Counter bore Diameter , duetrolleys shall be implimented (b) Stool having rubber mat shall be provided for keeping
Pin Hole Damage
15 Wellingboroug 42043 CKB 69208 1/19/2007 to which the parts are getting Damaged on Hub Face. 3.Parts kept in bins single part for inspection immediate after processing. (CNC 500) 3.Remove Bins & 23
on Hub Diameter at Broaching Stage , Stool not available at Broaching M/C to check the
h provide Trolleys & Stool of keeping & checking the processed part.(ODIN Broaching
operation completed part.Parts are checked on the M/C Table where M/C) 4.Awarness to be given to OE'S regarding cleaning of locator . 5.Rubber sheet
dinks are observed, 4. Opn : Nib milling , Drilling & Tapping M/C Hass : : shall be provided on deburring table 6.Rubber sheet / Thick plastic sheet to be
Cleaning of the locator after machining was improper Chips remained at provided on Final inspection table
the bottom face of the locator. 5.Parts received for deburring are deburred
on the table which is of metal sheet , metal to metal conta occures during
deburring & scratches are formed on the hub face. 6.At final inspection
parts are inspected on the table which is with metal sheet , parts are
dragged during inspection due to which dents , damages, scratches
occurs because of metal to metal contact.
Dana 1.Chamfer diameter less in First operation. Spec : 40.0±0.20 2.During

Burr on Spline
16 Wellingboroug 42872 CKB 69208 29-03-2007 finish turning hub face will be further reducded by 0.20mm 3.Deburring 1.Setting piece will be checked by variable method ( Vernier ) 223
entry.
h missed after chamfer rework.
DM WATER & CUTTING OIL MONITORING FLOW.
Input From Supplier Container
Sealed Plastic Barrels
200lts capacity
Incoming Inspection Parameters checked Spec Maintained Frequency

By Maintenance personnel TDS 0-40 Daily
PH 6.9/7.2
Every New supply before
Chloride 10-30ppm
pumping to Tank
Incoming Inspection by Haritha Hardness 0-10ppm
Personnel Concentration As per below spec Daily
Approved DM Water Pumped to

Sintex.
DM Water 100% PVC Line
PVC Pipeline
DM Water collection point.
Coolant oil mixing and maintaining Operation Maintained Spec. Frequency

concentration. Surface Broach 8-10 Daily
Turning 4-6 Daily
Counter Boring 4-6 Daily
Drilling & Tapping 4-6 Daily
Spline Broaching 6-8 Daily
Nib Milling Dry cutting Daily
Grinding 4-5 Daily
Concentration inspection by Frequency

maintenance personnel everyday Daily
and Top up if low.
Concentration checked by Harita NTI

Frequency
Daily
THINGS GONE WRONG / LESSONS LEART - AT HOSUR PPAP LOT
3-4-14441-1 - CATTERPILLAR (End Yoke)
Things Gone Long Term Corrective Action (LTCA)a Status (Revieved on

Opearation Date / ShWrong Root Cause Immediate Corrective Action (LTCA) rget Resp :27.08.08…….)
Reject the lot at incomming stage

and send back to supplier, Insit
supplier to cover the material and Nagaraj
Raw material 10.06.08 Rust in raw material Received rust from supplier Shot plasting done at our end carrying vehicle. Next Lot a
All 1410 Half round Completed , PPAP Lot

broach has radius PPAP approved by
which is not in CKB Radius is made and approved To submit PPAP with Radius and Approva customer.radius is already
Drawing. by dana for better strength To do with Radius get approval from customer. l Venkat incorporated in CP.
Incorporate in control plan to

maintain syemtry within 0.5 and
wallthichness with in 0.8/1.0mm
Did cavity wise seggregation and also add note symety and
maintained symetry with in 0.5to wallthickess as mention if not part
maintain residual unbalanvce and will reject i if unbalance is more Will be incorporated for
Wall thickness 1.00 Symetry and wall thichness also wall thickness with in .8 to than 20grs,as wee should not do CKB only for all endyokes
Surface broaching12.06.08 to 1.2 mm variation 1.0mm. linishing as per drawing. 1 .06.08 Rajan after trails.
Make specific bunck locator for

CKB and add in PCP in locating
diagram view, as part not to be
liniched, need to maintain witin
20grms , part need to be rejected
if unbalance is more than 20grs,
add the above note in Control plan
Residual unbalance and add unbalance parameter
more observed Bunck locator not locating Corrected the bunk ocator and 15grs in turning and checking
maximum side proper checked residual unbalance frequency 1/50part. 18.06.08 Venkat
Dent scratch ON Add additional note for material

Hub face and Step Communicated OE's again on the handling to avaide dent scratch
Turning 16.06.08 OD's Improper handling of parts stingent requirement of customer, .Make respect to product to CKB
APQP Output not incorporated in
Counter boring as controp plan (part need to be Add part to be located in prebroach and
normal practice trying counterbored locating prebroach hold with collet in PCP. And add note
Counter Boring 17.06.08 to do in jaws and holding with collet. Held in collet and produced Hold in collet. 18.06.08 Rajan
Prebroach Locator over Kept oversize as per PCP as broach
Drilling Tapping 17.06.08 size was not received Pre broach Diametre ground to size Not requied
Add in control plan to maintain
Spline broaching 17.06.08 Orientation more Orientation not require in drawins. Orientation corrected and produced orientation with in ±2.g. 17.06.08 Rajan
Ra assumed regular Spec is in tabular colum and regular Add in control plan a big note as 0.4
Grinding 23.06.08 0.5 and min not mentioned in drawing Maintaine as per dna 0.25min. max and 0.25min. 23.6.08 Rajan
Improper Handling and customer
Dent scratch on Hub stingent requirement not Rework done were possible and rejected Make special note in control plan top in
Final Inspection face and Step OD comunicated visual were dent is more bold letters 23.06.08 Rajan
Note : Incorporate all Long term actions into FMEA.

FEASIBILITY LISTING FOR MANUFACTURING & INSPECTION
Dated : 30/05/2009 Part No. : 3-4-14441-1 Description : End yoke
MDT Members present : K.Satishwar Reddy, Satyendra Hussain Walikar, Ezhil, Subramaniam, Nagaraja
Feasible
Lay out Sl. Proposed with
Parameter Specification Suggested Machine Suitable Checking Method Remarks
No. Operation- Existing
Resources
1 Perpendicularity 0.13 40-1 CNC Turning Centre Bench centre Yes
2 Length 41+/-0.5 40-1 CNC Turning Centre Height gauge Yes
3 Perpendicularity 0.13 60 Vertical broaching Bench centre Yes
4 Surface Finish 1.6 30 CNC Turning Centre Comparator specimen Yes
5 Length 13 90 Grinding Machine Vernier Yes
6 Radius R1 30 CNC Turning Centre Profile Projector Yes
7 Radius R2 30 CNC Turning Centre Profile Projector Yes
8 Lead Nil 90 Grinding Machine Lead Tester Yes
9 Concentricty 0.15 30 CNC Turning Centre Symmetry Gauge Yes
10 Step Diameter 68.00 / 67.95 30 CNC Turning Centre Snap Gauge Yes
11 Surface Finish No spec 30 CNC Turning Centre Comparator specimen Yes
12 Slinger Diameter 61+/-0.5 30 CNC Turning Centre Snap Gauge Yes
13 Hub Diameter 48.00 / 47.84 90 Grinding Machine OD Comparator Yes
14 Surface Finish 0.25 -0.5 90 Grinding Machine Surface Roughness Tester Yes
15 Chamfer Dia 39.12 30 CNC Turning Centre Profile Projector Yes
16 Angle 30 deg 30 CNC Turning Centre Profile Projector Yes
17 Chamfer Angle 20 deg 30 CNC Turning Centre Profile Projector Yes
18 Removal of Sharp Edges 30 CNC Turning Centre Profile Projector Yes
19 Chamfer Length 2 30 CNC Turning Centre Profile Projector Yes
20 Chamfer 0.5 x 45 deg 30 CNC Turning Centre Profile Projector Yes
21 Concentricty 0.05 90 Grinding Machine Bench centre Yes
22 Chamfer Angle 30 deg 30 CNC Turning Centre Profile Projector Yes
23 Chamfer Length 1 30 CNC Turning Centre Profile Projector Yes
24 Length 15 30 CNC Turning Centre Vernier Yes
27 Total Length 89 30 CNC Turning Centre Height gauge Yes
28 Radius R 0.5 Max 40-1 CNC Turning Centre Profile Projector Yes
29 Radius R 0.13 / 0.25 40-1 CNC Turning Centre Profile Projector Yes
30 C'Bore Depth 5.5 40-1 CNC Turning Centre Vernier Yes
31 Surface Finish No spec 40-1 CNC Turning Centre Comparator specimen Yes
32 C'Bore Dia 39.7/39.6 40-1 CNC Turning Centre Plug Gauge Yes
33 Concentricty 0.05 40-1 CNC Turning Centre Bench centre Yes
34 Stamp 69208 Stamping Machine Visual Yes
35 Radius R 1.57 Max 40-1 CNC Turning Centre Profile Projector Yes
36 C'Bore Dia 60 40-1 CNC Turning Centre Plug Gauge Yes
37 Nib Distance 106.248/106.286 80 Burke Mill Nib Distance Gauge Yes
38 Drill & Tap 5/16"-24 UNF 40-2 Vertical Machining Cen Drill Hole & Thread Plug GauYes
39 Swing Dia 125.5 40-1 CNC Turning Centre Vernier Yes
40 Hole Position : X 45.7 40-2 Vertical Machining Cen Receiver Gauge Yes
41 Hole Position : Y 95.2 40-2 Vertical Machining Cen Receiver Gauge Yes
42 Half Round Dia 30.157/30.188 20 Tunnel Broaching MachHR Plug Gauge Yes
43 Center Height 0.8 20 Tunnel Broaching MachCentre Height Gauge Yes
44 Splines 1.528-23-I-3J 60 Vertical Spline Broach Spline Plug Gauge Yes
45 Raw material hardness 235 /293 BHN
SPICER INDIA LIMITED -JODALLI
FMEA NUMBER : EY/C/020 Issue # :00
POTENTIAL FAILURE MODE EFFECTS ANALYSIS (PROCESS FMEA)
ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PREPARED BY : VENKAT.K
MODEL YEAR (S) / VEHICLE(S) : 1310,1350,1410,1480 & 1550
FMEA DATE(ORIG): 25/8/2003 REV:01/05.08.200
CORE TEAM : SATISHWAR REDDY (PM),WALIKAR(TSG),SAVEENDRA RAJU(QA),SAKKARAVARTHI(MAINT),NAGARAJA.(MATLS),LOKESH(TOOLING),ANJINEYA(PR
KEY DATE :25/8/2003
PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSEBILITY ACTION RESULTS

FUNCTION / FAILURE EFFECT(S) E L CAUSE(S) / C CURRENT CONTROL E P ACTION(S) & TARGET ACTIONS S O D R
REQUIREMENTS MODE OF FAILURE V A MECHANISM(S) OF C T N COMPLETION TAKEN E C E P
S FAILURE U E DATE V C T N
PREVENTION DETECTION
S R C
10
RAW MATERIAL 1. CASTING CRACKS/ ENDANGERS OPERATOR 9 MATERIAL/PROCESS 6 (D)SAMPLE INSPECTION AS PER 2 108
INSPECTION DEEP BLOW HOLES FIELD FAILURE, REDUCE THE AT SUPPLIERS' END NONE AT PRESENT CONTROL PLAN NONE AT PRESENT
(TO CONFIRM THE LIFE PERFORMANCE & CUSTOMER
QUALITY OF DIS-SATISFACTION
INPUT MATL) 2. DIMENSIONS NOT UNCLEAN AFTER MACHINING
AS PER DRAWINGS IN THE UNBALANCE 6 PATTERN NOT DESIGNED PROPERLY 3 NONE AT PRESENT (D)SAME AS ABOVE 2 36 NONE AT PRESENT
CASE OF RIB,CAVITY LESS ASSBLY PROBLEM
2.1. LUG DIMENSION UNCLEAN IN LUG TOP AFTER 5 PATTERN OVER USED 4 NONE AT PRESENT (D)SAME AS ABOVE 2 40 NONE AT PRESENT
UNDERSIZE MACHINING RE SINKING OF DIE
2.2. LUG DIMENSION SURFACE BROACH 6 PATTERN DIMENSION NOT 3 NONE AT PRESENT (D)SAME AS ABOVE 3 36 NONE AT PRESENT
OVERSIZE BREAKAGE DUE TO MAINTAINED AS PER
HEAVY LOAD DIMENSION
3. HALF ROUND SIZE UNCLEAN ON HALF ROUND AREA 5 SAME AS ABOVE 3 NONE AT PRESENT (D)SAME AS ABOVE 3 45 NONE AT PRESENT
OVER SIZE AFTER MACHINING
3.1 UNDER SIZE BROACH BREAKAGE OR TOOL 6 PATTERN OVER USED 2 NONE AT PRESENT (D)SAME AS ABOVE 3 36 NONE AT PRESENT
WEAR (TOOLING COST INCREASE) LIFE COMPLETED
3.2. MISMATCH UNBALANCE & MORE LOAD 6 ALIGNMENT OF PATTERN 3 NONE AT PRESENT (D)SAME AS ABOVE 2 36 NONE AT PRESENT
ON SURFACE BROACHING
4.DIMENSION NOT AS PER
PRINT OVER SIZE IN OD & NONE AT PRESENT
OTHER MACHINING AREAS. MORE LOAD ON NEXT 5 PATTERN OVER USED 3 (D)SAME AS ABOVE 2 30 NONE AT PRESENT
OPERATION
STEP GENERATED IN THE 5 PATTERN OVER USED 3 NONE AT PRESENT (D)SAME AS ABOVE 3 45 NONE AT PRESENT
CAVITY DURING NIB GROOVING RE SINKING OF PATTERN
4.1 DRILL HOLE(CORE) SHIFT
MORE LOAD ON NEXT 5 PATTERN OVER USED 3 NONE AT PRESENT (D)SAME AS ABOVE 2 30 NONE AT PRESENT
OPERATION
5.METALURGICAL FIELD FAILURE 7 CHEMISTRY, MICROSTRUCTURE 2 NONE AT PRESENT (D)EVERY HEAT CHECKED 3 42 NONE AT PRESENT
& MIX UP OF STEEL IN STEEL MILL & VERIFIED
NO PROPER HEATTREATMENT. 7 HEAT TREATMENT 2 NONE AT PRESENT DO- 3 42 NONE AT PRESENT
HEAT TREATMENT PROBLEM

6. MORE HARDNESS FIELD FAILURE 7 OR QUENCH MEDIUN NOT 2 NONE AT PRESENT (D)SAME AS ABOVE 3 42 NONE AT PRESENT
TOOL WEAR MORE / BREAKAGE SELECTED
7. IMPROPER FETTLING IMPROPER CLAMPING OF THE 5 OPERATOR ERROR IN FLASH 2 NONE AT PRESENT (D)SAME AS ABOVE 3 30 NONE AT PRESENT
(FLASH REMOVAL) COMPONENT REMOVAL & PATTERN OVER USED
8.IMPROPER HEAT TRACEABILITY 5 PATTERN WEAR 3 NONE AT PRESENT (D)SAME AS ABOVE 3 45 NONE AT PRESENT
(PART) IDENTIFICATION VARIATION IN CASE DEPTH
IN INDUCTION HARDENING
Note: If any problem has been found (which is addressed above or new problem) during inward inspection (Sample inspection-as per quality plan or control plan) Supplier will be intimated immediately correction will be implemented as preventive action, the same time defected components also been
segregated,rejected and send back to supplier.

CORE TEAM : SATISHWAR REDDY (PM),WALIKAR(TSG),SAVEENDRA RAJU(QA),SAKKARAVARTHI(MAINT),NAGARAJA.(MATLS),LOKESH(TOOLING),ANJINEYA(PROD)
KEY DATE :25/8/2003
PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

FUNCTION / FAILURE EFFECT(S) E L CAUSE(S) / C CURRENT CONTROLS E P ACTION(S) & TARGET ACTIONS S O D R
REQUIREMENTS MODE OF FAILURE V A MECHANISM(S) OF C T N COMPLETION DATE TAKEN E C E P
S FAILURE U E V C T N
S R C
10-1 ►MARKING NOT VISIBLE ►DIFFICULT FOR CUSTOMER TO ►NOT ADJUSTED THE STROKE ►MARKING ON FIXTURE. ►OE ►INSPECTION AS PER FREQUENCY ►MAKE NEW FIXTURE FOR MARKING VENKAT / 30.8.08
IDENTIFY THE PART NUMBER PROPERLY.►WI NOT FOLLOWED TRAINING. INPROCESS ►100% INSPECTION IN
PART MARKING ►CUSTOMER DISSATISFACTION 4 4 FINAL 4 64 4 1 4 16
(PART IDENTIFICATION)
►MARKING LETTER HEIGHT

LESS. 4 1 4 16 4 1 4 16
►WRONG PART NUMBER ►CUSTOMER DISSATISFACTION ►WRONGLY MENTIONED IN ►CONTROLLED PROGRAM ►INSPECTION AS PER FREQUENCY NONE AT PRESENT
MARKED ON PART CONTROL PLAN►WRONG PROGRAM NUMBER AND PASSWORD LOCK IN PROCESS ►100% INSPECTION IN
USED►OE NOT FOLLOWED WORK FINAL
4 1 4 16 4 1 4 16
INSTRUCTION
►LETTER / NUMBER MISSING ►CUSTOMER DISSATISFACTION ►WRONGLY ENTERED IN PROGRAM NONE AT PRESENT
►NOT LOCATED COMPONENT
4 PROPERLY ONE OR TWO DIGITS NOT 2 4 32 4 2 4 32
ETCHING.►WORK INSTRUCTION NOT
FOLLOWED.
►PART MARKING DONE IN ►CUSTOMER DISSATISFACTION ►WI NOT FOLLOWED ►WORK INSTRUCTION►OE ►INSPECTION AS PER FREQUENCY
WRONG PLACE / INVISIBLE TRAINING. INPROCESS ►100% INSPECTION IN
PLACE. 4 1 FINAL 4 16 4 1 4 16
►MARKING MISSING. ►CUSTOMER DISSATISFACTION ►NOT LOADED PART PROPERLY IN ►INSPECTION AS PER FREQUENCY ►MAKE NEW FIXTURE FOR MARKING VENKAT / 30.8.08
FIXTURE►WI NOT FOLLOWED. INPROCESS ►100% INSPECTION IN
4 2 FINAL 4 32 4 1 4 16
ACTIONS TO BE TAKEN IF THE RPN IS > OR =80 OR FOR ONE HIGHEST RPN & FOR ANY CUSTOMER COMPLAINTS

KEY DATE :25/8/2003

S R C
20 HALF ROUND OVERSIZE. ►LOOSE FITMENT OF BEARING ►CUTTING PARAMETERS AND TOOL SETTING ►CUTTING SPEED ►MATERIAL REMOVAL IN ►SETUP/FIRST PIECE INSPECTION. 1.) INCORPORATE ALL BELOW PROCESS PARAMETERS IN LOKESH
SURFACE BROACHING CUP.►PREMATURE FAILURE OF PARAMETERS NOT TO SPECIFICATION►BROACH HALF ROUNDH►HALF ROUND FORM AND ►SAMPLE INSPECTION CONTROL PLAN WITH SPECIFICATION AND CHECKING 03.03.2009
(FOR ASSEMBLY OF UJ CROSS & ENDYOKE.►POSITION SIZE IS NOT TO SPECIFICATION►BROACH STOCK IN ROUGH MAGAZINE. ►COOLANT INPROCESS ►100 % NO GO METHOD ►FINISH SUB MAGAZINE ALIGNMENT SPEC AND
Kit) VARIATION.►POSITION ACCURACY NOMENCLATURE NOT TO CONCENTRATION ►ALIGNMENT OF FINISH .FINAL. THROUGH PLUG GAUGE METHOD WITH APPROVED DRAWING.►STOCK FOR FINISH
PROBLEM IN ALL OTHER SUBSEQUENT 4 <SC> SPECIFICATION.►BROACH SHARPENING WI NOT 4 BROACH ►BROACH TRACKING & (MONTHLY PROCESS 5 80 BROACH AND ROUGH MAGAZINE SETTING METHOD WITH 4 2 5 40
OPERATIONS WHERE HALF ROUND FOLLOWED. ►BROACH CHANGE FREQUENCY NOT RESHARPENING FREQUENCY ►CHECKING STABILITY MONITORED DRAWING AND WI ADD COOLANT PUMP PRESSURE IN
LOCATION IS TAKEN FOR MACHINING. FOLLOWED. ►BURR ON BROACH BROACH SIZE INCOMMING& AFTER THROUGH NP CHART) MAINTENANCE CHECK LIST . ►PUT OK NOT OK FLOW OF
AFTER RESHARPENING. RESHARPENING. .►BROACH COOLANT WITH PHOTOS FOR FINISH TOOL. ► ADD
RESHARPENING WI & CLEANING OF BROACH CLEANING OF BROACH WITH WIRE BRUSH IN BROACH
AFTER RESHARPENING WITH WIRE GRINDING METHOD WORK INSTRUCTION 2.)►BROACH
BRUSH.►COOLANT PRESSURE ON PUMP SIZE IDENTIFICATION WITH DIFFERENT SIZES
►IMPROPER FITTING OF CROSS GAUGE►COOLANT FLOW FROM OUTPUT OF INCREMENTAL.3.)GET THE FINISH BROACH INSPECTION
►CUTTING PARAMETERS AND TOOL SETTING PIPE ON FINISH HALF ROUND REPORT FROM SUPPLIER AND INSPECT SIZE DURING
CHANCES OF GAP BETWEEN END
PARAMETERS NOT TO SPECIFICATION►BROACH BROACH.►SUBMAGAZINE BOSTER SETTING , INCOMING AND MAINTAIN REPORTD4.)ADD COOLANT
YOKE & CROSS HOLE AND BEARING
SIZE IS NOT TO SPECIFICATION►BROACH STOCK FOR FINISH HALF ROUND.►TRAINING ►100% INSPECTION THRU CONCENTRATION SPEC ALONG WITH PROCESS
CUP ►CHANCES OF CROSS COMING
NOMENCLATURE NOT TO FOR OE ON ALL PROCESS CONTROL PLUG GAGE ON PARAMETER IN CONTROL PLAN.5.) TRAINING FOR OE ON
OUT. ►PREMATURE FAILURE DUE TO
HALF ROUND SIZE LESS.
MORE FRICTION. AS FITMENT WILL BE
4 <SC> SPECIFICATION.►BROACH SHARPENING WI NOT 6 SPECIFICATIONS, SETTING & INSPECTION MACHINE(MONTHLY PROCESS 5 120 ALL PROCESS CONTROL SPECIFICATIONS, SETTING & 4 4 5 80
FOLLOWED. ►BROACH CHANGE FREQUENCY NOT METHODS FOR PROCESS PARAMETERS. STABILITY MONITORED INSPECTION METHODS FOR PROCESS
TIGHT.►POSITION ACCURACY
FOLLOWED. ►BURR ON BROACH THROUGH NP CHART) PARAMETERS..►LOWER SIZE BROACHES NOT TO BE USED.
PROBLEM IN ALL OTHER SUBSEQUENT
AFTER RESHARPENING..►COOLANT .►RAW MATERIAL WISE BROACHES IDENIFIED.
OPERATIONS WHERE HALF ROUND
CONCENTRATION NOT OK ►MORE STOCK.
LOCATION IS TAKEN FOR MACHINING.
NIB HEIGHT LESS. ►CUTTER BREAKAGE DURING NIB ►SUBMAGAZINE BOSTER SETTING NOT DONE TO ►SUBMAGAZINE BOSTER SETTING.AS PER ►SETUP/FIRST PIECE & ►REVIEW AND UPDATE ROUGH MAGAZINE SETTING WALIKAR & PERUMAL /
GROOVING. SPECIFICATION DRAWING AND WORK INSTRUCTION INPROCESS SAMPLING METHOD WITH DRAWING AND WI . 20.08.08
2 1 INSPECTION..
3 6 2 1 3 6
NIB HEIGHT MORE. ►CONTACT AREA FOR BEARING CUP

LES CHANCES OF BEARING CUP
COMING OUT.. 5 1 4 20 5 1 4 20
►REDUCED LEVEL OF
PERFORMANCE.
HALF ROUND CL HEIGHT ►POSITION VARIATION. ►SUB MAGAZINE & FINISH MAGAZINE SETTING ►SUBMAGAZINE BOSTER & F FINISH ►SETUP/FIRST PIECE & ►REVIEW AND UPDATE ROUGH MAGAZINE & FINISH WALIKAR & PERUMAL /
MORE. ►BEARING CUP FITMENT PROBLEM. NOT SET TO SPECIFICATION. MAGAZINE SETTING AS PER DRAWING AND INPROCESS SAMPLING MAGAZINE SETTING METHOD WITH DRAWING AND WI . 20.08.08
►FAILURE OF ASSEMBLY. WORK INSTRUCTION INSPECTION..
►CUSTOMER
DISSATISFACTION.►POSITION
5 CP 2 4 40 5 1 4 20
ACCURACY PROBLEM IN ALL OTHER
HALF ROUND CL HEIGHT ►POSITION VARIATION.

LESS. ►BEARING CUP FITMENT PROBLEM.
►SYMMETRY & FACE OUT MORE.
►BALANCING OF PART DIFFICULT 5 CP 2 4 40 5 1 4 20
►STRAP ASSEMBLY NOT POSSIBLE
►CUSTOMER DISSATISFACTION.
CHAMFER MORE ►REDUCE CONTACT AREA FOR HALF ►SUB MAGAZINE & FINISH MAGAZINE SETTING ►SUBMAGAZINE BOSTER SETTING.AS PER ►SETUP/FIRST PIECE & ►REVIEW AND UPDATE ROUGH MAGAZINE SETTING WALIKAR & PERUMAL /
ROUND 5 NOT SET TO SPECIFICATION. 3 DRAWING AND WORK INSTRUCTION INPROCESS SAMPLING 4 60 METHOD WITH DRAWING AND WI . 20.08.08 5 1 4 20
INSPECTION..
CHAMFER LESS ►BEARING CUP ENTRY PROBLEM.
►INCONVENIENCE DURING
ASSEMBLY OF MATING PART.
POSITION ACCURACY PROBLEM IN
5 2 4 40 5 1 4 20
ALL OTHER OPERATIONS WHERE
HALF ROUND LOCATION IS TAKEN
FOR MACHINING.
DAMAGE IN ►CLAMPING PROBLEM AT NEXT ►INPROCESS MATERIAL HANDLING.►UNLOADING ►OE TRAINING►UNLOADING AREA RUBBER ►SETUP/FIRST PIECE & ADD IN WORK INSTRUCTION FOR USE OF RUBBER PAD OR WALIKAR & PERUMAL /
LUG/HALF ROUND/CHAMFER OPERATION AREA RUBBER PAD DAMAGE PAD. INPROCESS SAMPLING ADD GI WITH PHOTOS. 20.08.08
AREAS ►INCONVENIENCE DURING INSPECTION.. ►VISUAL
ASSEMBLY OF MATING PART. INSPECTION
►NO DISCERNABLE
EFFECT.►POSITION ACCURACY
3 3 7 63 3 2 7 42
PROBLEM IN ALL OTHER SUBSEQUENT
CO PLANARITY MORE ►CREATES PROBLEM IN TURNING ►MORE STOCK ON FACE / MATERIAL REMOVING ►SUBMAGAZINE BOSTER & F FINISH ►SETUP/FIRST PIECE & ►REVIEW AND UPDATE ROUGH MAGAZINE SETTING WALIKAR & PERUMAL /
SYMMETRY CANNOT BE (DEPTH OF CUT IS MORE) SUB MAGAZINE & FINISH MAGAZINE SETTING AS PER DRAWING AND INPROCESS SAMPLING METHOD WITH DRAWING AND WI .►PUT OK NOT OK 20.08.08
MAINTAINED.►LEADS TO MORE OUT MAGAZINE SETTING NOT SET TO WORKINSTRUCTION.►CUTTING INSPECTION.. FLOW OF COOLANT WITH PHOTOS FOR FINISH TOOL
IN TURNING WHICH WILL CAUSE 2 SPECIFICATION.►COMPONENT NOT CLAMPED 2 SPEED.►COOLANT 3 12 2 1 6 12
MORE IMBALANCE►TOTAL LENGTH FIRMLY VIBRATING DURING CUTTING. CONCENTRATION►O.E.TRAINING.
VARIATION & PERPENDICULARITY
PROBLEM IN TURNING.
THIN WALL THICKNESS ►REDUCED STRENGTH OF END ►FIXTURE SETTING WI NOT FOLLOWED.►FALLING ►O.E.TRAINING.►FIXTURE SETTING ,WALL ►SETUP/FIRST PIECE INSPECTION ►IMLEMENT EFFECTIVELY POKAYOKE FOR SADDLE COMPLETED
YOKE. ►REDUCED LEVEL OF OF OFFSET SETTING SHIMS►POKA YOKE FAILURE THICKNESS & SYMMETRY SETTING ►IN PROCESS SHIFT►DEVELOP LOCAL RAW WITH MORE
PERFORMANCE. TO DETECT THE SHIFT►CASTING DEFECT FROM WI.►POKAYOKE FOR SADDLE SHIFT►LOCAL INSPECTION.►GOOD & BAD STOCK►DISPLAY GOOD & BAD PARTS
5 SUPPLIER MORE RAW MISMATCH 3 RAW DEVELOPED WITH MORE STOCK PARTS DISPLAY. 4 60 5 1 4 20
SYMMETRY MORE ►MASS SHIFT IN TURNING WRT HALF ►REVIEW THE WORK INSTRUCTION FOR SETTING WALIKAR & PERUMAL /
ROUND. ► MORE UNBALANCE PROCEDURE OF SYMETY.►CFT TO DO STUDY AND 20.08.08
ON PART. ►CREATES VIBRATION IN DECIDE ON PART NUMBERS, FOR WHICH ONLY SYMMETRY
SHAFT. ►CUSTOMER 4 1 4 16 TO BE MAINTAINED AND FOR PART NUMBERS WHICH 4 1 4 16
DISSATISFACTION.►PREMATURE ONLY WALL THICKNESS NEED TO BE MAINTAINED ( IF
FAILURE. ONLY WALL THICKNESS THEN NEED TO CONSIDER
BALANCING SPEC)
HR FINISH NOT OK/RUBBING ►CONTACT AREA OF BEARING CUP. ►CUTTING PARAMETERS AND TOOL SETTING ►BROACH RESHARPENING WI & CLEANING ►SETUP/FIRST PIECE & ►REVIEW AND UPDATE ROUGH MAGAZINE & FINISH WALIKAR & PERUMAL /
►BEARING CUP WEARS FAST DUE TO PARAMETERS NOT TO SPECIFICATION ►BROACH OF BROACH AFTER RESHARPENING WITH INPROCESS SAMPLING MAGAZINE SETTING METHOD WITH DRAWING AND WI 20.08.08
ROUGHNESS AND FAILS PREMATURE. 4 NOMENCLATURE NOT TO 1 WIRE BRUSH.►COOLANT PRESSURE ON PUMP INSPECTION..100% CERTIFIED 4 16 .►PUT OK NOT OK FLOW OF COOLANT WITH PHOTOS FOR 4 1 4 16
►CUSTOMER DISSATISFACTION SPECIFICATION.►BROACH SHARPENING WI NOT GAUGE►COOLANT FLOW FROM OUTPUT OF PARTS @ FI FINISH TOOL. ► ADD CLEANING OF BROACH WITH WIRE
FOLLOWED. ►BROACH CHANGE FREQUENCY NOT PIPE ON FINISH HALF ROUND BRUSH IN BROACH GRINDING METHOD WORK
FOLLOWED. ►BURR ON BROACH BROACH.►SUBMAGAZINE BOSTER SETTING , INSTRUCTION
BURR ►CONTACT AREA OF BEARING CUP.
AFTER RESHARPENING►MATERIAL TOO SOFT / STOCK FOR FINISH HALF ROUND.
►CUSTOMER
DUCTILE TO CUT. ►COOLANT FLOW NOT ►INCOMING INSPECTION OF RAW FOR
DISSATISFACTION.►PREMATURE 4 4 HARDNESS►GOOD & BAD PHOTOS 4 64 4 2 4 16
OK►COOLANT CONCENTRATION NOT TO SPEC.
FAILURE.
DISPLAYED►CP BURR REMOVED AT SOURCE
IF OBSERVED
LUG HEIGHT UNDERSIZE ►POSITION ACCURACY PROBLEM IN ►FIXTURE SETTING WI NOT FOLLOWED.►INPUT ►O.E.TRAINING.►FIXTURE SETTING ,WALL ►SETUP/FIRST PIECE ►REVIEW FIXTURE SETTING WORK INSTRUCTION . WALIKAR & PERUMAL / 2 1 4 16
ALL OTHER SUBSEQUENT MATERIAL QUALITY NOT OK THICKNESS & SYMMETRY SETTING WI. INSPECTION 20.08.08
LOCATION IS TAKEN FOR 3 2 4 24
MACHINING.►LEADS TO MASS SHIFT
IN TURNING WRT HALF ROUND.
NICK, DENT & SCRATCH ON LUG ►PROBLEM DURING ENTRY OF UJ CROSS. ►IMPROPER MATERIAL HANDLING ► 10MM HEAVY THICKNESS POLYURETHANE ►FINAL INSPECTION ►ADD IN WORK INSTRUCTION FOR USE OF RUBBER PAD & IN WALIKAR & PERUMAL /
FACE , LUG CHAMFER, HALF ►WILL NOT SEAT PROPERLY IN ►USE OF MORE FORCE WHILE CHECKING ►ANY METAL RUBBER PAD . ►CHECKING AT REGULAR DONTS FOR NOT RUNNING THE M/C WITH OUT RUBBER PAD / 20.08.08
ROUND. & MACHINED AREA SUBSEQUENT OPERATIONS WERE HALF CONTACT►RUBBER PAD DAMAGED IN UNLOADING FREQUENCY DAMAGED RUBBER PAD.
ROUND IS TAKEN AS REFERENCE AND AREA►RUBBER PAD NOT USED. ►VISUAL INSPECTION AT
WHICH WILL CREATE PROBLEM IN 'FI'.►VISUAL INSPECTION OF OUT PUT
MAINTAINING POSITION TOLERANCES 5 3 PART TO ENSURE DENTS NOT 4 60 4 2 4 32
WRT TO HALF ROUND.► CUSTOMER CREATED DURING PROCESS
DISSATISFACTION INSPECTION AN DHANDLING.OUT PUT
VISUAL INSPECTION.
OPERATION MISSING ►NEXT OPERATION NOT POSSIBLE. 1

►ASSEMBLY NOT POSSIBLE. 1 3 3 1 1 3
FMEA NUMBER : EY/C/030-1 ISSUE #:03

FMEA DATE(ORIG): 25/8/2003 REV:03.19/03/2009
KEY DATE :25/8/2003

S R C
30-1 ►HUB OD UNDERSIZE ►UNCLEAN PATCHES AFTER GRINDING . WHICH ►WRONG TOOL OFFSET ►WRONG ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION, & ►REVIEW THE WORK INSTRUCTION ANJANEYA 02.02.2009
LEAVES SURFACE UNGROUNDED AFTER GRINDING INSERT USED (NOSE RADIUS FINISH FREQUENCY CHECKING AT REGULAR FOR INSERT CHANGE FREQUENCY ,
LEADS TO EARLY WEAR OF OIL SEAL AND OIL TOOL )►INSERT SEATING & CLAMPING ►O.E.TRAINING ►SETTING FREQUENCY OFFSET METHOD AND SPEC AFTER
LEAKAGE. NOT CORRECT►SETTING WI NOT WORK INSTRUCTION . ►CHECKING 100% RELATED INSERT CHANGE►TRAIN & REFRESH
►CUSTOMER DISSATISFACTION.►DOEST CLAMP IN FOLLOWED►INSERT CHANGE PARAMETERS AFTER INSERT OE'S WORKING ON TURNING ON
CHUCK IN COUNTER BORE AND COMPONENT COMES 6 FREQUENCY NOT FOLLOWED. ►LESS 3 INDEXING /CHANGE. 5 90 INSERT NOMENCLATURE , TOOL 6 1 5 30
OT DURING CUTTING LEADS TO TOOL/EQUIPMENT AND KNOWLEDGE ON TURNING M/C CHANGE METHOD AND TOOL
FINISH TURNING OE DAMAGE. .►CUTTING PARAMETERS NOT AS PER OFFSET.►.MAKE CONTROLLED COPY
(MATING PART STANDARDS FOR NON GRINDING PARTS OF PROGRAM AND ISSUE TO
ASSEMBLY) WERE TOLERANCE IS LOW.►SETTING PRODUCTION..► FOR DETECTION
PIECE / TAKEN OUT FROM MACHINE POKAYOKE COUNTER BORE JAWS TO B
THE FIRST PIECE AFTER INSERT MACHINED WITH MASTER RINGS TO
►HUB OD OVER SIZE ►CHANCES OF ACCIDENT IN GRINDING OPERATION Poke yoke
CHANGE WHICH IS PLUS AND GOT 0.5/0.6 PITCH IF PART IS OVER SIZE
LEADS WHEEL BREAKAGE & INJURY TO PERSON NEAR implemented on
MIXED IN OUTPUT. THAN 0.5 WILL NOT ENTER INTO THE
BY.►GRINDING WHEEL LOADS FAST AND CREATES grinding machine
CHUCK & UPDATE THE RING SPECS IN
SURFACE FINISH PROBLEM WHICH LEADS TO OIL 10 2 5 100 10 1 4 40
JAW BORING WORK INSTRUCTION IN
LEAKAGE AND OILSEAL WEAR ►LOCATES TIGHT
COUNTER BORING
DIFFICULT TO INSERT IN JAWS WHICH WILL CREATE
OPERATION.►CLAMPING STROKE
DENT/NICK ON HUB FACE .
ADDED IN W/I.►AXIS SHIFT
►SLINGER OD ►SLINGER FITMENT NOT POSSIBLE. ►LOOSE / CORRECTED IN MORISEKI
DESIGNED FIT WILL NOT BE ACHIEVED SLINGER WILL
UNDERSIZE
COME OUT.►SLINGER WILL FALL DURING
PERFORMING. LEADS ENTRY OF FOREIGN PARTICLES
AND LEADS TO PREMATURE FAILURE OF SEAL AND 6 3 5 90 6 2 5 40
PART.►CUSTOMER DISSATISFACTION.
►SLINGER OD OVER SIZE ►SLINGER ASSEMBLY NOT POSSIBLE.►FIT WILL BE

MORE THAN DESIGNED WHICH WILL LEAD TO
BREAKAGE OF SLINGER DURING PERFORMANCE AND 6 2 5 60 6 1 5 30
LEADS TO ENTRY OF FOREIGN PARTICLES WHICH
LEADS TO PREMATURE FAILURE OF SEAL AND PART.
►PREBROACH BORE OVERSIZE ►ALLOWANCE MORE IN LOCATION DATUM IN ►WRONG TOOL OFFSET ►WRONG ►INSERT INDEXING / CHANGE ►CHECKING 100% RELATED ►REVIEW THE WORK INSTRUCTION ANJANEYA & RAJAN / 20.08.08
DRILLING CREATES POSITION ACCURACY INSERT USED (NOSE RADIUS FINISH FREQUENCY PARAMETERS AFTER INSERT FOR INSERT CHANGE FREQUENCY ,
PROBLEM►ALLOWANCE MORE WRT TO PILOT DIA OF TOOL )►INSERT SEATING & CLAMPING ►O.E.TRAINING ►SETTING INDEXING /CHANGE. OFFSET METHOD AND SPEC AFTER
BROACH AND LEADS POSITION VARIATION IN SPLINE NOT CORRECT►SETTING WI NOT WORK INSTRUCTION . INSERT CHANGE►TRAIN & REFRESH
BROACHING ►. SPLINE FORMATION WILL NOT BE AS FOLLOWED►INSERT CHANGE OE'S WORKING ON TURNING ON
PER SPEC REQUIRED LEADS TO LESS CONTACT OF FREQUENCY NOT FOLLOWED. ►LESS INSERT NOMENCLATURE , TOOL
MATING PARTS FITMENT WILL NOT BE TOTAL AND 3 KNOWLEDGE ON TURNING M/C 2 4 24 CHANGE METHOD AND TOOL 3 1 4
CREATES VIBRATIONS AND WEAR OF TEETH FAST AND .►CUTTING PARAMETERS NOT AS PER OFFSET.►.MAKE CONTROLLED COPY
PREMATURE FAILURE OF PART. STANDARDS.►COOLANT FLOW AND OF PROGRAM AND ISSUE TO
PRESSURE NOT OK. PRODUCTION►ADD OK COOLANT
FLOW AND NOT OK COOLANT FLOW
PICTURES IN WI..
►PEBROACHBORE UNDER SIZE ►LEADS TO BREAKAGE OF BROACH DURING SPLINE ►INSERT INDEXING / CHANGE ►CHECKING 100% RELATED ►REVIEW THE WORK INSTRUCTION
BROACH OPERATION.►EARLY WEAR OF BROACH FREQUENCY PARAMETERS AFTER INSERT FOR INSERT CHANGE FREQUENCY ,
LEADS DIFFICULT TO MAINTAIN BROACH SPEC, ►O.E.TRAINING ►SETTING INDEXING /CHANGE.►POKAYOKE OFFSET METHOD AND SPEC AFTER
WORK INSTRUCTION . NEXT DRILLING OPERATION PRE INSERT CHANGE►TRAIN & REFRESH
BROACH LOCATOR IS MADE ONLY OESWORKING ON TURNING ON INSERT
0.05LESS IF UNDERSIZE MORE THAN NOMENCLATURE , TOOL CHANGE
0.05 WILL NOT ENTER AND METHOD AND TOOL OFFSET. ►.MAKE
10 2 FURTHER OPERATION WILL NOT BE 4 80 CONTROLLED COPY OF PROGRAM AND 10 1 4
POSSIBLE. ISSUE TO PRODUCTION►ADD OK
COOLANT FLOW AND NOT OK COOLANT
FLOW PICTURES IN WI.►ADD IN
DRILLING WI SIZE OF PRE BROACH
LOCATOR AS MAX -0.05 TO PRE BROACH
SIZE.
►SYMMETRY MORE HR ►MASS SHIFT UNBALANCE SPEC WILL BE NOT AS PER ►FIXTURE / DUMBLE NOT AS PER ►OE TRAINING ON FIXTURE ►FIRST PIECE INSPECTION & ►SINGLE PIECE DUMBLE TO BE TRIED. ANJANEYA & RAJAN / 01.02.2009
DRAWING. ►WILL BE DIFFICULT TO MAINTAIN SPLINE DRAWING ►FIXTURE SETTING NOT SETTING►FIXTURE / DUMBLE SAMPLING INSPECTION AS PER ►TRAIN & REFRESH OES WORKING ON
SYMMETRY WRT HALF ROUND IN BROACHING DONE AS PER WI►READING DIAL 1.MM SETTING. FREQUENCY. TURNING ON INSERT NOMENCLATURE
OPERATION. ► DUE TO MORE MASS SHIFT LEADS TO 5 AS 1.0 3 5 75 TOOL CHANGE METHOD AND TOOL 5 1 5 25
VIBRATION VEHICLE/REDUCED LEVEL OF OFFSET► BASE LOCATOR
PERFORMANCE. COMMONISED► SOLID DUMBELL
INSTEAD OF SPLIT ONE
►SYMMETRY MORE NIB ►MASS SHIFT UNBALANCE SPEC WILL BE NOT ►RAW MATERIAL MISMATCH / CAVITY ►BUNCK LOCATOR AS PER INPROCESS INSPECTION AS PER ►MAKE DRAWING FOR BUNCK ANJANEYA & RAJAN / 01.03.2009
SIDE AS PER DRAWING.►WILL CREATE TO LESS WALL SHIFT. ►BUNK LOCATOR NOT TO DRAWING►DEDICATED BUNK FREQUENCY & SAMPLE INSPECTION LOCATOR ►DEDICATED BUNK
THICKNESS OF NIB IN WHICH WILL SURFACE IN SPEC►BUNCK LOCATOR NOT LOCATOR FOR CKB AS THIS OF UNBALANCE WEIGHT AFTER LOCATOR FOR CKB►ADD IN WORK
NIB MILLING OPERATION AND PARTS WILL GET RELEASED AND CLAMPED WITH PART IS NOT TO BE LINISHED TURNING. INSTRUCTION AND CONTROL PLAN
6 REQUIRED STROKE AS PER WI
►NIB 3 NEED TO MAINTAIN WITH IN 5 90 6 2 5 60
REJECTED►WILL CREATE LESS WALTHICKNESS AS CKB NOT TO BE LINISHED
SYMMETRY NOT CHECKED AS PER 20GRMS.►CONTROLLED COPY
IN DRILLING AND PARTS GET REJECTED ► DUE PARTS WILL BE REJECTED IF
FREQUENCY. PROGRAM AND EDIT LOCK
TO MORE MASS SHIFT LEADS TO VIBRATION UNBALANCE IS MORE THAN
VEHICLE/REDUCED LEVEL OF PERFORMANCE. 20GRMS.►MECHANICAL STOPPER
►TOTAL LENGTH MORE ►MORE CHAMFER IN DRILLING OPERATION AND PART ►WRONG TOOL OFFSET► INSERT ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION & ►TRAIN & REFRESH OES WORKING ON ANJANEYA & RAJAN / 20.08.08
REJECTS ►CONTRIBUTES SHAFT LENGTH SEATING & CLAMPING NOT CORRECT FREQUENCY SAMPLING INSPECTION AS PER TURNING ON INSERT NOMENCLATURE
SPECIFICATION VARIATION PROBLEM. 5 ►SETTING WI NOT 2 ►O.E.TRAINING ►SETTING FREQUENCY. 5 50 TOOL CHANGE METHOD AND TOOL 5 1 5 25
FOLLOWED►SETTING PIECE / TAKEN WORK INSTRUCTION . OFFSET
►TOTAL LENGTH LESS ►LESS CHAMFER IN DRILL OPERATION ►BOLT ENTRY OUT FROM MACHINE THE FIRST PIECE
PROBLEM IN THREAD CHECKING STATION AND AFTER INSERT CHANGE WHICH IS PLUS
DAMAGES STARTING THREADS ►BOLT ASSEMBLY 5 AND GOT MIXED IN OUTPUT. 2 5 50 5 1 5 25
DIFFICULT FOR CUSTOMER MAT DAMAGE STARTING
THREADS
►GRINDING LENGTH LESS ►IF PARTS ARE WITH THIS DEFECT OBSERVED IN ►WRONG TOOL OFFSETSETTING WI ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION & ►NONE AT PRESENT
BETWEEN THE LOT ,GRINDING WHEEL WILL HIT NOT FOLLOWED►SETTING PIECE / FREQUENCY SAMPLING INSPECTION AS PER
DURING HUB DIA GRINDING OPERATION ►IF ALL TAKEN OUT FROM MACHINE THE FIRST ►O.E.TRAINING ►SETTING FREQUENCY.
PARTS ARE WITH WITH GRINDING LENGTH LESS, WILL PIECE AFTER INSERT CHANGE WHICH IS WORK INSTRUCTION .
BE DETECTED DURING MEASURING GRINDING LENGTH 6 PLUS AND GOT MIXED IN OUTPUT. 1 5 30 6 1 5 30
AND REWORK NEED TO BE DONE PARTS WILL GET
REJECTED DURING REWORK.
►GRINDING LENGTH MORE ►OIL SEAL WILL SEAT OUT LEADS TO MORE OIL ►WRONG TOOL OFFSETSETTING WI ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION & ►NONE AT PRESENT
LEAKAGE ►OIL SEAL FITMENT WILL NOT BE NOT FOLLOWED►SETTING PIECE / FREQUENCY SAMPLING INSPECTION AS PER
PROPER, ►PREMATURE FAILURE & CUSTOMER TAKEN OUT FROM MACHINE THE FIRST ►O.E.TRAINING ►SETTING FREQUENCY.
DISSATISFACTION PIECE AFTER INSERT CHANGE WHICH IS WORK INSTRUCTION .
4 PLUS AND GOT MIXED IN OUTPUT. 1 5 20 4 1 5 20
►ID/OD CONCENTRICITY ►UNCLEAN IN GRINDING OPN.►OIL SEAL LEAKAGE ►TOOL HOLDER ALIGNMENT WRT ►O.E.TRAINING ►SETTING ►FIRST PIECE INSPECTION & ►NONE AT PRESENT
3 CHUCK AXIS NOT SET 1 WORK INSTRUCTION . SAMPLING INSPECTION AS PER 4 12 3 1 4 12
FREQUENCY.
►CHAMFER MORE/LESS OR ►SLIGHT INCONVENIENCE DURING ASSEMBLY. ►IMPROPER BUTTING IN HALF ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION & ►NONE AT PRESENT
UNEVEN ROUND►WRONG OFFSET►SETTING FREQUENCY SAMPLING INSPECTION AS PER
1 PART MIXED UP. 1 ►O.E.TRAINING ►SETTING FREQUENCY. 4 4 1 1 4
WORK INSTRUCTION .
►DAMAGE ON CHAMFER & ►SEAL MAY GET DAMAGED WHILE ASSEMBLING ►IMPROPER HANDLING►WOODEN ► SINGLE PIECE FLOW. ►FINAL INSPECTION ►NONE AT PRESENT
RADIUS/DIGGING ON RADIUS ►CUSTOMER DISSATISFACTION. UNLOADING TRAY NOT USED / ►NO METAL TO METAL ►CHECKING AT REGULAR
WORN►NYLON / BRASS ENTRY BUSH CONTACT DURING HANDLING ,FREQUENCY
FOR GAUGES DAMAGED/ CAME OUT. MOVEMENT AND INSPECTION ►VISUAL INSPECTION AT
BY USING PLASTIC BINS AND 'FI'.►VISUAL INSPECTION OF INPUT
WOODEN PROTECTION PART FOR ANY DENTS FROM
4 2 PREVIOUS OPERATION AND VISUAL 5 40 4 2 5 40
INSPECTION OF OUT PUT PART TO
ENSURE DENTS NOT CREATED
DURING PROCESS INSPECTION AN
DHANDLING.OUT PUT VISUAL
INSPECTION.►
►GROVE ID U/S ►OIL SEAL OD WILL NOT SEAT AND IMPROPER ►WRONG TOOL OFFSET ►WRONG ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION & ►TRAIN & REFRESH OES WORKING ON ANJANEYA & RAJAN / 20.08.08
FITMENT WILL OCCUR►EARLY WEAR OF OIL SEAL INSERT WIDTH & RADIUS FREQUENCY SAMPLING INSPECTION AS PER TURNING ON INSERT NOMENCLATURE
DUE TO TIGHT FITMENT AND OIL LEAKAGE.
►OIL SEAL USED.►INSERT SEATING & CLAMPING ►O.E.TRAINING ►SETTING FREQUENCY. TOOL CHANGE METHOD AND TOOL
FITMENT NOT POSSIBLE IF MORE UNDERSIZE. NOT CORRECT►SETTING WI NOT WORK INSTRUCTION . OFFSET
1 1 4 4 1 1 4 4
►PREMATURE FAILURE OF OILSEAL LEADS TO FOLLOWED►INSERT CHANGE
PREMATURE FAILURE OF PART. FREQUENCY NOT FOLLOWED. ►LES
KNOWLEDGE ON TURNING M/C
►SETTING PIECE / TAKEN OUT FROM
►GROVE ID O/S ►LOOSE SEATING OF OIL SEAL WILL OCCUR.►OIL MACHINE THE FIRST PIECE AFTER ►NONE AT PRESENT
LEAKAGE DUE TO LOOSE FITMENT OF OIL INSERT CHANGE WHICH IS PLUS AND
SEAL.►PREMATURE FAILURE OF PART. 1 GOT MIXED IN OUTPUT. 1 4 4 1 1 4 4
►GROVE DEPTH U/S ►OIL SEAL WILL SEAT OUTSIDE GAP WILL BE ►NONE AT PRESENT
BETWEEN HUB FACE L AND OIL SEAL LEADS TO, OIL
LEAKAGE. ► PREMATURE FAILURE. 1 1 4 4 1 1 4 4
►GROVE DEPTH O/S ►GAP BETWEEN OIL SEAL AND GROOVE LEADS TO . ►NONE AT PRESENT
IMPROPER FITMENT► PREMATURE FAILURE.
1 1 4 4 1 1 4 4
►RADIUS IN GROOVE MORE ►IMPROPER SEATING OF OIL SEAL AND WEAR IN OIL ►NONE AT PRESENT
SEAL
1 1 4 4 1 1 4 4
►C'BORE AT SPLINE ENTRY ►FITMENT PROBLEM MAY ARISE ►WRONG TOOL OFFSET ►WRONG ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION & ►NONE AT PRESENT
NOT AS PER DRAWING (C'BORE INSERT WIDTH & RADIUS FREQUENCY SAMPLING INSPECTION AS PER
MORE/LESS) 2 USED.►INSERT SEATING & CLAMPING 2 ►O.E.TRAINING ►SETTING FREQUENCY. 4 16 2 2 4 16
NOT CORRECT►SETTING WI NOT WORK INSTRUCTION .
FOLLOWED►INSERT CHANGE
►C'BORE AT SPLINE ENTRY ►DEFECT NOTICED BY DISCRIMINATING CUSTOMERS ►NONE AT PRESENT
FREQUENCY NOT FOLLOWED. ►LESS
CHAMFER LESS / MORE
KNOWLEDGE ON TURNING M/C
►SETTING PIECE / TAKEN OUT FROM
2 MACHINE THE FIRST PIECE AFTER 2 4 16 2 1 4 8
INSERT CHANGE WHICH IS PLUS AND
GOT MIXED IN OUTPUT.
NICK,DENT & SCRATCH HUB ►CUSTOMER DISSATISFACTION ► ►IMPROPER MATERIAL HANDLING ► SINGLE PIECE FLOW. ►FINAL INSPECTION ►ENSURE SINGLE PIECE FLOW. ANJANEYA & RAJAN / 20.08.08
FACE , J26J ENTRY RADIUS.& LEEDS TO OIL LEAKAGE. ►USE OF MORE FORCE WHILE ►NO METAL TO METAL ►CHECKING AT REGULAR ►ELIMINATION METAL TO METAL
MACHINED AREA CHECKING ►ANY METAL CONTACT CONTACT DURING HANDLING ,FREQUENCY CONTACT DURING HANDLING ,
MOVEMENT AND INSPECTION ►VISUAL INSPECTION AT MOVEMENT AND INSPECTION BY
BY USING PLASTIC BINS AND 'FI'.►VISUAL INSPECTION OF INPUT PROVIDING PLASTIC BINS AND
WOODEN PROTECTION PART FOR ANY DENTS FROM WOODEN PROTECTION
PREVIOUS OPERATION AND VISUAL
5 2 5 50 5 1 5 25
INSPECTION OF OUT PUT PART TO
ENSURE DENTS NOT CREATED
DURING PROCESS INSPECTION AN
HANDLING.OUT PUT VISUAL
INSPECTION.
BURR ON BLIND SPLINE AREA ►PROBLEM IN MATING PART ASSEBBLY►CAUSE ►CHAMFER REWORK DONE AFTER ►OE AWARE NESS ► WI ►FINAL INSPECTION ►REVIEW THE REWORK PROCEDURE ANJANEYA & RAJAN / 20.08.08
MINOR INJURY FOR MATING PERSON. SPLINE BROACHING ►REWORK PROCEDURE AND ADD NOTE CHAMFER REWORK
4 2 5 40 NOT TO BE DONE AFTER SPLINE 4 2 5 40
BROACHING.

FMEA DATE(ORIG): 25/8/2003 REV:03/ 19.03.2009
KEY DATE :25/8/2003
PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

FUNCTION / FAILURE EFFECT(S) E L CAUSE(S) / C C CURRENT CONTROLS E P ACTION(S) & TARGET ACTIONS S O D R
REQUIREMENTS MODE OF FAILURE V A MECHANISM(S) OF C C T N COMPLETION DATE TAKEN E C E P
S FAILURE U U E V C T N
S R R C
040-1 ►C'BORE DIAMETER ►WASHER ASSEMBLY NOT POSSIBLE ►WRONG TOOL OFFSET ►WRONG ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION, & ►REVIEW THE WORK INSTRUCTION FOR INSERT ANJANEYA & RAJAN 20.08.8
UNDERSIZE ►CUSTOMER DISSATISFACTION. INSERT USED (NOSE RADIUS FINISH FREQUENCY CHECKING AT REGULAR CHANGE FREQUENCY , OFFSET METHOD AND SPEC
C'BORING TOOL )►INSERT SEATING & ►O.E.TRAINING ►SETTING WORK FREQUENCY AFTER INSERT CHANGE ►TRAIN & REFRESH OE'S
CLAMPING NOT CORRECT ►SETTING INSTRUCTION . ►CHECKING 100% RELATED WORKING ON TURNING ON INSERT NOMENCLATURE
WI NOT FOLLOWED►INSERT CHANGE PARAMETERS AFTER INSERT , TOOL CHANGE METHOD AND TOOL OFFSET.►.MAKE
FREQUENCY NOT FOLLOWED.►LES INDEXING /CHANGE. CONTROLLED COPY OF PROGRAM AND ISSUE TO
KNOWLEDGE ON TURNING M/C PRODUCTION..► FOR DETECTION POKAYOKE
(WASHER SEATING & .►CUTTING PARAMETERS NOT AS PER COUNTER BORE JAWS TO BE MACHINED WITH
6 1 1 4 24 6 1 4 24
STANDARDS FOR PARTS WERE MASTER RINGS TO 0.5/0.6 PITCH IF PART IS OVER SIZE
TOLERANCE IS LOW. ►SETTING THAN 0.5 WILL NOT ENTER INTO THE CHUCK &
PIECE / TAKEN OUT FROM MACHINE UPDATE THE RING SPECS IN JAW BORING WORK
THE FIRST PIECE AFTER INSERT INSTRUCTION IN COUNTER BORING
CHANGE WHICH IS PLUS AND GOT OPERATION..►UPDATE WORK INSTRUCTION FOR
MIXED IN OUTPUT. TAKING VALUES ON OD/ID SAFER SIDE TO AVOID
BEARING STRAP RETENTION) REJECTIONS & ADD NOTE NOT TO KEEP THIS SETUP
PIECE NEAR TO MACHINE AS THERE WILL BE
►C'BORE DIAMETER ►WALL THICKNESS REDUCED
CHANCES OF MIX UP.
OVERSIZE ►STRENGTH OF PART WILL BE
REDUCED ►REDUCED LEVEL OF 5 2 2 4 40 5 2 1 10
PERFORMANCE.
►SPLINE LENGTH ►LOCKNUT FITMENT PROBLEM. ►WRONG TOOL OFFSET ►WRONG ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION, & ►REVIEW THE WORK INSTRUCTION FOR INSERT LOKESH
OVER SIZE LESS ENGAGEMENT OF LOCK NUT INSERT USED (NOSE RADIUS FINISH FREQUENCY CHECKING AT REGULAR CHANGE FREQUENCY , OFFSET METHOD AND SPEC 01.01.2009
CHANCES OF NUT COMING OUT. TOOL )►INSERT SEATING & ►O.E.TRAINING ►SETTING WORK FREQUENCY & X BAR -R CHART AFTER INSERT CHANGE ►TRAIN & REFRESH OE'S
►REDUCED LEVEL OF CLAMPING NOT CORRECT ►SETTING INSTRUCTION . ►CHECKING 100% RELATED WORKING ON TURNING ON INSERT NOMENCLATURE
PERFORMANCE. WI NOT FOLLOWED►INSERT CHANGE PARAMETERS AFTER INSERT , TOOL CHANGE METHOD AND TOOL OFFSET.►.MAKE
5 <SC> FREQUENCY NOT FOLLOWED.►LES 2 2 INDEXING /CHANGE. 4 40 CONTROLLED COPY OF PROGRAM AND ISSUE TO 5 1 4 20
KNOWLEDGE ON TURNING M/C PRODUCTION..► FOR DETECTION POKAYOKE
.►CUTTING PARAMETERS NOT AS PER COUNTER BORE JAWS TO BE MACHINED WITH
STANDARDS FOR PARTS WERE MASTER RINGS TO 0.5/0.6 PITCH IF PART IS OVER SIZE
TOLERANCE IS LOW. ►SETTING THAN 0.5 WILL NOT ENTER INTO THE CHUCK &
PIECE / TAKEN OUT FROM MACHINE UPDATE THE RING SPECS IN JAW BORING WORK
►SPLINE LENGTH U/S ►REDUCED SPLINE CONTACT AREA THE FIRST PIECE AFTER INSERT INSTRUCTION IN COUNTER BORING
WITH MATING PART. ►NUT WILL CHANGE WHICH IS PLUS AND GOT OPERATION..►UPDATE WORK INSTRUCTION FOR
NOT CLAMP ON COUNTER BORE FACE MIXED IN OUTPUT. ►HEIGHT MASTER TAKING 'Z' SAFER SIDE TO AVOID REJECTIONS & ADD
WILL CLAMP ON MATING PART FACE SET WRONGLY OR READ THE DIAL NOTE NOT TO KEEP THIS SETUP PIECE NEAR TO
AND LESS TORQUE WILL BE ON READING WRONGLY. MACHINE AS THERE WILL BE CHANCES OF MIX UP.
6 <SC> 3 3 4 72 6 1 4 24
COMPONENT ►REDUCED LEVEL OF ►CUTTER PRESETTING
PERFORMANCE.
►C'BORE RADIUS ►IMPROPER WASHER SEATING AND ►WRONG TOOL NOSE RADIUS INSERT ►INSERT INDEXING / CHANGE ►FIRST PIECE INSPECTION, & ►TRAIN & REFRESH OE'S WORKING ON TURNING ON ANJANEYA & RAJAN 20.08.8
MORE TIGTENING TORQUE WILL BE USED ►SETTING WI NOT FREQUENCY CHECKING AT REGULAR INSERT NOMENCLATURE , TOOL CHANGE METHOD
UNEVEN. ►CUSTOMER FOLLOWED►INSERT CHANGE ►O.E.TRAINING ►SETTING WORK FREQUENCY AND TOOL OFFSET►REVIEW THE WORK
DISSATISFACTION. 4 FREQUENCY NOT FOLLOWED.►LES 1 1 INSTRUCTION . 4 16 INSTRUCTION FOR INSERT CHANGE FREQUENCY , 4 1 4
KNOWLEDGE ON TURNING M/C OFFSET METHOD AND SPEC AFTER INSERT CHANGE
►INSET NOSE RADIUS WRONGLY
GIVEN IN OFFSET.
NICK, DENT & ►LEADS TO OIL LEAKAGE ► ►IMPROPER MATERIAL HANDLING ► SINGLE PIECE FLOW. ►FINAL INSPECTION ►NONE AT PRESENT
SCRATCH HUB LEADS TO VARIATION IN ►USE OF MORE FORCE WHILE ►NO METAL TO METAL ►CHECKING AT REGULAR
FACE, J26J ENTRY POSITION ACCURACY IN CHECKING ►ANY METAL CONTACT DURING HANDLING , FREQUENCY
RADIUS.& MACHINED SUBSEQUENT OPERATIONS CONTACT►HITTING THE JAWS MOVEMENT AND INSPECTION ►VISUAL INSPECTION AT
AREA WERE HUB FACE IS WHILE LOADING THE PART. BY USING PLASTIC BINS AND 'FI'.►VISUAL INSPECTION OF
LOCATED.►NEED TO MAKE WOODEN PROTECTION INPUT PART FOR ANY DENTS
REWORK ON HUB FACE 4 2 2 FROM PREVIOUS OPERATION 3 24 4 2 3 24
CHANCES OF 626 J CHAMFER AND VISUAL INSPECTION OF
LESS AND SPLINE LENGTH OUT PUT PART TO ENSURE
UNDERSIZE .►REDUCED LEVEL DENTS NOT CREATED DURING
OF PERFORMANCE PROCESS INSPECTION AN
HANDLING.►OUT PUT VISUAL
INSPECTION.
BURR IN BACK OF INJURY TO ASSEMLER / BURR ►DRILL NOT CHANGED AS PER ►OE TRAINING VISUAL / DRILL CHANGE ►UPDATE WI FOR CHANGE IN RESHARENING
5 2 2 3
30
TAPPED HOLE ENTRY INTO THREADS FREQUENCY ►VISUAL FREQUENCY FREQY. CASTING 700 FORGINGS 500
►C'BORE MISSING. ►CANNOT ASSEMBLE. ►MIX UP OF COMPONENTS INPUT ►OE TRAINING ►FIRST PIECE INSPECTION,/SETUP ►NONE AT PRESENT
►CUSTOMER DISSATISFACTION. OUTPUT. & CHECKING AT REGULAR
4 1 1 FREQUENCY.► ERROR PROOFING 4 16 4 1 4 16
TO BE PROVIDED AT NIB
GROOVING OPERATION.

KEY DATE :25/8/2003

S R R C
►DRILL HOLE OVER ►THREAD FORMATION NOT PROPER►LESS THREAD ►IMPROPER DRILL SHARPENING. ►DRILL CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►CARBIDE DRILL RESHARPENING NEED TO BE DONE VENKAT / LOKESH 20.08.08
SIZE DEPTH REQUIRE FITMENT WILL NOT BE ►WRONG BASIC SIZE DRILL USED►CUTTING ►O.E.TRAINING ►SETTING WORK & ►CHECKING AT REGULAR FREQ BY SUPPLIER MAINTAIN STOCK AND ROTATE
040-2 ACHIVED.►MAY LEAD TO EARLY WEAR OF THREAD PARAMETERS NOT AS PER STANDARDS►DRILL INSTRUCTION . ►DRILL ►CHECKING RELATED ►IMPLEMENT TOOL LIFE MONITORING OPTION IN
DRILLING , COUNTER SINKING, DURING PERFORMANCE.►PREMATURE FAILURE OF CHANGE FREQUENCY NOT FOLLOWED ►EARLY RESHARPENING AS PER PARAMETERS AFTER DRILL ACE VMC's.REVIEW THE WORK INSTRUCTION FOR
STEP DIA DRILL&TAPPING. THREADS AND PART. DRILL DRILL WORE OUT DUE TO BAD QUALITY OF FREQUENCY AND DRILL ANGLE OK CHANGE FOR RESHARPENING TOOL CHANGE FREQUENCY OFFSET METHOD AND
4 DRILL ► COOLANT FLOW AND PRESSURE LESS 3 2 NOT OK IS PASTED IN FRONT OF 5 40 SPEC AFTER TOOL CHANGE.►ADD CUTTING 4 2 5 40
DRILL RESHARPENING M/C. PARAMETERS IN WI/CP/PROGRAM MATRIX.
(BEARING STRAP RETENTION)

►DRILL HOLE ►THREAD FORMATION NOT PROPER.
UNDERSIZE ►TAP DAMAGE DURING TAPPING
►TAP WILL NOT BE THROUGH 4 3 3 5 60 4 2 5 40
►DRILL HOLE NOT ►BOLT WILL BREAK DURING ASSEMBLY / ►WRONG TOOL OFFSET►DRILL DEPTH GIVEN LESS ►DRILL CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►STANDARDIZE PROGRAM PART WISE WITH MATRIX VENKAT /SANGAMESH 20.08.08
THROUGH ASSEMBLY NOT POSSIBLE►BOLT WILL NOT ENTER IN PROGRAM ►DRILL BROKEN DURING OPERATION ►O.E.TRAINING ►SETTING WORK & CHECKING AT REGULAR CONTROLLED AND CUTTING PARAMETERS IN
FULLY AND UJ CROSS WILL NOT FIT FIRMLY INSTRUCTION . FREQUENCY. MATRIX TO BE MENTIONED►PRESET THE TOOLS
CHANCES OF BREAKAGE DURINGPERFORMANCE FOR REQUIRED HEIGHT OUTSIDE TO AVOID TAKING
►TAP WILL BREAK DURING OPERATION OFFSET.TO AVOID DRILL BREAKAGE DUE TO
►WILL NOT PASS THROUGH THREAD CHECKING EXCESSIVE USE IMPLEMENT TOOL LIFE MONITORING
MACHINE WILL DAMAGE BOLT. 6 1 1 5 30 OPTION.►MAINTAIN TWO PRESET TOOLS OUTSIDE 6 1 5 30
DULY IDENTIFIED READY FOR USE TOOLING
APPROVED STICKER.
►CHAMFER LESS ►BOLT ENTRY DIFFICULT MAY LEAD TO THREAD ►WRONG TOOL OFFSET►DEPTH GIVEN LESS IN ►DRILL CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP
DAMAGE DURING ASSEMBLY ►BOLT ENTRY PROGRAM ►WRONG TOOL OFFSET ►O.E.TRAINING ►SETTING WORK & CHECKING AT REGULAR
PROBLEM IN THREAD CHECKING MACHINE WILL SELECTED►PRESETTING OF TOOL NOT DONE TO INSTRUCTION . FREQUENCY.
LEAD TO DAME OF THREAD IF GOES TO CUSTOMER SPECIFICATION.►SETTINF PIECE MIXED UP.
WILL BOLT WILL NOT ASSEMBLE . 4 1 1 5 20 4 1 5 20
►CHAMFER MORE ►BOLT & STRAPASSEMBLY PROBLEM ►WRONG TOOL OFFSET► DEPTH GIVEN MORE IN ►FIRST PIECE INSPECTION,/SETUP
►CUSTOMER DISSATISFACTION. PROGRAM ►WRONG TOOL OFFSET & CHECKING AT REGULAR
SELECTED►PRESETTING OF TOOL NOT DONE TO FREQUENCY.
SPECIFICATION.►SETTINF PIECE MIXED UP.
4 1 2 5 40 4 1 5 20
►HOLE POSITION ►IN CONVENIENCE DURING ASSEMBLY.►FITMENT ►WRONG PROGRAM CALLED►CD BASIC ►HALF ROUND DUMBLE DAMAGED►FIRST PIECE INSPECTION,/SETUP ►STANDARDIZE PROGRAM PART WISE WITH MATRIXVENKAT /SANGAMESH 20.08.08
SHIFT WILL NOT BE AS PER DESIGN REDUCED LEVEL OF DIMENSION ENTERED WRONGLY IN & NOT TO SPEC►PREBROACH & CHECKING AT REGULAR CONTROLLED ►INSPECT THE DUMBLE &
PERFORMANCE.. PROGRAM►HALF ROUND DUMBLE NOT AS PER LOCATOR SIZE►OE TRAINING FREQUENCY. PREBROACH LOCATOR AS PER DRAWING WITH
SPEC►PREBROACH LOCATOR UNDERSIZE NOT AS REGULAR INTERVAL ADD THE SAME IN WI►IDENTIFY
PER SPECIFICATION.►IMPROPER ALL DUMBLES AND LOCATORS WITH PAT NUMBERS
CLAMPING.►DRILL PASSING TAPER. MAKE PROPER / STAND IN SOFT MATERIAL TO AVOID
DAMAGES.
4 2 4 5 80 4 1 5
►THREAD GO GAGE ►IN CONVENIENCE DURING ASSEMBLY. ►TAP WEAR OUT ►USE OF ►TAP CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►MAKE PICTURES IN WI TYPE OF TAPPING ADAPTORS VENKAT /SANGAMESH 20.08.08
TIGHT ►WILL PASS TIGHTLY IN THREAD CHECKING M/C DIFFERENT SPEC TAPS ( TOLERANCE / CLASS SPEC & ►O.E.TRAINING►WORK & CHECKING AT REGULAR TO BE USED FLOATING IN HARTFORD / RIGID IN
LEADS TO THREAD DAMAGE. COATING / FORGING INTERCHANGED) INSTRUCTION►APPROVED TAP FREQUENCY. OTHER VMC'S AS PER THE M/C OPTIONS.
►ADD TAP
►ONLY FOR HART FORD.(USING IMPROPER TOOL SOURCE SPEC AND COATING & FORGING TAPS PHOTOS IN
HOLDING DEVICE BASED ON M/C , USING SOLID WI.STANDARDISE PROGRAM PART WISE WITH MATR
COLLECTS HOLDING DEVICE IN HARTFORD IN PLACE CONTROLLED AND CUTTING PARAMETERS IN
OF FLOATING ADOPTER.)►WRONG CUTTING MATRIX TO BE MENTIONED
5 2 1 5 25 5 1 5
PARAMETERS USED►LESS COOLANT
FLOW/PRESSURE.
►THREAD NO GO DESIGNED FIT / TORQUE WILL NOT BE ACHIEVED ►TAP WEAR OUT ►USE OF ►TAP CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►CONDUCT TRIALS FOR 125NOS WITH EXISTING ►VENKAT/ LOKESK RAJU / 21.11.2008 ►
GAGE ENTRY REDUCED STRENGTH OF END YOKE. DIFFERENT SPEC TAPS ( TOLERANCECLASS
/ / ►O.E.TRAINING►WORK & CHECKING AT REGULAR CUTTING PARAMETERS VERIFY THE CAUSES AND VENKAT / LOKESH / VIKAS 25.11.08
►CUSTOMER DISSATISFACTION ►REDUCED GEOMENTRYSPEC & COATING / FORGING INSTRUCTION►APPROVED TAP FREQUENCY.►100 % IN FINAL. VAILDATE THE CUTTING PARAMETERS AND UPDATE►VENKAT / LOKESH / VIKAS 25.11.08
LIFE OF PART INTERCHANGED) ►ONLY FOR HART SOURCE . IN WORKINSTRUCTION.►CONDUCT TRAILS WITH VENKAT / LOKESH / VIKAS 25.11.08
FORD.(USING IMPROPER TOOL HOLDING DEVICE SECOND SPIRAL END TAP INPLACE OF BOTTOM TAP VENKAT 25.11.08 VENKAT / LOKESH /
BASED ON M/C , USING SOLID COLLET HOLDING USED AT PRESENT.►UPDATE WORK INSTRUCTION VIKAS 25.11.08 SENTHIL KUMAR 29.11.08.
6 DEVICE IN HARTFORD IN PLACE OF FLOATING 2 2 5 60 AFTER TRAILS OF ABOVE
►TRAINING AND TEST TO BE 6 1 5 30
ADOPTER.) ►WRONG CUTTING PARAMETERS USED CONDUCTED TO UPDATE THE KNOWLEDGE ON TAPO
►BUILT UP EDGE ON TAP DUE TO LOW CUTTING FOR PROCESS & QA ENNGINEERS.
SPEED ►
►TAP BREAKAGE ►CANNOT ASSEMBLE. ►TAP QUALITY ►DESIGNED CUTTING PARAMETERS ►TAP CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►MAKE PICTURES IN WI TYPE OF TAPPING ADAPTORS VENKAT /SANGAMESH 20.08.08
►CUSTOMER DISSATISFACTION. ►WILL NOT NOT USED►WRONG PITCH GIVEN IN ►O.E.TRAINING►WORK INSP.& INPROCESS INSP. TO BE USED FLOATING IN HARTFORD / RIGID IN
PASS THROUGH THREAD CHECKING MACHINE WILL PROGRAM►USAGEDIFFERENT SPEC TAPS ( INSTRUCTION►APPROVED TAP ►POKA YOKE AT SLINGER PRESS OTHER VMC'S AS PER THE M/C OPTIONS.
►ADD TAP
DAMAGE THREAD CHECKING BOLTS AND IF SAME TOLERANCE / CLASS SPEC & COATING / FORGING SOURCE SPEC AND COATING & FORGING TAPS PHOTOS IN
BOLTS ARE USED FOR FURTHER CHECKING CREATES INTERCHANGED) WHICH WILL NOT SUIT TO WI.STANDARDISE PROGRAM PART WISE WITH MATR
DAMAGE TO THREADS. CUTTING PARAMETERS AS TAPS FOR STEEL & CONTROLLED AND CUTTING PARAMETERS IN
CASTING WILL WORK IN DIFFERENT CUTTING MATRIX TO BE MENTIONED
PARAMETERS IF INTERCHANGED TAPS WILL BREAK.
6 ►WRONG TOOL OFFSET / PROGRAM USED DIRECTLY 2 3 5 90 6 1 5 30
ENTERED THE DRILL HOLE IN RAPID AND BROKEN
►DRILLING MISSING ►IN CONVENIENCE DURING ASSEMBLY.►FITMENT ►PREMATURE WEAR OF DRILL ►EXCESSIVE USE OF ►DRILL CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►CARBIDE DRILL RESHARPENING NEED TO BE DONEVENKAT /SANGAMESH 20.08.08
(OCCURRENCE IS VERYWILL NOT BE AS PER DESIGN REDUCED LEVEL OF DRILL ►IMPROPER RESHARPENING. ►O.E.TRAINING ►RESHARPENING & CHECKING AT REGULAR BY SUPPLIER MAINTAIN STOCK AND ROTATE
VERY LOW ) PERFORMANCE.. PROCEDURE.►USE OF ONLT FREQUENCY.►. ►IMPLEMENT TOOL LIFE MONITORING OPTION IN
CARBIDE DRILLS ACE VMC's.REVIEW THE WORK INSTRUCTION FOR
TOOL CHANGE FREQUENCY OFFSET METHOD AND
5 1 1 5 25 6 1 5 30
SPEC AFTER TOOL CHANGE.►DRILL
►THREAD MISSING. ►CANNOT ASSEMBLE. ►MIX UP OF PARTS. ►TAP BROKEN DUE TO TAP ►OE TRAINING►REJECTION ►FIRST PIECE INSPECTION,/SETUP ►MAKE PICTURES IN WI TYPE OF TAPPING SATISHWAR REDDY/VENKAT
►CUSTOMER DISSATISFACTION.►DAMAGE OF POOR QUALITY / EXCESSIVE WEAR / WRONG OFFSET REWORK BINS.►REWORK OF & CHECKING AT REGULAR ADAPTORS TO BE USED FLOATING IN 10.11.2009
BOLTS IN THREAD CHECKING M/C. / PROGRAM , IN ONE HOLE , SUBSEQUENT HOLES / PARTS DONE IN SAME FREQUENCY. ►DURING 100 % HARTFORD / RIGID IN OTHER VMC'S AS PER THE
LAST HOLE NOT TAPPED , PART REMOVED AND KEPT SHIFT.►WORK INSTRUCTIONS TPG NO GO INSPECTION IN M/C OPTIONS. ►ADD TAP SPEC AND COATING &
TO DO REWORK BY HAND TAPPING PART MIXED IN FINALWILL BE FOUND & IN FORGING TAPS PHOTOS IN WI.STANDARDISE
LOT AND THE SAME PART SKIPPED IN THREAD THREAD CHECKING MACHINE. PROGRAM PART WISE WITH MATRIX
6 CHECKING.►ALL POTENTIAL CAUSES OF TAP TIGHT 1 1 5 30 6 1 5 30
CONTROLLED AND CUTTING PARAMETERS IN
& NO GO. MATRIX TO BE MENTIONED ►REPLACING THE
SPM TO VMC
►THREAD DEPTH LESS►BOLT WILL BREAK DURING ASSEMBLY / ►WRONG TOOL OFFSET►DEPTH GIVEN LESS IN ►OE TRAINING►REJECTION ►FIRST PIECE INSPECTION,/SETUP ►STANDARDIZE PROGRAM WITH MATRIX VENKAT /SANGAMESH 20.08.08
ASSEMBLY NOT POSSIBLE►BOLT WILL NOT ENTER PROGRAM ►WRONG TOOL OFFSET / PROGRAM REWORK BINS.►REWORK OF & CHECKING AT REGULAR CONTROLLED .
FULLY AND UJ CROSS WILL NOT FIT FIRMLY SELECTED►PRESETTING OF TOOL NOT DONE TO PARTS DONE IN SAME SHIFT.WORK FREQUENCY.►WILL BE DETECTED
CHANCES OF BREAKAGE DURING PERFORMANCE SPECIFICATION.►SETTINF PIECE MIXED UP. INSTRUCTIONS IN THREAD CHECKING M/C.
►WILL NOT PASS THROUGH THREAD CHECKING
MACHINE WILL DAMAGE BOLT.
6 1 1 5 30 6 1 5 30
►BURR AT THE END ►CUSTOMER DISSATISFACTION ►ICAUSES INJURY ►IMPROPER DRILL RESHARPENING ►DRILL NOT ►DRILL CHANGE FREQUENCY ►FIRST PIECE INSPECTION,/SETUP ►DISPLAY GOOD AND BAD PHOTOS ON COMPLETED
OF TAPPED HOLES TO FURTHER OPERATION OE's & FOR ASSEMBLY CHANGED AS PER FREQUENCY EXESSIVE USE OF ►O.E.TRAINING ►SETTING WORK & CHECKING AT REGULAR MACHINE►OE AWARENESS►DRILL CHANGE
PERSON AT CUSTOMER END. DRILL LIFE.►DRILL CUTTING PARAMETERS NOT AS INSTRUCTION . ►DRILL FREQUENCY. & VISUAL FREQUENCY FOR FORGING PARTS TO BE
PER SPEC►COOLANT FLOW NOT TO CUTTING RESHARPENING AS PER INSPECTION ON M/C FOR DRILL STANDARDISED AND UPDATED IN WI.
3 POINT►LESS COOLANT FLOW PRESSURE. 1 1 FREQUENCY AND DRILL ANGLE OK BLENT 5 15 6 1 5 30
NOT OK IS PASTED IN FRONT OF
DRILL RESHARPENING M/C.
►TAPPED HOLES ►BOLT WILL BREAK DURING ASSEMBLY / ►WRONG TOOL OFFSET►DEPTH GIVEN LESS IN ►OE TRAINING►REJECTION ►FIRST PIECE INSPECTION,/SETUP ►STANDARDIZE PROGRAM WITH MATRIX VENKAT /SANGAMESH 20.08.08
NOT PARELLEL TO ASSEMBLY NOT POSSIBLE►BOLT WILL NOT ENTER PROGRAM ►WRONG TOOL OFFSET / PROGRAM REWORK BINS.►REWORK OF & CHECKING AT REGULAR CONTROLLED .
EACH OTHER. FULLY AND UJ CROSS WILL NOT FIT FIRMLY SELECTED►PRESETTING OF TOOL NOT DONE TO PARTS DONE IN SAME SHIFT.WORK FREQUENCY.►WILL BE DETECTED
CHANCES OF BREAKAGE DURING PERFORMANCE 6 SPECIFICATION.►SETTINF PIECE MIXED UP. 1 1 INSTRUCTIONS IN THREAD CHECKING M/C. 5 30 6 1 5 30
►WILL NOT PASS THROUGH THREAD CHECKING
MACHINE WILL DAMAGE BOLT.
►NICKS / DENT ON ►CANNOT MAINTAIN THE SPECIFICATIONS IN ►DUE TO MATERIAL MOVEMENT►NOT CLEANED ►OE TRAINING ►FINAL INSPECTION REVIEW WORK INSTRUCTION ADD NOTE FOR USE OF VENKAT /SANGAMESH 20.08.08
HUB FACE , CHAMFER BROACHING ►CUSTOMER PROPERLY►LOCATOR IS HARD MATERIAL AND ► CLEANING THE LOCATOR BY AIR►CHECKING AT REGULAR BRASS LOCATOR AND CORRECTIVE ACTION FOR ALL
,& MACHINED AREA DISSATISFACTION. ENTRY CHAMFER LESS.►SHIPS NOT GETTING WIPED PROPERLY► SOFT MATERIAL , FREQUENCY DENTS & SCRATCHES.
CLEANLY AND DIFFICULT TO ENSURE BACK SIDES BRAZE WITH BRASS AND MORE ►VISUAL INSPECTION AT
CHIPS CLEAN►DENT ON BOTTOM RESTING ENTRY CHAMFER FOR PREBROACH 'FI'.►VISUAL INSPECTION OF OUT
LOCATOR.►CHIPS NOT REMOVED / CLEANED ON LOCATOR► PUT PART TO ENSURE DENTS NOT
BOTTOM OF LOCATOR ►INPUT COMPONENT CREATED DURING PROCESS
BOTTOM FACE HAVING CHIPS AND LOADED INSPECTION AN DHANDLING.OUT
WITHOUT CLEANING.►BRASS BRAZING WORN OUT / PUT VISUAL INSPECTION.
WITH OUT BRASS LOCATOR USED.
4 2 2 5 40 4 2 5

KEY DATE :25/8/2003

S R R C
060 ►SPLINE OVER ►MATING PART FITMENT ►BASIC SIZE OF SPLINES IN ►WORK INSTRUCTION FOR ►FIRST PIECE/SETUP ►REVIEW WORK INSTRUCTION VENKAT/25.8.08
SIZE LOOSE BROACH NOT TO SPEC.► RESHARPENING & BURR INSPECTION & CHECKING AND ADD COOLANT FLOW & ADD
►MATING PART FITMENT IMPROPER BROACH CLEANING ► AS PER FREQUENCY 1/5 BURR REMOVAL NOTE AFTER
WILL BE LOOSE DESIGNED RESHARPENING O.E.TRAINING► BROACH ON MACHINE (MONTHLY RESHARPENING OF
SPLINE BROACHING FITMENT AND TORQUE WILL ►GAGE WRONGLY MASTER SAMPLE CUT PROCESS STABILITY BROACH►.REFRESH BROACH
BE NOT BE ACHIEVED. CALIBRATED.►GAUGE PIECE INSPECTION. MONITORED THROUGH X RESHARPENING METHOD FOR
WEAR OUT .►IMPROPER BAR - R CHART) RESHARPENING PERSONNEL AND
COOLANT FLOW AND CHIPS UPDATE RESHARPENING
STICKING IN BROACH NOT PROCEDURE AND WI
6 <SC> FLUSHED OUT 1 1 5 30 ACCORDINGLY. 6 1 5 30
PROPERLY..►SETUP
COMPONENT MIX UP (AFTER
(ASSEMBLY OF SHAFT& RESHARPENING BROACH
NOT CLEANED WITH WIRE
FOR BURR WHICH GIVES
OVERSIZE FIRST
COMPONENT.)►
TORQUE TRANSMISSION)
►SPLINE UNDER ►MATING PART ENTRY ►PREMATURE BROACH ►OE TRAINING ►FIRST PIECE/SETUP ►AWARENESS TO OE'S AND VENKAT/25.8.08
SIZE / SPLINE TIGHT TIGHT / NOT POSSIBLE WEAR OUT ►REFER BROACH INSPECTION BROACH FREQUENCY MONITORING
DURING ASSEMBLY . ►EXCESSIVE USE OF USAGE RESHARPENING ►CHECKING AS PER VERIFICATION THROUGH
►CUSTOMER OF BROACH ►GAUGE FREQUENCY FREQUENCY 1/5 ON PCP►.REFRESH BROACH
DISSATISFACTION. CALIBRATION NOT DONE ►GAGE CALIBRATION MACHINE (MONTHLY RESHARPENING METHOD FOR
►GAUGE WEAR OUT FREQUENCY INCREASED PROCESS STABILITY RESHARPENING PERSONNEL AND
.►IMPROPER COOLANT FROM 3 MONTHS TO TWO MONITORED THROUGH X UPDATE RESHARPENING
FLOW AND CHIPS STICKING WEEKS. BAR - R CHART) PROCEDURE AND WI
IN BROACH NOT FLUSHED ACCORDINGLY.
6 <SC> OUT PROPERLY. 2 1 5 30 6 1 5 30
►SYMMETRY MORE ►CREATES VIBRATION ON ►PREBROACH SYMMETRY ►OE TRAINING. ►FIRST PIECE/SETUP ►REVIEW WORK INSTRUCTION LOKESH 02.02.2009
DRIVE SHAFT AND VEHICLE. MORE. IN TURNING ►GAGES AT TURNING INSPECTION & INPROCESS AND INCLUDE BOTTOM FIXTURE
►REDUCED LEVEL OF OPERATION.►PRE BROACH STAGE SAME CONCEPT AS INSPECTION INSPECTION FREQUENCY AND
PERFORMANCE. SIZE MORE►ALIGNMENT OF IN BROACHING..►BOTTOM ►1/5 CHECKING ON M/C CRITICAL PARAMETERS TO BE
BROACH WRT HALF ROUND LOCATOR INSPECTION AND (MONTHLY PROCESS INSPECTED AND RECORDED IN
6 <SC> LOCATER AXIS ►HALF 2 2 TRACKING CARD. STABILITY MONITORED 5 60 TRACKING CARD.►LOCATOR 6 1 5 30
ROUND DUMBLE SIZE NOT THROUGH X BAR - R PARALLELISM MAINTAIN WITH 0.02
TO SPEC. ►BUTTING CHART). MM
LOCATOR BOTTOM FACE
PARALLELISM NOT TO SPEC
& DENTS ON LOCATOR.
►RUN OUT ►UNCLEAR IN GRINDING ►BUTTING LOCATOR ►BROACH RESHARPENING ►FIRST PIECE/SETUP ►REVIEW BROACH RESHARPENING VENKAT/25.8.08
►OIL SEAL PREMATURE BOTTOM FACE PARALLELISM / INSPECTION WI. INSPECTION & IN PROCESS WORK INSTRUCTION ADD NOTE OF
FAILURE ►OIL LEAKAGE. NOT TO SPEC & DENTS ON ►O.E.TRAINING►BUTTING INSPECTION. RUN OUT CHECKING WITH PHOTO.
►REDUCED LEVEL OF LOCATOR. WRT BROACH LOCATORS INSPECTION
PERFORMANCE. 6 AXIS ►BEND IN BROACH 2 2 AND TRACKING 4 48 6 2 4 48
CARD.►SUPPLIER
INSPECTION REPORT.
►ORIENTATION ►ASSEMBLY OF THE PART ►FIXTURE LOCATOR TO BE ►FIXTURE CALIBRATION ►FIRST PIECE/SETUP ►NONE AT PRESENT
MIGHT BE DIFFICULT. ORIENTED WRT BROACH ON MACHINE INSPECTION.
►O.E.TRAINING
► NEW ORIENTATION
FIXTURE PROVIDED
FROM MARCH ONWARDS
& LOCKNUTS FOR
5 2 1 PULLERS PROVIDED 4 20 5 1 4 20
FROM APRIL 26TH
ONWARDS.
►SHOULD USE 546J FOR
ALL THE COMMON SPECS
UNLESS OTHERWISE
MENTIONED.
►OPERATION ►NEXT OPERATION NOT ►MIX UP OF PARTS ►SMALL LOT FLOW ►FIRST PIECE/SETUP ►NONE AT PRESENT
MISSING POSSIBLE 6 1 1 INSPECTION. 4 24 6 1 4 24
►NICKS / DENT ON ►CANNOT MAINTAIN THE ►DUE TO MATERIAL ►OE TRAINING ►FINAL INSPECTION ►REVIEW WORK INSTRUCTION VENKAT 02/02/2009
HUB FACE SPECIFICATIONS IN MOVEMENT►NOT CLEANED ► CLEANING THE ►CHECKING AT REGULAR ADD NOTE FOR USE OF ALUMINIUM
,CHAMFER & BROACHING PROPERLY►LOCATOR IS LOCATOR BY AIR FREQUENCY CORRECTIVE ACTION FOR ALL
MACHINED AREA ►CUSTOMER HARD MATERIAL AND ENTRY PROPERLY► ALUMINUM ►VISUAL INSPECTION AT DENTS & SCRATCHES.►NEW
DISSATISFACTION. CHAMFER LESS.►DENT ON BUSH ON OD OF LOCATOR 'FI'.►VISUAL INSPECTION COOLANT SOURCE TRAILS TO BE
BOTTOM RESTING OF OUT PUT PART TO CONDUCTED FOR CHIPS ADHERING
LOCATOR.►CHIPS NOT ENSURE DENTS NOT PROBLEM►COOLANT PRESSURE
REMOVED / CLEANED ON CREATED DURING INCREASEDM►LOCATOR DESIGN
BOTTOM OF PROCESS INSPECTION AN CHANGED►
LOCATOR►INPUT HANDLING.OUT PUT
4 COMPONENT BOTTOM FACE 2 3 VISUAL INSPECTION. 4 48 4
HAVING CHIPS AND LOADED
WITHOUT
CLEANING.►ALUMINIUM
BUSH ON OD OF LOCATOR
NOT USED.►CHIPS STICKING
IN BROACH AND FALLING ON
LOCATOR DURING RETRACT.
►DOUBLE SPLINE ►WILL NOT ASSEMBLE IN ►IMPROPER MATERIAL ►SINGLE PIECE FLOW,► ►VISUAL INSPECTION IN ►ADD NOTE DOUBLE SPLINE HOW VENKAT/25.8.08
MATING PART I IT IS SPLINED HANDLING AFTER OPERATOR TRAINING TO BROACHING►WILL NOT IT HAPPENS DO'S DON’T'S IN WI
VERY CLOSE►WILL BROACHING IS COMPLETED KEEP OUTPUT CLAMP IN COLLET IN NIB
ASSEMBLE INTO MATING PART IS NOT KEPT IS OUTPUT IMMEDIATELY IN BIN AND MILLING AND
PART IF SPLINES ARE BIN KEPT SAME PLACE NEAR TO CHECK INPUT ►PART BROACHING. ►FINAL
EQUALLY SPLINED AGAIN , INPUT AND LOADED FOR COMPLETION OF INSPECTION VISUAL 100%.
THIS IS VERY DANGEROUS AS AGAIN►(FORD INPUT WE PREVIOUS OPERATION.
IT MISS VISUAL AND REACH MAKE WIP FOR VENDOR - -
CUSTOMER AND FITTED 5 DURING ANY BREAK DOWN 2 1 4 20 5 1 4 20
AFTER SOME CYCLE TEETH OR OTHER LOSSES WIP IS
WILL BREAK AND CAUSES CREATED AND OUTPUT BIN IS
PREMATURE MIXED WITH INPUT BIN AND
FAILURE.►COLLECT WILL AGAIN BROACHONG IS DONE.
BREAK IN SUBSEQUENT
OPERATION.
►SPLINE DAMAGE ►MATING PART FITMENT ►IMPROPER BROACH ►BROACH RESHARPENING ►FIRST PIECE/SETUP ►NONE AT PRESENT
(RUBBING & TIGHT. ►ASSEMBLY IS RESHARPENING / INSPECTION WI. INSPECTION
CHATTERING) DIFFICULT ► WEAR WILL ►PREMATURE BROACH .►VISUAL INSPECTION AT
BE FAST DUE TO RUBBING WEAR OUT ►COOLANT FINAL
FINISH AND PREMATURE FLOW NOT OK►COOLOT
FAILURE. 5 FLOW NOT ON CUTTING 2 2 4 40 5 2 4 40
►REDUCED LEVEL OF AREA.
PERFORMANCE/CUSTOMER
DISSATISFIED.

KEY DATE :25/8/2003

S R R C
►GROOVE DISTANCE LESS ►ASSEMBLY OF UJ KIT IS ►CUTTER WEAR OUT ►CUTTER CHANGING FREQ., ►FIRST PIECE/SETUP ►NONE AT PRESENT .
DIFFICULT OR IT WILL FIT VERY ►SETTING PARTS ARE NORMALLY CUT ►SETTING MASTERS TO BE USED. INSPECTION & CHECKING
TIGHT WHICH IS NOT DESIGNED UNDERSIZE TO CHECK SYMMETRY AND AS PER FREQUENCY.
80 AND LEADS TO PREMATURE THEN SET THE DISTANCE MIX-UP OF 100% INSPECTION.
FAILUE.►SETTING PARTS WITH THESE SETTING PARTS ►NIB DISTANCE
MORE UNDERSIZE UJ KIT WILL NOT CHECKED AS PER FREQUENCY IN
NOT ASSEMBLE (WITH OUT 6 <SC> PCP. 1 1 5 30 6 1 5 30
SLINGER PARTS - WITH SLINGER
PARTS WILL BE DETECTED AT
NEXT PROCESS SLINGER PRESS
POKAYOKE.)
FINISH NIB
►GROOVE DISTANCE ►ASSEMBLY OF UJ KIT LOOSE ►SETTING WI NOT FOLLOWED. ►OE TRAINING. ►FIRST PIECE/SETUP ►NONE AT PRESENT
GROOVING MORE ►CRATES UNBALANCE AND ►GAGE OUT OF CALIBRATION ►SETTING WI INSPECTION & CHECKING
VIBRATION ►PREMATURE AS PER FREQUENCY.
FAILURE OF PART. 5 <SC> 2 2 100% INSPECTION. 5 50 5 2 5 50
►SYMMETRY/POSITION ►UNBALANCE MORE AFTER ►SETTING WI NOT FOLLOWED. ►NO ►OE TRAINING. ►FIRST PIECE/SETUP ►REVIEW WORK INSTRUCTION AND RAJAN/20.08.08
ASSEMBLY POSITIVE DRIVE KEY NOT USED. ►SETTING WI INSPECTION & CHECKING ADD NOTE OF KEY TO BE USE, IN
►CUSTOMER DISSATISFACTION. ►NIB MILLING BODIES WITH KEY AS PER FREQUENCY. DO'S & DON’T''S.
6 <SC> 2 2 1/5INSPECTION. 5 60 6 1 5 30
(MONTHLY PROCESS
STABILITY MONITORED BY
X-BAR R CHART )
►DEPTH MORE ►REDUCED PERFORMANCE ►MIX UP OF SETTING PARTS. ►OE TRAINING. ►FIRST PIECE/SETUP ►NONE AT PRESENT
LEVEL.►MORE DEPTH WILL ►IMPROPER BUTTING OF PART.WILL BE ►MECHANICAL DEAD LOCK INSPECTION & CHECKING
LEAVE BURR IN HALF ROUND AND MORE DEPTH ONE SIDE. ►PROPER BUTTING AS PER FREQUENCY.
WILL CREATE DAME TO UJ 5 2 1 ►STOPPER DOGS PLATE 5 25 5 2 5 50
BEARING CUP. ►SETTING MASTERS TO BE USED.
►/CHAMFER MORE ►REDUCED PERFORMANCE ►MIX UP OF SETTING PARTS. ►OE TRAINING. ►FIRST PIECE/SETUP ►NONE AT PRESENT
LEVEL.►WILL LEAVE LESS LAND ►IMPROPER BUTTING OF PART.WILL BE ►MECHANICAL DEAD LOCK INSPECTION & CHECKING
IN NIB FOR UJ BEARING CUP MORE DEPTH ONE SIDE. ►BASIC ►PROPER BUTTING AS PER FREQUENCY.
CHAMFER DEPTH ON CUTTER NOT TO ►STOPPER DOGS PLATE
5 SPEC. 2 1 ►SETTING MASTERS TO BE 5 25 5 2 5 50
USED.►CUTTER SUPPLER INSPECTION
REPORT
►NIB THICKNESS ►WEAK TANG . ►DUE TO NIB SYMMETRY SHIFT IN ►OE TRAINING. ►VISUAL INPROCESS & ►TURNING WI UPDATE FOR BUNK RAJAN/20.08.08
VARIATION ►REDUCED PERFORMANCE TURNING.►NOT DUE TO NIB MILLING ►SETTING WI►AWARE NESS TO OE TO FINAL LOCATOR USE ( VERIFY TURNING
LEVEL. OPERATION EXCEPT IF SYMMETRY IS INFORM TURNING OE' / QUALITY FMEA FOR THE SAME)
MORE IN MM DUE TO WRONGLY READ PERSON IF NIB THICKNESS VARIATION
6 DIAL . 1 1 IS OBSERVED.►USE OF BUNK LOCATOR 4 24 6 1 4 24
IN TURNING TO CENTRALIZE NIB AXIS.
►HALF MILLED WITHOUT ►UJ ASSEMBLY WILL SEAT UP ►SETTING WI NOT FOLLOWED ►OE TRAINING. ►SETUP ►NONE AT PRESENT
CHAMFER, MIX UP OF NOT REST ON HALF ROUND AND ►MIX UP OF SETTING PARTS ►SETTING WI INSPECTION/INPROCESS
SETUP PIECES WILL CLAMP HALF WHEN TORQUE ► SETTING MASTERS PROVIDED FOR INSPECTION
CHANCES OF KIT COMING OUT SETTING THE NIB DEPTH.
►PREMATURE FAILURE ►PROVIDE PROXY SWITCH (MISTAKE
CUSTOMER DISSATISFACTION PROOFING) TO ENSURE PROPER
POSITION OF END YOKE. THUS CYCLE
WILL NOT START TILL THE PART
LOCATES IN PROPER POSITION.
► PROVIDE STOPPER PLATE USING
6 1 1 DOWEL PINS TO AVOID AXIAL 5 30 6 1 5 30
MOVEMENT, WHICH WILL AVOID DEPTH
VARIATION, WHICH IN TURN WOULD
ENSURE THE REQUIRED NIB ANGLE.
►DRAWBOLT WITH FLATS PROVIDED
WHICH WILL ACT AS ERROR PROOFING
FOR DRAWBAR GETTING LOOSE.
TAPER ON MILLED NIBS ►ASSEMBLY PROBLEM MAY ►SETTING WI NOT FOLLOWED ►MILLING BODY TO BE SQUARE W.R.T ►SETUP 4 20 FIXTURE ALIGNMENT FREQUENCY RAJAN/20.08.08 5 1 4
ARISE. .►CUTTER CHANGE FREQUENCY NOT TO HALF ROUND. INSPECTION/INPROCESS TO BE ADDED IN WI
5 1 1
FOLLOWED►FIXTURE ALIGNMENT ►OE TRAINING.►CUTTER CHANGE INSPECTION.
FREQUENCY. .
NICK, DENT & SCRATCH ►CUSTOMER DISSATISFACTION ►IMPROPER MATERIAL HANDLING ► SINGLE PIECE FLOW. ►FINAL INSPECTION ►ENSURE SINGLE PIECE FLOW. RAJAN/20.08.08
HUB FACE , J26J ENTRY ► LEEDS TO OIL LEAKAGE. ►USE OF MORE FORCE WHILE ►NO METAL TO METAL CONTACT ►CHECKING AT REGULAR ►ELIMINATION METAL TO METAL
RADIUS.& MACHINED CHECKING ►KEEPING HUB FACE ON DURING HANDLING , MOVEMENT AND FREQUENCY CONTACT DURING HANDLING ,
AREA HARD SURFACE CHECKING GAUGE INSPECTION BY USING PLASTIC BINS ►VISUAL INSPECTION AT MOVEMENT AND INSPECTION BY
AND WOODEN PROTECTION 'FI'.►VISUAL INSPECTION OF PROVIDING PLASTIC BINS AND
INPUT PART FOR ANY WOODEN PROTECTION
DENTS FROM PREVIOUS
OPERATION AND VISUAL
4 2 2 4 32 4 1 4 16
INSPECTION OF OUT PUT
PART TO ENSURE DENTS
NOT CREATED DURING
PROCESS INSPECTION AN
HANDLING.OUT PUT VISUAL
INSPECTION.
NIB MILLING ►CUSTOMER MIX UP OF COMPONENTS ERROR PROOFING PROVIDED AT 100% INSPECTION. AT ►NONE AT PRESENT
MISSING/OPERATION DISSATISFACTION.►UJ KIT WILL SLINGER PRESS FOR OPERATION FINAL INSPECTION.
MISSING NOT ASSEMBLE - WITH OUT MISSING.APPLICABLE ONLY FOR
SLINGER PART ) WITH SLINGER 6 1 1 SLINGER PRESSED COMPONENTS. 4 24 6 1 4
PARTS WILL BE DETECTED AT
NEXT PROCESS SLINGER PRESS
POKAYOKE. WILL NOT REACH

KEY DATE :25/8/2003
PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY CTION RESULTS

S R R C
90 ►SURFACE FINISH NOT OK / ►WILL WEAR OIL SEAL AND LEADS ►DRESSING FREQUENCY NOT FOLLOWED ►DRESSING ►DRESSING FREQUENCY , DEPTH , FEED ►IN PROCESS INSPECTION ►INTERLOCK COOLANT MOTOR TO SYSTEM IF COOLANT MOTOR SAKKARAVARTHI 25.08.08
LESS OIL LEAKAGE. NOT HAPPENING►DRESSING DEPTH LESS / MORE & CUTTING PARAMETERS SET IN SYSTEM FREQUENCY IN SURFACE OFF THEN CYCLE SHOULD STOP.►INTERLOCK SYSTEM IF
►PREMATURE FAILURE OF SEAL & ►LESS COOLANT AND NOT DIRECTING ON AND LOCKED. ►SETTING WI TESTER & X BAR - R CHART .AS COOLANT OFF SWITCH IS ON DURING AUTO CYCLE SHOULD NOT
PART ►CUSTOMER CUTTING.►COOLANT MOTOR OFF DURING OPERATION ►OE TRAINING ►LOW LEVEL COOLANT PER THE GUIDELINES ON START .
HUB GRINDING DISSATISFACTION►LESS COOLANT ►COOLANT FLOW CONTROL VALVE BLOCKED & INTERLOCK. DATA COLLECTION FOR
6 <SC> 2 2 4 48 6 1 4 24
AND NOT DIRECTING ON CUTTING. RELEASING LOW FLOW OF COOLANT DRESSING & FINISH VISUAL
INSPECTION .
(CNC GRINDER)
►HUB DIAMETER UNDER ►OIL LEAKAGE THRU SEAL ►OFFSET GIVEN IN WRONG DIRECTION ►WRONG ►SETTING WI ►OE ►FIRST PIECE INSPECTION. , IN ►FIXED COUPLING SIZE TO BE CHANGED TO AVOID DRIVE WALIKAR
SIZE MASTER USED ►WRONGLY READ THE DIAL►WI NOT TRAINING.►DIAL CALIBRATION PROCESS INSPECTION & FINAL SLIPPAGE DURING LOAD.►CG-1 CNC CONVERSION 03.03.2009
FOLLOWED ►INSPECTION FREQUENCY OF MASTER & FREQUENCY ►ALL FIXED END POINTER INSPECTION.
PART NOT FOLLOWED►DIAL & FIXED ENT POINTER STANDARDIZED.► PULLEY DRIVE
6 <SC>
DISTURBED AND OFFSET GIVEN
3 3 CHANGED TO FIXED COUPLING TYPE.
4 72 6 1 4 24
OCCORDINGLY.►VARIATION IN MACHINE X AXIS.
►HUB DIAMETER OVER ►OIL SEAL ASSEMBLY NOT

SIZE POSSIBLE ►OIL SEAL WILL
ASSEMBLE TIGHT CHANCES OF 6 <SC> 1 1 4 24 6 1 4 24
BREAKAGE / COMING OUT.
► CUSTOMER DISSATISFACTION.
►RUN OUT ON HUB OD ►OIL SEAL DAMAGE & OIL ►BASIC MANDREL RUN OUT MORE ►MANDREL RUN ►SETTING WI ►OE ►FIRST PIECE INSPECTION. ►MAKE SPACER MATRIX WITH DRAWING. VENKAT / 20.08.08
LEAKAGE ►CUSTOMER OUT ON M/C MORE ►COLLET BLUE MATCHING TRAINING ►INCOMING ►IN PROCESS INSPECTION
DISSATISFACTION. NOT OK►SPACER PARALLELISM MORE ►COLLET USED INSPECTION OF COLLETS FOR BLUE FREQ.
WITH OUT POSITIVE LOCK OF KEY.►MANDREL NOT TO MATCH.
LENGTH TO SUIT THE PART SPLINE LENGTH COLLECT
6 LOCATION ONLY LESS AREA OF SPLINE AND 2 1 4 24 6 1 4 24
OVERHANGING GIVES RUN OUT►SPACER THICKNESS
WRONG USED GIVES OVER HANG AND RUN OUT.
►GRINDING LENGTH ►OIL SEAL MOVEMENT IS ►SETTING WI NOT FOLLOWED.►SETTING PART ►SETTING WI ►OE ►FIRST PIECE INSPECTION. ►NONE AT PRESENT
VARIATION RESTRICTED/REDUCED OIL 4 MIXUP.►COMPONENT NOT BUT FULLY TO SPACER. 2 1 TRAINING ►INPROCESS INSPECTION FREQ. 4 16 4 2 4 32
LEAKAGE.
OPERATION MISSING ►CUSTOMER DISSATISFACTION. ►MIX-UP OF COMPONENTS ►SETTING WI ►OE ERROR PROOFING WITH BRASS 4 20 ►NONE AT PRESENT
►OIL SEAL ASSLY NOT POSSIBLE 5 1 1 TRAINING AT BALANCER FOR THE PARTS 6 1 4 24
WHICH UNDERGO BALANCING.
►OVALITY/TAPER ►OIL LEAKAGE & SEAL DAMAGE ►SETTING WI NOT FOLLOWED.►TAPER NOT ►SETTING WI ►OE ►FIRST PIECE INSPECTION. ►NONE AT PRESENT
►CUSTOMER DISSATISFACTION. 4 INSPECTED AS PER FREQUENCY. 2 1 TRAINING ►IN PROCESS INSPECTION 4 16 4 2 4 32
FREQ.
►STAINING , RUST ►OIL LEAKAGE ON SEAL DAMAGE ►COOLANT CONCENTRATION NOT AS PER COOLANT CONCENTRATION AND DM ►MAKE VISUAL NOTE OF PH VALUE OF DM WATER NEAR THE DM SAKKARVARTHI 13.08.08
►DEVELOPS RUST AND MATERIAL SPECIFICATION►DM WATER NOT AS PER WATER INSPECTION & MONITORING WATER INPUT AREA.
& PITTING ON HUB WILL BE EATEN PREMATURE SPEC►REWORK PARTS NOT CLEARED SAME DAY AND DAILY / EVERY INPUT OF DM WATER
DIAMETER & FAILURE OF PART
5 KEPT WITHOUT RUST PREVENTIVE.►FILTRATION
2 2 ►WORK INSTRUCTION .
RUSTY AND SYSTEM NOT EFFECTIVE.
PITTING
►SCRATCH / NICK ON ►OIL SEAL DAMAGE ►OIL .1 While checking Hub dia runout by using plunger dial. ►WORK INSTRUCTION►MASTER VISUAL INSPECTION ON 1. To be considred as a check point in New part development for Inspection HW 17-7-08
HUB OD GROUND LEAKAGE►CUSTOMER 1.2While checking Hub diameter with Comparator gauge SAMPLES. GRINDING MACHINE & FINAL requirements. Vikas 15-7-08
SURFACE.& RUST DISSATISFACTION. 1.3.While checking grinding length with vernier ( Nick / Straight INSPECTION. 2. Lever dial to be used for checking runout instead of Plunger dial . Venkat 17-7-08
MACHINED AREA line scratch ) 3. Work Instruction to be updated. Raju 17-7-08
1.4 Circular line while checking Hub dia runout with plunger dial 4. Quality Alert to be displayed at all Bench centres. Vikas 15-7-08
. 1. Flat extension should not be used. HW 16-7-08
1.5 While checking surface finish with surface tester. 2. During APQP itself , Selection of Dial pointer to be considered for all the Vikas 22-7-08
1.6 While using finishing stick for correcting the dent / scratch on future new part development. Vikas 22-7-08
hub face at Final Inspection . 3. New dial pointer with spherical shape to be tried. HW 16-7-08
1.7 Circular line generating due to grinding wheel . 4. Fixed extension pointer with soft material instead of Standard pointer. Raju 17-7-08
1.8 More parts keeping on table after Final inspection . ( near Nib 1. During manufacturing feasability of new part development , the concern of Lokesh 22-7-08
checking poka yoke ) scratches to be considered and action to be taken at that stage. Vikas 15-7-08
1.9 More parts at Inspection table near the machine. 2. Check in Soft materail Go / Nogo Attribute gauge to be Introduced for Lokesh 17-7-08
1.10 While using cycle start button along with the part in One checking Grinding length instead of vernier as shown in figure. SS 15-7-08
hand.( CG 4 machine ) 3. Dedicated spacers to be keep for High runners for Grindling length control SS 30-7-08
1.11 Guard touching while un loading the part. same to be Aproved by QA and should be common for all grinding machines. SS 21-7-08
1.12 While keeping part into out put bin , sides are touches 1. Change the orientation of the gauge SS 27-7-08
1.13 While keeping last part in to out put Plastic bin touches to 2. Stopper Poka yoke to be provided , so that pressure can be controlled. Raju 16-7-08
hub face and chamfer. 3. Provide light . Lokesh 20-7-08
1.14 Defect part skipped from Final inspection . 1. Find coolant with less viscosity / Surface tension . Raju 16-7-08
1.15 Defect Parts skiped from Dock Audit 1a.. Trial to be conduct with IPOL brand synthetic. Raju 16-7-08
1b . Trial to be conduct with CIM COOL brand coolant. Venkat 16-7-08
2.. Finishing stick should not be used. Raju 16-7-08
Add periodic Inspection after consultant the manufacture for any damage. Raju 16-7-08
1.Single piece to be followed and only one part to be handled while moving sta HW 16-7-08
2.Awarenss training about scratches / Dent to be given to the Contractuals. Lokesh 22-7-08
3.Work instruction at Packing to be display ( Do & Don't photos) SS 23-7-08
4.Fixed contractuals. Venkat 20-7-08
5. Maximum 4 parts to be used for washing tray. SS 20-7-08
1.Awareness to OE's ( Should not be keep more parts on Inspection table ). NeSS 20-7-08
2. Dedicated spacers to be keep for High runners for Grindling length control s AVN 20-8-08
3.Bracket with dial to be fixed for Grinding length adjustment at CG 3 MachineAVN 20-7-08
1.Process Engr has to do method study Raju 16-7-08
2.Soft material Beeding to be provided for cycle start button guard. Raju 17-7-08
Since no option to reduce guard height , Soft material ( Aluminium / PolyuretheLognath20-7-08
6 8 8 5 240 1. Use new plastic bins between Grinding and Final inspection with different coVikas 16-7-08 6 2 5 60
2. Plastic bins should be free from chips , dust ( Daily cleaning of bins ) Raju 16-7-08
1. Quality Alert to be displayed. 1. Vikas 4/12/2008 2. AVN
2. Training on scratches not acceptable for Final inspection OE's 4.12.2008 3. AVN 14.12.2008 4.
3.Light intensity to be checked for All Final Inspection Operating Engr's and In VIKAS 1.12.2008 5. VIKAS AVN
4. Rabbit run to be used for scratches at Final Insp more frequently. 1.12.2008 7. AVN 1.12.2008.
Scratch Parameter to be added in Dock audit.
1. Process wise WIP to be designed by mfg eng.

KEY DATE :25/8/2003

S R R C
►MACHINE SETTING NOT ►UNBALANCE MORE IN ►SETTING WI NOT ►OE TRAINING. ►SETUP ►NONE AT PRESENT
DONE PARTS 5 FOLLOWED. 1 1 APPROVAL.►MASTER WEIGHT 4 20
CALIBRATION START OF
100 ►BALANCING ►UNBALANCE MORE IN ►RAW MISMATCH ►OE TRAINING. /
►VISUAL INSPECTION 7 28 ►NONE AT PRESENT
IDENTIFICATION PARTS MORE►SYMETRY INHR & NIB
AXIS MORE IN TURNING
OPERATION►POSITION
4
ACCURACY NOT MAINTAINED 1 1
BALANCING IN PREVIOUS OPERATIONS
(TO REMOVE
►HIGH UNBALANCE ►SHAFT BALANCING NOT ►OE TRAINING.►PCP & ►SETUP APPROVAL. 4 32 ►MECHANICALSTOPPER PROVIDED ANJINEYA 02.01.2009 4 1 4 16
POSSIBLE WORKINSTRUCTION IN ALL ►VISUAL INSPECTION
►VIBRATION IN THE SHAFT OPERATIONS ►SAMPLE INSPECTION AFTER
ASSEMBLY TURNING & 100%INSPECTION
4 3 2 IN BALANCING & REJECT PART
UNBALANCE OF THE PART) IF MORE UNBALANCE THAN
SPEC IN PCP
NICK,DENT & SCRATCH ►CUSTOMER ►IMPROPER MATERIAL ► SINGLE PIECE FLOW. ►FINAL INSPECTION ►ENSURE SINGLE PIECE FLOW. VENKAT / 20.08.08
HUB FACE, J26J ENTRY DISSATISFACTION HANDLING ►NO METAL TO METAL ►CHECKING AT REGULAR ►ELIMINATION METAL TO METAL
RADIUS.& MACHINED ► LEEDS TO OIL LEAKAGE. ►KEEPING PARTS HUB FACE CONTACT DURING HANDLING FREQUENCY CONTACT DURING HANDLING ,
AREA DOWN ON MACHINE AREA. , MOVEMENT AND ►VISUAL INSPECTION AT MOVEMENT AND INSPECTION BY
INSPECTION BY USING 'FI'.►VISUAL INSPECTION OF PROVIDING PLASTIC BINS AND
PLASTIC BINS AND WOODEN INPUT PART FOR ANY DENTS WOODEN PROTECTION
PROTECTION FROM PREVIOUS OPERATION
5 2 1 AND VISUAL INSPECTION OF 4 20 5 1 4
OUT PUT PART TO ENSURE
DENTS NOT CREATED DURING
DHANDLING.OUT PUT VISUAL
INSPECTION.

KEY DATE :25/8/2003

S R R C
110 ►FACE OUT MORE ►MATING PART RUBBING ►FIXTURE SETTING/ ALIGNMENT ►SETUP WORK INSTRUCTIONS ►FISRT PIECE /SETUP PIECE & ►NONE AT PRESENT
►O.E.TRAINING INPROCESS INSP.
4 1 1 4 16 4 1 4 16
SLINGER FITMENT
(WHEREEVER APPL) ►END FACE TO SLINGER ►ASSEMBLY NOT POSSIBLE. ►SPINDLE STROKE NOT OK ►SETUP WORK INSTRUCTIONS ►FISRT PIECE /SETUP INSP. & ►NONE AT PRESENT
FACE 4 ( IMPROPER SETTING) 1 1 ►O.E.TRAINING INPROCESS INSP. 4 16 4 1 4 16
(TO PROTECT FROM
DUST IN ASSBLY) ►DAMAGED SLINGER USED. ►DIFFICULT TO ASSEMBLE. ►PROPER PROCEDURE NOT ►SUPPLIER CERTIFICATION. ►FISRT PIECE /SETUP INSP.& ►NONE AT PRESENT
OR OUT OF SPECIFICATION ►CUSTOMER IMPLEMENTED ►INCOMING INSPECTION INPROCESS INSP.
5 1 1 4 20 5 1 4 20
SLINGER USED. DISSATISFACTION. ►INTERNAL MATERIAL HANDLING PROCEDURE
►O.E.TRAINING.
►INCORRECT SLINGER ►ASSEMBLY NOT POSSIBLE. ►WRONG SLINGERS ISSUED. ►OE TRAINING ►FISRT PIECE /SETUP INSP.& ►NONE AT PRESENT
USED. ►CUSTOMER ►PUNCH DESIGN CHANGED INPROCESS INSP.
DISSATISFACTION. TO DETECT AT SOURCE (EP)
►SLINGER FITMENT.
5 1 1 4 20 5 1 4 20
►ONLY RUNNING SLINGER
PART ISSUED AT THE
MACHINE.
►SLINGER FALLOUT FROM ►CUSTOMER ►FIXTURE SETTING/ ALIGNMENT ►OE TRAINING. ►FISRT PIECE /SETUP PIECE & ►NONE AT PRESENT
END YOKE DISSATISFACTION. ►FLAT AREA IN THE SLINGER NOT ►SUPPLIER CERTIFICATION INPROCESS INSP.
MAINTAINED ►INCOMING INSPECTION.
6 ►DESIGN NOT PROPER AS RADIUS 1 1 4 24 6 1 4 24
OF THE PART INTERFERS WITH THE
SLINGER
SLINGER NOT FULLY ►CUSTOMER 6 MIX UP OF SETTING PART 1 1 ►OE TRAINING. ►FISRT PIECE /SETUP PIECE & 4 24 ► WORK INSTRUCTION FOR
PRESSED DISSATISFACTION. ►PROCESS POKA YOKE. INPROCESS INSP. MANUAL PULL CHECK AT FINAL 6 1 4 24
INSPECTION TO BE INTRODUCED
NICK,DENT & SCRATCH HUB ►CUSTOMER ►IMPROPER MATERIAL HANDLING ► SINGLE PIECE FLOW. ►FINAL INSPECTION ►ENSURE SINGLE PIECE FLOW. VENKAT/20.08.08
FACE , J26J ENTRY DISSATISFACTION ►KEEPING PARTS HUB FACE ►NO METAL TO METAL ►CHECKING AT REGULAR ►ADD IN WI PHOTOS OF NOT
RADIUS.& MACHINED AREA ► LEEDS TO OIL LEAKAGE. DOWN ON MACHINE CONTACT DURING HANDLING , FREQUENCY GOOD KEEPINGS PARTS ON M/C &
AREA.►PUNCH FACE WITH DENT MOVEMENT AND INSPECTION ►VISUAL INSPECTION AT DONTS. & PUNCEH & BOTTOM
WERE FACE IS ACTING AS STOPER BY USING PLASTIC BINS AND 'FI'.►VISUAL INSPECTION OF LOCATOR PHOTOS AND INDICATE
4 TO MAINTAIN LENGTH►BOTTOM 1 1 WOODEN PROTECTION INPUT PART FOR ANY DENTS 4 16 DENT ON THIS FACE WILL CREATE 4 1 4 16
LOCATOR FACE WITH DENT FOR FROM PREVIOUS OPERATION DENTS ON PARTS.
PARTS WERE HUB FACE IS SEATED AND VISUAL INSPECTION OF
ON BOTTOM LOCATOR. OUT PUT PART TO ENSURE
DENTS NOT CREATED DURING
DHANDLING OUT PUT VISUAL
SLINGER NOT FORMED ►DIFFICULT TO ASSEMBLE. IMPROPER LOCATION OF BLANK IN ►CORRECT TOOL DEPTH TO ►SET UP APPROVAL ►BLANK LOCATING DIA TO BE S.RAJU/01.08.8 Completed 5 1 4 20
PROPERLY ►CUSTOMER FORMING OPERATION (AT SLINGER BE MAINTAINED AS PER OPERATION INCREASED FROM 148.9 to 149.2,
DISSATISFACTION. MANUFACTURING PROCESS). ►LOCATOR / STOPPER TO BE STANDARDS.►SETUP ►POKAYOKE INTRODUCED 4
REPLACED AS PER TOOL APPROVAL INPROCESS LOCATING PINS TO BE PROVIDED
5 1 1 4 20
HISTORY CARD.►OE INSPECTION. IN STRIPPER PLATE TO AVOIDE
AWARENESS ON DEFECT BLANK MIS LOCATION..
PARTS.
FMEA NUMBER : EY/C/120 Issue # 02

KEY DATE :25/8/2003

S R C
120 ►INSPECTION PROCEDURE ►DEFECTIVE PARTS ►PROPER PROCESS CONTROL ►QA PERSONNEL TRAINING ►CHECKING AS PER FINAL ►NONE AT PRESENT
NOT FOLLOWED REACHING METHODS NOT INSPECTION QUALITY PLAN.
CUSTOMER►►CHANCES FOLLOWED►UNTRAINED OE
FINAL INSPECTION OF CUSTOMER USING THE DOINING INSPECTION►SAME OE
PARTS WHICH MAY CAUSE DOING CONTINIUOSLY FOR 2 OR
PRMATURE FAILURE 6 3 DAYS. 1 5 30 6 1 5 30
REWORK /
(TO ENSURE DEFECT REJECTION/SORTING AT
OUR CUSTOMER END
FREE PARTS)
►UNCLEAN ►CUSTOMER ►USE OF COTTON GLOVES AT ►USE OF COTTON GLOVES AVOIDED. FINAL INSPECTION ►NONE AT PRESENT
PARTS.(FOREIGN MATERIAL DISSATISFACTION.►CLEANI FINAL INSPECTION.►PARTS NOT ►WASHING MEDIA WILL BE FILTERED
IN THREADS & SPLINES) NG OIL BATH WILL GET INSPECTED FOR DUST AND AFTER EVERY 1000 PARTS.
CONTAMINATED FAST AND CLEANED FOR ANY HEAVY DUST ►PACKING PERSONNEL TRAINED TO
IMPROPER CLEANING DUST . ►WASHING OBSERVE SUCH DEPOSITIONS.
REMAINS ON PART WILL 2 MEDIA NOT CHANGED AS PER 2 7 28 2 2 7 28
LEADS TO FAILURES DUE FREQUENCY.
TO DUST LEFT ON SEAL DIA,
THREADS ETC.
►BLOW HOLE OR POROSITY ►CUSTOMER ►FINAL INPECTION OE's ARE ►TRAINING TO FINAL INSPECTION ►QA PERSON ENSURING FINAL ►NEED TO STUDY THE BLOW HOLE DIRECTION
ON MACHINED AREA DISSATISFACTION.►OIL NEW NOT AWARE OF PEOPLE BY QA PERSONNEL INSPECTION OE's ARE AND ENSURE THE SHIFT IN TURNING IS
LEAKAGE►OIL SEAL DEFECTS►UNTRAINED OE QUALIFIED CONTROLLED AS PER SPECIFICATION.►NEED TO
PREMATURE WEAR AND DOINING INSPECTION►SAME OE COMMUNICATE THE BLOW HOLE DEFECT TO
FAILURE►PART DOING CONTINIUOSLY FOR 2 OR TURNING & GRINDING WITH PHOTOS AND ASK TO
PREMATURE FAILURE. 3 DAYS. REJECT IF OBSEREVED IN RESPECTIVE STAGES.
.►QA TO TRAIN FINAL INSPECTION OE's FOR
DIFFERENT DEFECTLEVEL► INSPECTION PROCESS
FLOW NEED TO BE MADE WITH PICTURES,►ALL
6 8 7 336 6 3 7 126
CUTOMER CUMPLAINTS NEED TO BE DISPLAYED
WITH PICTURES AND AWARENESS NEED TO BE
GIVEN ON DEFECT OF POROSITY AND OTHER
DEFECTS.►EFFECTIVENESS OF TRAINED
INSPECTION PERSONNEL NEED TO BE MADE
RABBIT RUN FOR ALL DEFECTS BY DIFFERENT
FUNCTIONAL TEAMS.
►COMPONENTS REACHING ►CUSTOMER BOLTS FIXED FOR ENSURING 1 SEQUENCE CHANGE. FINAL INSPECTION 5 10 ►NONE AT PRESENT
CUSTOMER WITH BOLTS DISSATISFACTION. TAPPING NOT BEING REMOVED FIXING BOLTS AT ALLEN DRILL EXIT
2 AT PACKAGING. AND REMOVE THEM BEFORE
SUBMISSION TO FINAL INSPECTION.
►BLOW HOLE OR ►CUSTOMER ►DUE TO CASTING PROCESS. ►TRAINING TO FINAL INSPECTION FINAL INSPECTION ►COMMUNICATED TO SUPPLIER FOR PROCESS Venkat 80 % HIGH RUNNERSPARTS
POROSITY ON UN DISSATISFACTION. PERSONNEL IMPROVEMENT AND MEAN TIME LOCALISATION OF ARE LOCALISED AND ARE IN
MACHINED AREA ►COMMUNICATED TO SUPPLIER AND RAW SUPPLIER IS INITIATED.ALL FINAL TESTING,WAITING FOR
AWAITING FOR CA. INSPECTION ENGINEERS ARE TRAINED ON THE APPROVAL (POROSITY AND
DEFECT LEVELS AND THE SAME IS DISPLAYED IN BLOW HOLE IN UN MACHINED
FINAL INSPECTION. AREA WITH THIS LOCAL RAW
6 8 7 336 6 2 7 84
HAS COME DOWN COMPARE
TO IMPORTED RAW). AND
DEFECT LEVELS ARE
DISPLAYED IN FINAL
INSPECTION.
►MIXUP OF DIFFERENT ►DEFECT NOTICED BY ►HIGH VOLUME & LOW ►A DEDICATED 'LOW VOLUME' PARTS FINAL INSPECTION ►AFTER REWORK WITHOUT COMPLETE OF VIKAS / ANJINEYA Completed 2 1 6 12
PART NUMBER. CUSTOMERS(LESS THAN VOLUME BEING RUN AT THE LINE IS BEING PLANNED, CONSIDERING OPERATIONS PARTS SHOULD NOT MOVE TO FINAL
25%) NO DISCERNABALE SAME TIME & DIFFERENCE THE OTHER SUCH CASES INSPECTION ►AFTER REWORK FINAL OE' HAS TO
25%), NO DISCERNABALE SAME TIME & DIFFERENCE THE OTHER SUCH CASES INSPECTION ►AFTER REWORK FINAL OE's HAS TO
EFFECT. BETWEEN BOTH PARTS IS VERY INSPECT AND QA ENG. HAS TO RE SERTIFY
LESS. MATERIAL BEFORE MOVING TO FINAL.►REWORK
SHOULD BE COMPLETED IN THE SAME SHIFT /
SAME SETUP.
2 2 6 24
►SLINGER LOOSE ►CUSTOMER ►NOT FOLLOWED MACHINE ►OE AWARE NESS ►FOLLOW WI FINAL INSPECTION ►MANUAL PULL OF TEST ON MACHINE AND ►VENKAT 8/12/2007 (Need feed back from 2 1 7 14
DISSATISFACTION.►REDUC SETTING PROCEDURE. FINAL. customer on complaint)
E LIFE. 2 5 7 70
►STAINING & RUST ON ►OIL SEAL DAMAGE ►OIL ►WORK INSTRUCTION►MASTER VISUAL INSPECTION ON 6 2 5 60
HUB DIAMETER & RUSTY LEAKAGE►CUSTOMER 1.6 While using finishing stick for SAMPLES. GRINDING MACHINE & FINAL 2.. Finishing stick should not be used. Raju 16-7-08
AND PITTING DISSATISFACTION. correcting the dent / scratch on hub INSPECTION. Add periodic Inspection after consultant the manufacture for Raju 16-7-08
face at Final Inspection . any damage. Venkat 16-7-08
1.7 Circular line generating due to 1.Single piece to be followed and only one part to be Raju 16-7-08
grinding wheel . handled while moving stage to stage. Raju 16-7-08
1.8 More parts keeping on table after 2.Awarenss training about scratches / Dent to be given to HW 16-7-08
Final inspection . ( near Nib checking the Contractuals. SS 20-7-08
poka yoke ) 3.Work instruction at Packing to be display ( Do & Don't AVN 20-8-08
1.14 Defect part skipped from Final photos) AVN 20-7-08
inspection . 4.Fixed contractuals. Raju 16-7-08
1.15 Defect Parts skiped from Dock 5. Maximum 4 parts to be used for washing tray. Raju 17-7-08
Audit 1. Use new plastic bins between Grinding and Final Lognath20-7-08
inspection with different colour and also try with Vikas 16-7-08
6 8 5 240 Polyurethene proterction sides of bin. Raju 16-7-08
2. Plastic bins should be free from chips , dust ( Daily
cleaning of bins )
1. Quality Alert to be displayed.
2. Training on scratches not acceptable for Final inspection
OE's
3.Light intensity to be checked for All Final Inspection
Operating Engr's and Increase the light lence at Final
inspection .
4. Rabbit run to be used for scratches at Final Insp more
frequently.
Scratch Parameter to be added in Dock audit.
FMEA NUMBER : EY/C/130 Issue # 01

KEY DATE :25/8/2003

S R C
130 ►RUST ON COMPONENT ►ASSEMBLY PROBLEM MAY ►RUST PREVENTIVE NOT WORK INSTRUCTION FOR OILING VISUAL INSPECTION ►SEARCH FOR COOLANT SUPPLIERS COMPLETED
OILING & PACKING ARISE. APPLIED / CONTAMINATED RUST TIME DELAY AFTER RUST WHO CAN GURANTEE ATLEAT 72 HOURS
PREVENTION OIL PREVENTIVE OIL APPLICATION RUST FREE AFTER MACHINING.
(TO ENSURE RUST/
►MIXING OF WASHING MEDIA & RUST PREVENTIVE APPLICATION
DEFECT FREE PARTS)
RUST PREVENTIVE OIL AFTER EVERY PROCESS.
►IMPROPER COOLANT
CONCENTRATION.
►ENTRAPPED MOISTURE WITHIN
DUST CAP.
4 ►IN COMPATABILITY BETWEEN 4 5 80 4 2 7 56
RP OIL/VCI/COOLANT/CLEANING
MEDIA.
►CORRUGATED SHEET SEPARATOR TO BE SEALED BOTH ENDS

CONTACTED WITH COMPONENTS
DUE TO SEPARATPRS ARE NOT
SEALED ON BOTH ENDS
►LOOSE PACKING ►BOX DAMAGED ►WORK INSTRUCTIONS NOT WORK INSTRUCTION FOR DOCK AUDIT ►CONTINIOUS TRAINING TO PACKING NAGARAJA / INPROCESS
►COMPONENT SPILLAGE FOLLOWED PACKING FOR PACKING PERSONAL
►COMPONENT DAMAGED 4 ►PACKING PERSON UNTRAINED 2 PERSONNEL 7 56 4 1 7 28
►BAD SMELL/ODOUR ►CUSTOMER DISSATISFACTION. ►WASHING MEDIA. ►WASHING MEDIA STANSOL-80 ►DOCK AUDIT ►NONE AT PRESENT
►EXCESSIVE RUST PREVENTIVE USED ►MIXING OF WASHING MIDIA & TESTED & STARTED USING
& STARTED USING.
MIXING OF WASHING MEDIA & WASHING & RUST

PREVENTIVE APPLICATIONS
6 1 5 30 6 1 5 30
RUST PREVENTIVE OIL.
PACKING OF THE END YOKES TIME DELAY AFTER RUST

BEFORE COMPLETE DRAINING PREVENTIVE OIL
►STAINING & RUST ON HUB ►RUST WILL EAT THE METERIAL ►INPUT MATERIAL FOR WASHING ►TRAINING FOR PACKING ►DFIR & DOCK AUDIT REVIEW THE TRAINING PLAN AND NAGARAJA / 20.08.08
DIAMETER & RUSTY AND PITTING AND CREATES DAMEAGE TO SEAL AFTER FI HAVING MORE DUST , PERSONNEL►WORK REFRESH THE PACKING PERSONNEL
AND PARTS CAUSES PREMATURE COOLANT AND FORIEN INSTRUCTION ►DFIR & DOCK AGAIN.►REVIEW WORKINSTUCTIONS
FAILURE OF PART. PARTICLES ►WASHING MEDIA FOR CHANGE FREQUENCY AND
AUDIT
NOT CHANGED AS PER SPECIFICATION AND PUT VISUAL TO
FREQUENCY / BAD QUALITY MAKE LOCAL PEOPLE UNDERSTAND
►MIXING OF WASHING MIDIA & EASILY.ADD IN WI NOT TO HADLE PARTS
RUST PREVENTIVE OIIL ►RUST WITH TOURN GLOVES BARE HANDS .
PREVENTIVE OIL GOT
CONTAMINATED AND CHANGE
FREQUENCY NOT FOLLOWED.
6 ►PACKING OF ENDYOKES 2 5 60 6 1 5 30
BEFORE COMPLETE DRAINING OF
RUST PREVENTIVE OIL.►PARTS
ARE HANDLED WITH TOUR
GLOVES DURING PACKING
PROCESS / TOUCHED PARTS IN
BARE HADE FINAL PART FOR ANY
REASON AND NOT A[[LIED RUST
PREVENTIVE AGAIN.
NICK,DENT & SCRATCH HUB FACE , ►CUSTOMER DISSATISFACTION ►IMPROPER MATERIAL ► SINGLE PIECE FLOW. ►DFIR ►DOCK AUDIT ►ENSURE SINGLE PIECE FLOW. RAJU / 20.08.08
J26J ENTRY RADIUS.& MACHINED AREA ► LEEDS TO OIL LEAKAGE. HANDLING ►NO METAL TO METAL ►ADD IN WI PHOTOS OF NOT GOOD
►KEEPING PARTS HUB FACE CONTACT DURING HANDLING , KEEPINGS PARTS ON M/C & DONTS. &
DOWN IN ALL AREAS DURING MOVEMENT AND INSPECTION PUNCEH & BOTTOM LOCATOR PHOTOS
PACKING (NIBCHECKING, AND INDICATE DENT ON THIS FACE WILL
5 CLEANING, 2 4 CREATE DENTS ON PARTS. 5 1 4 20
THREADCHECKING).►NOT USING
SOFT POLY URETHEN MATERIAL
IN TRAY .
►(PLASTIC CONTAMINATION)PLASTIC ►CUSTOMER DISSATISFACTION. ► DEFLASHING WAS NOT DONE DEFLASHING AND CLEANING INCOMING INSPECTION. COMPLETE ELIMINATION OF SH / 25.04.06(Action implemented ACTIONSCOMPLE
FLASHES OF PROTECTIVE CAPS ON ON PLASTIC CAPS BY SUPPLIER 7 1 1 7
INTRODUCED AT SUPPLIER PROTECTIVE CAPS FOR ALL PARTS for earlier complaint dated TED
PARTS . 10.02.06, complaint now received is
for old lot.
6 1 8 48
SPICER INDIA LIMITED -JODALLI WI/TSG/10-1
TS16949: Work Instruction for Stamping Sheet 01 of 01
Element Issue No 0
Revision No 1
Machine STAMPING MACHINE Prepared By MDT
Date 28/03/2009
SETUP PROCEDURE OPERATION PROCEDURE

S/No Description S# Description
1 Swich on the Machine,Screen as shown in Fig.3 will be displayed 1 Load the Componet as shown fig.
2 Press F1 on Screen for Level to be changed from Operator to Suprevisor 2 Adjust the marker if required by rotating handwheel.
Press F2 to change mode from ONLINE to OFFLINE 3 Load the Part # by pressing F3 as shown fig.
3 Being on Supervisor level, Press Page down Arrow until 'F6-DESIGN' appears on screen 4 Once Part # was loaded Press F2 to change to ONLINE
4 Press 'F6-Design' for defining new Part #. 5 Press CYCLE START Button
5 In Design pattern Screen,Press F1-LOAD, as shown in Fig. 4 will be screened. 6 Keep holding the part until Marker prints
6 Type down the Part # (Eg.2-4-8541-1) that to be printed on component ,then press ENTER 7 Unload the component and keep in bin.
7 The Prompt "Define new pattern for this? " will be asked.
8 Press F1 -Yes to change desired pattern parameters if required or else press F2- No for default pattern parameters.
Once you have selected the F2-No,You have to press F4-ADD to add the part #, then press F2-save to save the
9
item described
10 Press F1-Accept to confirm the Pattern defined
Fig 3
Fig.1
Supervisor Mode Design pattern screen
GENERAL INSTRUCTIONS
1 Place parts in bins/baskets with separators/partition &maintain a good layering pattern
2 All the trollies/wire baskets/bins must have correct WIP tags
3 Don't mix lots Fig.4
4 If machine is inoperable, notify shift coordinator
5 Enter the number of parts produced from the particular broach in respective history cards
6 If there are any abnormalities in the process, inform the shift leader
SAFETY REVISION DETAILS
1. Wear Goggles Rev Change Details
2. Use gloves during inspection. 0 Document original date Approved By
3. Handle all glass items carefully 1 Manufacturing Location change
4. Donot handle chemicals with out wearing gloves.
Prepared By
9+65).&';
9QTM+PUVTWEVKQP
SPICER INDIA LTD-JODALLI Sheet 01 of 01
TS 16949 Issue No 00
Title: Work Instruction for Surface Broaching
Element Rev. No 01
Opn. No. Opn. Name: 5WTHCEG$TQCEJ M/c. No.: - M/c. Name: 1&+0 Prepared by: /&6 Origin Dated 28/03/2009
5GVWR2TQEGFWTG 1RGTCVKPI2TQEGFWTG 5[OOGVT[
Start Start Non-conformance Cause CA Rework Instruction

Loose the 4 Bolts of the Bottom fixture
1. Select the Fixture Unit based on the Series &
1. Clean the Fixtures Symmetry Wrong Setting of Base fixture Correct the Same Move the Table Left / Right by adjusting the Screws 3 & 4
Jaws as per the Raw Tight the 4 Bolts
2. Load the Component as 1 Centre Height Wrong Setting Correct the Same Remove / add sim from the lug blades
shown
2. Mount the Fixtures over the Base Locator HR nogo/ go tight Broach problem Correct the Same Replace the broach
using 6mm Allen key 3. Clamp the Component Chamfer more /less Wrong Chamfer Blade Setting Correct the Same Add/ remove the shim from chamfer blade
by activating the Foot Change the butting pins
lug thickness variation Wrong Setting Correct the Same
3. Align the Lever of the Crane perpendicular to pedal Ensure the parallelity of butting pins
that of Bolster using Chain
4. Start the Dual Cycle
Start Button
4. Take down the Hook & Lock it with the Bolster
using the Pin 5. After the Completion of
the Cycle, Declamp the
Component using Foot 6QQNKPI
5. Remove the 16 Bolts of the Bolster pedal
Sl# Description
Remove the Middle 2 Screw
finally after removal of 6. Unload the Component 1 Bolster
6.Take the Boltster toward front using the Chain remaining Screws
2 Broaches
7 Clean the Component
7.Take out & Keep it over the Tray using the
Chain & Crane operating buttons 3 Fixtures
Not Ok
8.Remove the Hook & Lock it with the New 8.Check for 9. Place it in the respective 4 Jaws
required Bolster all Quality "Reject"/ "Rework"Bin with
Ensure that One person Parameters Tagged for specific reason
9.Lift the Bolster using the Crane should hold the tray
Ok
10.Move Bolster toward the Ram & Fix it with the 10. Place the Part in Bin &
Ram using 16 Bolts Pass for Turning
End
11.Loosen the Bolts of the Bottom Fixture
%WVVKPI2CTCOGVGTU
12.Take back the full stroke of the Bottom fixture by Sl.No. Do's Do-Not's
rotating the knob1 clockwise & knob2 anticlockwise
Hold the tray while interchanging of Feed: 4.5 metres / min or 22 sec Cutting Time only
1 Bolster, so that the tray won't move Don't remove the Bolster alone
13.Load the Component forward
Ensure that the base fixture is at a safer
2
distance to avoid hitting of Broach
14.Activate the Manual mode switch
4GCEVKQP2NCP
8CNKFCVKQP
15.Press the Control &Clamp button
1 If a defect is discovered, Stop the Process, Inform the Shift Coordinator
simultaneously so that the part gets clamped
Check previous Run parts for the same defect. Check until the condition is
16.Press the Control & Trunion simultaneously so 2
no longer found Validation for Machine, Process & Tooling will be carried out during initial process study .As per the study all tool/insert changing & in process
that the Fixture tilt & faces towards the Bolster Ensure Jaws should not touch the Segregate the parts as "Reject, "Rework" & "Ok" in previously Run parts & inspection frequencies will be defined.
Bolsterwhich taking Ram down 3
17.Move towards the Bolster by pressing Control Move to the respective places Also Validation will be done if there is any input change (tools/coo
& Shuttle button simultaneously #UUQEKCVGF&QEWOGPVU &GHKPKVKQPU
18.Machine the Component manually by taking
the Ram down by pressing Control & Ram Down
1 PCP - Part No. - 020 Cp - Critical Parameter 4G8CNKFCVKQP
19.After manual cycle completion, take back the 2 PCS - Part No. - 020
fixture by pressing both Control & shuttle button
1 Processes involving CPs validation study will be done once in every 6 months.
simultaneously & Take Ram Up 3 Rejection Tag
20.Tilt the Component so that the Component 2 Processes not involving CPs validation study will be done once in every 12 months.
4 Rework Tag
along with fixture faces up by pressing Control &
Truenion simultaneously
5 WIP Identification Tag
4GXKUKQP&GVCKNU
21.Declamp the Component by pressing both )GPGTCN+PUVTWEVKQPU
Control & Declamp button Rev. Level Change Details
1 Place the Parts in the Bins & Maintain a Good Layering Pattern
2 All the Bins must have the Correct WIP Tags
22.Take out the Component & Clean it 00 Newly Issued
3 Don't Mix the Lots
4 If the Machine is inoperable, Notify to the Shift Coordinator
01 Manufacturing Location changed from Hosur to Jodalli
5 Enter the No.of Parts produced from the Particular tool in the Respective History card
Not Ok
23.Check for Quality 6 If there are any abnormalities in the Process, Inform the Shift Leader
24.Continue with Corrective Action
parameters
Ok 5CHGV[
25.Continue with Operating Procedure in Auto 1 Wear Goggles Approved by

mode 2 Never Operate Machines, if Guards are not in Place
3 Don't put any parts of your Body into the machine, Once it has been cycled S
4 Wear Chemical Resistant Gloves & Safety Glasses with Side Shields
End
5 Check the Area frequently for any Slip, Trip & Fall Hazards Prepared by
SPICER INDIA LIMITED-JODALLI WORK INSTRUCTION WI/TSGCF/7
TS16949: Sheet 01 of 01
Element Title: Work Instruction End Yokes Drilling, countersinking & Tapping on MORISEKI VMC. Issue No 0
Revision No 1
Operation No. 40-2 Operation Name ounter sinking, step d Machine No. Machine Name MORISEKI-VMC Prepared By MDT
Date of Origin 28/03/2009
HANDLE PARTS CAREFULLY & ZERO TOLERANCE TO BE MAINTAINED AS REGARDS TO NICKS, SCRATCHES & DENTS
SET UP PROCEDURE OPERATION SEQUENCE
S/ No Description REMARKS S/No Description
Once the Machine pallet is indexed and come towards loading /
Get critical parameters (locator locating dia , prebroach locating dia , locator height& Brass coating) inspected and tooling
1 1 unloading station, Declamp the fixture and remove the
approved prebroach locator from tooling.
3&4 component. 2
2 Clean the bottom face ensure no chips and dent is left on butting
Remove the existing locator by loosening the 3/8 grub screw, Check the grub screw head and clamping face is not
2 1 Ensure the input part for completion of all previous operation and
rounded , if wear is observed change the new one . 3
free from dent, chips on hub face.
clean the base and bore thoroughly and apply oil stone to remove any high points / burr. Now insert the next set up 4 Load the component in the direction shown and ensure it is not
3
tooling approved locator and clamp by tightening 3/8 screw. 5 Press the clamp bottom and ensure part is clamped .
Locator
4 Remove the existing HR Dumble by lessening 24Hexogonal nut and pulling put the threaded dowel pin. 6 Press the pallet ready button.
3
Blow air inside the tapped hole and check visually below
5 Ensure the input part for completion of all previous operation and no burr on hub face clean burr, dent free. 7
parameters
1.) Flat threads 2.) Full thread 3.) Hub face dent. 3
6
6 Load the tool holders in respective tool holders as per program. Check DHPD & TPG of last hole of the cycle
If any quality parameter is observed deviation from control plan
8
switch on single block.
7 GO to MDI give M60 and bring the Pallet were tooling is changed into m/c.
ABNORMALITY HANDLING
Following are the abnormal conditions:
8 Select the right pallet program from program matrix .
Hole position & drill plug gauge 1.Tooling Change 4.Shift change
4 2.Gaging change 5.Operating Engineer Change
9 GO to MEM Mode and switch on single block , and cut first piece in single block mode and Rapid control.
3.Fixturing change 6.Reworking Locator with components loaded
7.Breakdown.
10 Call the pallet out and press declamp button and remove the component check all parameters as per control plan.
In all the above mentioned abnormal conditions, first
11 If any parameters observed deviated follow corrective action and correct. Piece inspection to be done & QA approval to be got
Drill & chamfer tool Tapping holder Hole position gauge
Cycle start,Clamp/Declamp,Emergency Buttons

TOOLING
1 If a defect is discovered, Stop the Process, inform Shift 1 5.5 Step drill (Adission Make ) 400Parts
coordinator. 2 6.9 Step drill (Adission make ) 400Parts
2 Check previous run parts for same defect. Check until condition is 3 8.5 step drill (Adission Made ) 400Parts
no longer found. 4 1/4*28UNF TAP (OSG Make) 250Parts
3 5 5/16*24UNF TAP (OSG Make) 250Parts
Segregate the parts as "reject", rework and "OK" in previously run
6 3/8*24UNF TAP (OSG Make) 250Parts
parts and move to respective places
CORRECTIVE ACTIONS ERROR PROOFING
S/No Non-conformance Cause CA 1 Machine Will stop in case of Over Load
1 Drill U/S 1)Basic drill size used wrong2.) Drill wear out 3)Coolant flow low 4)Coolant 1.)Change drill to correct size as required, 2.)If drill is worn out change to new or resharpened tooling approved and 2 Equipment will stop if there is low coolant level and low lubrication level
2 Chamfer more or less 1. Tool offset not as per Program matrix. 2. Chamfer dept in program not as 1).Confirm the Tool offset on offset Page is as per the program matrix if not ok inform L4 Person / TSG and correct . 2.) 3 Machine will not start if any door is open
1.Basic CD in program is not as per the required series.2.)Work piece cut 1.Verify the CD of the series and r with Program Matrix if wrong inform to L4 / TSG and get corrected as per Program S/No Do's DO-NOT
3 Hole position shift with wrong program number .4) Half round dumble not to spec5.)Prebroach matrix. 2.Verify the program number with Program matrix if worn call the correct program number 3.Return the Half Load the part only if previous Donot operate / do any
1
locator dia & height less u/s not as per spec round and Prebroach locator to tooling and receive the OK Locators operation is completed and free changes if you are not aware /
1.)Tap premature wear outwear out .2)Tap excessive usage being the set 1 & 2 ).Replace new tooling approved Tap. 3.)check the coolant level and ensure the pressure and flow .4.)correct the DO reference of all Axis if m/c is VALIDATION
4 Thread go gauge tight
frequency 3.)Coolant flow less 4.) coolant pipes not directed on cutting pipes and direct on to cutting edge.5.)Refer the required to be used fro Work instruction and use the correct Tap. 2 when started after m/c is off / Don't change the CNC Program
power off / .
Thread No-go gauge 1.) Bad quality of Tap 2.) Tapping cutting parameters not as per matrix. 3.) 1.)Replace new tooling approved Tap.2.)Verify cutting parameters as per Matrix if not ok inform L4/TSG and correct
5 Clean the part thoroughly before Don't clamp the collets without
answering Required spec / Grade Tap (Casting /Forging ) not used. 4.)Refer the required to be used fro Work instruction and use the correct Tap. 3
putting the same in bins component on it
Validation for Machine, Process & Tooling will be carried out during initial
Donot use BT 40 Tool holder Use
process study .As per the study all tool/insert changing & in process inspection
only Green dot CAT 40 tool
Donot use BT 40 / OTHER frequencies will be defined.
3 holders , Before loding tool
Taper Tool holders Also Validation will be done if there is any input change (tools/coo
holder ensure availability of
green dot.
GENERAL INSTRUCTIONS ASSOCIATED DOCUMENTS
1 Place parts in bins/baskets with separators/partition &maintain a good layering pattern 1 PCP-Part#-70
2 If machine is inoperable, notify shift coordinator 2 PCS-Part#-70 REVALIDATION
3 Enter the number of parts produced from the particular tool in respective history cards 3 Reject tag 1 Processes involving CPs validation study will be done once in every 6
4 If there are any abnormalities in the process, inform the shift leader 4 Rework Tag months.
5 WIP Indent Tag 2 Processes not involving CPs validation study will be done once in twelve
months.
2. Never operate machines if guards are not in place 0 Origin date
s Prepared By
3. Don't put any body parts into the machine once it has been cycled 1 Manufacturing Location change
4.Wear Required PPE's
Approved By
5. check area frequently for any slip, trip or fall hazards
SPICER INDIA LIMITED-JODALLI WORK INSTRUCTION WI/TSG/100
TS16949: Sheet 01 of 01
Element Title: Work Instruction for Balancing Issue No 01
Revision No 01
Operation No. 100 Operation Name Balancing Machine No. - Machine Name Hines Balancer Prepared By MDT Date 28/03/2009
SET UP PROCEDURE OPERATION SEQUENCE
Main instructions S/No Description
1. Verify correct counter bore locator and colletCheck the tolerances Ounce -inch(gms-cms).Check, add, or remove modes.Ensure table Place the part on the collet.
is balanced.Do tooling compensation as below. Perform tooling compensation twice per shift 1.Activate the dual start buttons.
2.Allow part to cycle.
3.Note the variance .if the screen shows OK .identify the part
with daub of paint & put in trolley/wire basket/bins for next
operation.
4.Use the belt grinder to remov
Nib ground off
Ensure we don't cross the boundary samples as shown (Minimum .090” thickness needed) Thin bolt hole wall
(Minimum .100 thickness needed)
2. On the computer keypad, press the "SETUP" key until you see the words "SELECT MODE" on the computer screen.Press the besidewhile removing material from belt grinding
"SETUP" key one more time.
Press "NEXTLINE" or "BACKSPACE" until the computer cursor is next to the words "DO COMP CYCLE". REACTION PLAN
Press the "E If a defect is discovered, Stop the Process, inform
1
Shift coordinator.
Check previous run parts for same defect. Check until
2
condition is no longer found.
Slinger diameter gap Burn and threads exposed
Segregate the parts as "reject", rework and "OK" in
3
previously run parts and move to respective places
Press both Start buttons on the machine control box. Error proofings
When the part stops spinning, you will see the following on the computer screen: "TURN PART AROUND". Equipment has been provided with a gauge to check the
Remove the part from the tooling. completion of grinding operation TOOLING
Rotate the part clockwise 30 minutes (180 degrees), and place it b 1 Belts Change as it wears
VALIDATION
CORRECTIVE ACTIONS
S/No Non-conformance Cause CA Rework Instruction S/No Do's DO-NOT Validation for Machine, Process & Tooling will be
Setting problem Set the same again Follow reaction plan Ensure component buts on Don't take half cut forcarried out during initial process study .As per the
1 Unbalance variation 1
Machine electronics problem Correct the same. all four lugs propely setting study all tool/insert changing & in process inspection
GENERAL INSTRUCTIONS ASSOCIATED DOCUMENTS DEFINITIONS frequencies will be defined.
Also Validation will be done if there is any input change
1 Place parts in bins/baskets with separators/partition &maintain a good layering pattern 1 PCP-Part#-100 crirical parameter <CP> (tools/coo
2 All the trollies/wire baskets/bins must have correct WIP tags 2 PCS-Part#-100 REVALIDATION
3 Don't mix lots 3 Reject tag Processes involving CPs validation study will be
4 If machine is inoperable, notify shift coordinator 4 Rework Tag 1 done once in every 6 months.
5 Enter the number of parts produced from the particular tool in respective history cards Processes not involving CPs validation study will
6 If there are any abnormalities in the process, inform the shift leader 5 WIP Ident Tag 2 be done once in twelve months.
2. Never operate machines if guards are not in place s 00 New format of WI issued
3. Don't put any body parts into the machine once it has been cycled 01 Manufacturing Location Change Prepared By
4.Wear chemical resistant gloves and safety glasses with side shields
5. check area frequently for any slip, trip or fall hazards Approved By
WI/ Matls / 04
Issue No / Date 00 / 04.08.08
Packing Instruction
Part # 3-4-14441-1 Box Size 1030X860X705(7 ply corrugated)

Description End Yoke Assy Box Qty 480 Nos
Packing Method Continuous Hub OD Down
LAYER 1 Total
10 10 10 10 10 10 10 10 80
LAYER 2
10 10 10 10 10 10 10 10 80
LAYER 3
10 10 10 10 10 10 10 10 80
LAYER 4
10 10 10 10 10 10 10 10 80
LAYER 5
10 10 10 10 10 10 10 10 80
LAYER 6
10 10 10 10 10 10 10 10 80
Prepared By Approved By
QF/MR/03-01
DANA WORK INSTRUCTION Doc. No. : WI /Matls /04
People Finding A Better Way Issue No./ Date: 01/13.01.2006
SPICER INDIA LTD. TITLE: PACKING PROCEDURE Rev. No./ Date : 02/18.07.2008
Drive Shaft Component HINO COMPANION CF
Plant, Hosur Page : 1 of 7
1. PURPOSE :
This Work instruction describes the steps to be followed for the packing & despatching
finished components to Customer.
2. SCOPE :
The Procedure will applicable to all types of Finish parts to be

despatched to the customer.
3. DEFINITION : NONE
4. RESPONSIBILITY :
The Materials Incharge and the Stores Incharge are responsible for this Work Instruction.
5. PROCEDURE :
5.1 Select the box as per the Figure.
Designation Stores Incharge Designation Materials Incharge

QF/MR/03-01
5.2 Put extra corrugated sheets for more strength
5.3 Insert VCI (Volatile Corrosion Inhabitor) bag & place it on the Corrugated Box.

QF/MR/03-01
5.5 Insert a VCI corrugated layer in the Box on each Row & Put layer.
Layer should be protected with flat VCI cover.
5.6 Clean the parts with stansoil , check for Nib & Thread.

QF/MR/03-01
5.7 Apply Rust Preventive Oil ( Axxanol 33CD ) on machined area by manual brushing.
5.8 Arrange all components in Row wise as per packing arrangement standard with
corrugated sleeves with plastic cover.

QF/MR/03-01
5.9 Seal the VCI Bag with Bob Tape.

QF/MR/03-01
5.10 Seal the Box with Ped strap Vertical ( 3 Nos.)& Horizontal.(3Nos.)
Write the INVOICE NO.,PART NO.BOX NO. & QTY. on the Box.
Note : Invoice No. we have to put once doc audit is over.
5.11 Wrap the Box by Strech Film.

QF/MR/03-01
5.12 Stick the Bar Code on the Box.

QF/MR/03-01
6. DOCUMENT REF. : NIL
7. RECORD REF. : Despatch record.
8. REVISION DETAILS : NIL.

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#232%JGEMNKUV

Status Revieved on Schedule Remarks

End Yole Line Shifted , Facilities , Personnel and Training Completed as

for all PPAP Approved Parts.

13 Bought out part submission NA

14 Part Manufacture Walikar

15 Standard Operation Sheets Walikar

18 Capability Studies Walikar

20 PPAP Approval Customer / Walikar 38

AREAS OF CONCERN FOR OTHER END YOKES

Customer complaint register - 2007

Dana 1.Chamfer diameter less in First operation. Spec : 40.0±0.20 20.

Dana 1.Chamfer diameter less in First operation. Spec : 40.0±0.20 2.During

Incoming Inspection Parameters checked Spec Maintained Frequency

Approved DM Water Pumped to

DM Water 100% PVC Line

DM Water collection point.

Coolant oil mixing and maintaining Operation Maintained Spec. Frequency

Concentration inspection by Frequency

Concentration checked by Harita NTI

Things Gone Long Term Corrective Action (LTCA)a Status (Revieved on

Reject the lot at incomming stage

All 1410 Half round Completed , PPAP Lot

Incorporate in control plan to

Make specific bunck locator for

Dent scratch ON Add additional note for material

Note : Incorporate all Long term actions into FMEA.

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSEBILITY ACTION RESULTS

NO PROPER HEATTREATMENT. 7 HEAT TREATMENT 2 NONE AT PRESENT DO- 3 42 NONE AT PRESENT

HEAT TREATMENT PROBLEM

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

►MARKING LETTER HEIGHT

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

NIB HEIGHT MORE. ►CONTACT AREA FOR BEARING CUP

HALF ROUND CL HEIGHT ►POSITION VARIATION.

OPERATION MISSING ►NEXT OPERATION NOT POSSIBLE. 1

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

►SLINGER OD OVER SIZE ►SLINGER ASSEMBLY NOT POSSIBLE.►FIT WILL BE

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

(BEARING STRAP RETENTION)

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY CTION RESULTS

►HUB DIAMETER OVER ►OIL SEAL ASSEMBLY NOT

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

ITEM : END YOKE (CAST VERSION) PROCESS RESPONSIBILITY:TSG/PROD/QA/MAINT/MATERIALS

PROCESS POTENTIAL POTENTIAL S C POTENTIAL O D R RECOMMENDED RESPONSIBILITY ACTION RESULTS

►CORRUGATED SHEET SEPARATOR TO BE SEALED BOTH ENDS