Part Quality issues June'20

Month Total issues Under monitoring

June 60 26

S.No Part Quality issues Action

Ad blue hose connection socket Orientation wrong Part rejected & waiting for feedback
1 X0W00469

2 MBP-Pump to filter out wrong connection
3 Bogie trunion shaft not entering in to spring
subassembly (bush)
79 nos AL H2 & 100 nos Godown stock
verified and "HC" Marked for Hose
connection OK Case- Awaiting feedback
Relief made for shaft entry & checked
with gauge

U 3520 Bogie Cobra bkt mounting holes offset in Rear

4 Axle 1 Thread not answering issue.Bolt got
stuck-Axle depth to be checked. 6 nos
store stock and found ok
5 V-rod bolt getting elongated - FYJ06611 Stepped torque (600,800,900,1000)
done as temporary action
EATS cover /brkt/fasteners not received in kit EATS cover & fasteners fitment moved
6 MB4011001 to plant scope
7 FES mounting holes offset Under analysis
8 Steering UJ not entering Under analysis
9 Bogie U-bolt broken -X3X01811 Under analysis
10 EATS cover holes offset F5C01400 Under analysis
11 Stg  Movement Hard in 1920 FES Vehs Under analysis
12 Fuel tank strap not able to seat for 400 litre tank under anlysis. Strap tightened with
length bolt & to close the gap
13 FZZ04800- steering box thread came out Rejected yet to be concluded
Front Engine mounting offset with engine bay X-
14 Under anlalysis
member

15 Rock body received without positive lock Part corrected by supplier & further
stock corrected
LB vehicle sideframe runner gap available in 30% of
16 Under anlalysis
vehicle

17 FTW00299- Leafspring misalignment Part rejected & further ensured by

supplier
18 Adblue tank cap unable to open - jammed Metal slider in cylinder was stuck due to
surface of groove being oxidized
Temporary action: Rusting oil is applied
on lock cylinder from 18th June
19 Burr on the 15 Lit air tank for U 4620 Check point added in firewall check
sheet to ensure burr free supplies.
Air leak from adblue tank filter Nut not tightened waiting for feedback
20

ECU mounting bkt Weld nut position not ok - After Re tapping and inspection
21 Identification Mark Introduced and
F8M02514
Implemented (Ok & Date)

MB402001- Exhaust pipe land availability less - unable 60 nos checked and found 1 no not ok
22
to seat rejected

Stiffener “V-bending squareness “ issue ,

23 tools were studied for further
improvement to eliminate the block
Fuel tank mounting bracket crack in weld portion setting.

Burr Observed inside of machining hole.

24 Line & Store stock 85 no's segregation
Shock absorber bracket holes undersixe under progress.

As a permanent action we removed

material from pattern & milling cut at a
depth of 2mm is kept as it is a
25 Stg Box Mtg bkt Castings excess, grinding done & fitted  preventive action. Detection : Spot face
depth of 2mm we calculated from 3D
model & same updated in control plan
with checking frequency 100%.

26
X3X01514- Rear axle U-bolt broken during torquing Part inspected & found ok under study
27 Stock blocked & corrected at supplier
MB404003- DEF tank received with wrong orientation end

28 Fitree clip location wrong in wiring - FAG77899-Moved Corrected by supplier

from marked location & corrected
29 Spring replaced with matched set &
Rear axle leafsprings received without half span grading further stocks rejected
30 MB401001- EATS Harness not able to connect Orientation correcetd by supplier &
Orientation wrong further stocks corrected
31 FES - CSO cable clamping Not in Yellow identification Orientation correcetd by supplier &
tape further stocks corrected
32 Nearby bolts are aligned & tightened in
Bogie internal flitch holes offset- EATS bracket offset conveyr for offset issue
33 Part rejected & further corrected by
U 3520 Wrong welding in air tank F1J06600 supplier
Part corrected by supplier & further
34 BC Lever Cottor Pin Direction Wrong
stock corrected with ok indication
35 Vin plate Rivetting holes offset Drilling done & corrected

36 Grading mark missing in Springs Spring rejected & corrected by supplier

37 Part rejected & further ensured by

Adblue tank key missing  supplier
38 Taken up with PNR Under analysis
2820 Front Spg Bkt holes offset in FSM Supplied by PNR
39 APU cut in not happening in F1E02400 under analysis
40 Part rejected & further ensured by
Weld stud broken in air tank (inside)- F1J07100 supplier
41 MBP ORT veh held for air bubbles in decal sticker- under analysis
repeated issue
Part corrected by supplier & further
42 CSO cable routing bracket fitted in wrong location stock corrected with ok indication

9mm dia Fitree used in all places.

43 Fitree difference between SCR Harness and Chassis
Harness (9 mm dia difficult to insert in bracket )
Issue observed in Hellerman make only.
No issues used in A Raymond make.
Spec. is same for both makes.
Part quality of Hellerman make to be
checked.

44 Frame wiring fitree clip dia mismatch with FSM hole - Corrected by supplier
FAG77899

45 Modular hose brass adaptor dia undersize - 3520 @ old level- Corrected by supplier
abutment bracket location)

Drop arm rejected. Further stocks

46 Steering box drop arm marking wrong- FZZ05500 will ensured at supplier end
affect draglink setting for 4X2 models
47 Part rejected & further corrected by
FM115813- Bolt not able to fit Weld nut location wrong supplier
48 Part correcetd by supplier & further
FMX08799 #4 Main wiring Pin protuding outside stock corrected
49 Part correcetd by supplier & further
MB52A033 Foot step brkt Length excess stock corrected
50 FES DAT Filler cap not able to open After leak test supplier asked to loosen
the cap
51 F7Z05314 EATS bracket casting excess - fixture fouling Casting growth corrected at HFL
observed

52 Part rejected & further corrected by

Gusset Plate FGK36813 Holes offset supplier
53 Radiator Guard FT500814 hole burr Part correcetd by supplier & further
stock corrected
54 Diflock solenoid hose length short in 2820 T- MB463112 Part correcetd by supplier & further
(1 vehicle) stock corrected
55 Pre EDM Dip Stick In Ntruck Engine Old level further stock ensured
56 Part rejected & further corrected by
Gearbox gusset plate welding wrong- F3P11313 supplier
Part corrected by supplier & further
57 Thread missing in BC lever shackle pin
stock corrected with ok indication

58 F1J04700- air tank mounting not matched with battery Part rejected & further ensured by
carrier supplier
59 Air hose kink in SP valve -2820 Part corrected by supplier & further
stock corrected with ok indication
60 FES recd with letter falls down Check points are added in the
Inspection check list.
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 PD issues June'20
Month Total issues Deviation
June 49 20

S.No Design issues Action

DMU is with holes for POL , 3D Experience DMU
1920 H cross member position wrong  in DMU,
not to be refered by mfg. team. 3D Experience
1 Prop shaft not able to connect (holes added in
DMU is only for PD and it’s a LIVE data. OLD DMU
FSM- latest DMU)
to be referred for Mfg

DMU is with VAVE springs, 3D Experience DMU

1920 POL Haulage Cross member and spring not to be refered by mfg. team. 3D Experience
2
bracket variation with EBOM and DMU DMU is only for PD and it’s a LIVE data.OLD DMU
to be referred for Mfg

Awaiting WABCO drawing from supplier with out

Air Pressure Sensor deleted from FES/G45 Scope Air Pressure sensor. KB make Air prssure sensor
3 and not added in BOM part stage 3 released.
Release by 30th June 2020.

Single modular hose for all models as like G45 FES

4 Single modular hose for G91 will be taken as OGI.
models- to eliminate abutment bracket
As per DMU no issues observed, clmping done
All FES Models E2 Valve hose Length Short ( also after E2 valve connection which is difficult after
5 difficult to clamp )
acb mounting
N truck Front Engine mtg not able to Torque due
6 DFA cleared by MBP mfg. before release.
to Radiator Guard bracket fouling

7 4X2(1920Tip)  VAVE Drag link Drawing error BOM updation after trial in plant . Matrix shared
by PD which is followed
Spare wheel carrier bolt length short- tipper Bolt length changed from 50mm to 65mmRelease
8
models by 24th June 2020

Gap available between Air tank br acket & FSM is

U 4220 Mod hose difficult to route in between
9 Airtank and FSM (getting crushed during airtank
tightening )
65mm x 65mm.
Modular Hose dia.- 30mm.
Modular hose to be assembled first & harness to
be assembeld.Already shared DMU details.
Currently modular hosr routed below air tank to
avoid fouling

FES Rear Cab mtg Bracket error proofing required Part number with LH & RH identification mark
10 provided to G45 Cab mounts, same will be
for Wrong assembly
incorporated for G91 Cab mounts also.

Flitch matching bolts not available as per design - currently managed with bolt tightening in X-
11
To be provided member location
 Adblue tank difficult to subassemble & fit- no DFA cleared by MBP mfg. team before release. 90
12 accessibility for tightening in Tipper models with degree tool tightening & torquing done - modified
SWC. bracket yet to release

4220 FA2 brake elbow difficult to connect behind

13 air tank Brake elbow hose taken from sleeve & connected

U-truck Front cab mounting alignment delay- DFA cleared by MBP mfg. team before release.
14 clearance less between cab bracket on NODO &
Under analysis
Cabin

15 ECU K-connector fouling with strap - unable to Strap is removed & connection done
remove

16 Steering UJ shaft fitment difficult in FES models under analysis

Manual torquing done from inside. As per PD

17 ECU mounting bracket difficult to align & torque  Weld nut introduced in ECU Box in Stage 3, with
reference to DFA requirement.
Radiator bypass pipe fitment delay- need stopper Connection ensured with difficulty Release by 23rd
18
at engine pipe June 2020

Integration of split X member as a single X Split X-member assembled & engine drop done for
19 member.for modular hose routing & wiring all vehicle Split cross member provided to
routing facilitate straight Engine + Gear Box drop.

Currently setting done manually. DFA cleared for

20 Relay drag link difficult to fit. Required with Preset powe max. cut setting by MBP mfg. team. PP
condition
working on Pre set option.

21 Steering UJ difficult to insert / Fouling with Design In progress

shroud.
22 ABS polewheel sensor not getting locked Corrected as rework. Under analyis
Earthing points loose even after torque
23 Spec revised to 30Nm. Under analysis
application of 20Nm

24 PTO hoses in LB(MM90000263) doesn't match Corrected by supplier

with PTO adaptor (MB90M1010)
25 SPV hose kink in all vehicles Corrected by supplier
SWC carrier tightening accessibity poor in tipper
26 models 90 deg tool used & Manual torquing done

Tie bar not received.Both tie bar called in SPEC

27 Corrected in Spec
( Regular and vave)

28 Lift axle kit fasteners to be called in vehicle BOM Received in deviation

CA-0051379 / 24th May 2020 released.

Parking brake sensor grommet not available in
29 Details of Modification : RUBBER BOOT ADDITION
drawing for KB
ON LP SWITCH OF HBV

FYJ06311 fitted as deviation as recommended by

Bogie X Mbr Mtg Bolt FYJ07311 Excess Shank ,
30 PD. EDM reversal done. Correct part number to be
Drawing wrongly updated, shank length excess
received
 3520 Tipper Spare wheel Carrier Hole missing in New revision for spare wheel carrier flitch to be
31
Flitch Drawing used.

32 X-member bolts fouling with Adblue tank bracket 4 bolts in X-member eliminated.Spec release by
-1920T 30th June
Washer not fitted . Washer available in EBOM will
33 ASA slack adjuster pinch bolt mtg length short
be eliminated
PD advised to use L3611018 / FYG10811, CA will
34 ASA slack adjuster pinch bolt mtg nut pitch mismat
be released by 10th July 2020

35 Front Axle U bolt wrong offtake (Offtake not CA-0052784 / 18th June 2020 / Released
changed after Antiroll bar bracket removal)
SCR harness received with fitree in parking
36 Fitree removed . ECN raised & corrected internally
location(wrongly called)

Clamp fitment done with difficuly

C- Clamp will be supplied along with Modular
Modular hose C-CLAMP (F9L02200/F9L02300) Hose, Corrugated sleeve will not be available in C -
37 difficult to fit Clamp portion, it will reduce overall diameter of
Modular hose and assembly issue will not be
there.

Currently done with manual intervention

FSR spring bracket mounting varies with model
38
need mistake proofing - VAVE & regular
VAVE Bracket - 2 mtg. on flange & 2 mtg. on Web
Non - VAVE Bracket - 4 mtg. on flange & 4 mtg. on
Web
We will share the applicability matrix for VAVE
bracket.
Bracket to be followed as per CBN.

Thread bolt alignment delay – EATS & Temporary stud fitted & aligned with FSM
39
Multifunction bracket Permanent Stud will be provided as OGI by PD

40 24 Lit Ad-Blue air hose strain at both sides Done as Q-gate rework

41 24 Lit SCR harness clamping not able to do Done as Q-gate rework

42 F8M05614- Brkt L Type Nut pitch wrong Alternate part no fitted
MB211001- Clutch bundy pipe Hose not able to Clip locking done with difficulty. Hose came out
43
connect during clutch oil filling

44 3520 LA models - Air tank mtg holes missing A level to be used #4 level FSM used as per DMU,
but holes not avl for mtg air tanks
Wheel choke loose in Haulage vehicles- concern Wheel choke mounting position changed yet t o
45
from field be updated in spec
46 MB631002- HCFB cable fitree unable to seat Design change in progress
F3S02368/2468 Bezel  wrongly called in SPEC
47 instead of F3Z00160/260 . Release by 30th June 2020

PLM attribute for BS VI  Denso ECU vehicle wrong Attributes corrected in LEAP, For all new releases
48
updation in LEAP. after March, the attribute is Denso N4 only.
 Cluster dataset id not available not available for Part nos. were available in BOM during the CBN
49
1920T release on 6th May’20. LEAP error will be checked.
 Pending Closed
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Closed
 Major Facility issues June'20
Month Total issues Temporary action
June 14 9

S.No Major Facility issues Action

NRS spring bracket thread bolt alignment
1 Manipulator planned for closure yet to introduce
delay
2 Bogie wearpad subassembly delay Fixture yet to be installed
U-truck Cab mounting dealy due to pitch Gauge developed. Offset observed in NODO
3
offset bracket mounting under progress
Manual Diesel Bleeding leads cycle time
4 Auto diesel bleeding yet to be installed
loss, Adapter required
Manual torquing done. E-rad tool under
5 Shock absorber bkt torquing difficult implementation
6 NRS spring bracket torquing delay Manual torquing done. Tool to be provided
7 Front cab mounting unable to torque Manual torquing done. Tool to be provided
24L Adblue tank unable fit for tipper Manipulator base modified. 90 deg tool & manual
8
models(U2820,U3520) torquing done
9 Threaded bolt difficult to align and Torque Temporary stud provided to align thread bolt

10 EATS mounting bracket fitment difficult Manipulator modified to fit EATS braket. Trolley
for loading EATS brackt pending

11 Adblue filling quantity less error indication Pipeline yet to be completed Quantity
programmed in machine

12 Bumper reflection tape difficult to paste Manual pasting done

13 Bogie shim selection process delay Manual setting done as 2 stage activity
14 Bogie bracket subassembly delay Bogie V-rod fixture activated & in use
Spring fixture stabilisation under process(clamp
15 Bogie spring subassembly delay -
came out in assembly)
Skid Not suitable for Bogie Vehicles , Tyre
16 Skid modification done
not able to do torquing
17 FES getting dent near footstep Tackle modified to avoid fouling
Engine bay Cross member /Rear Closure Track length extended for loading engine bay X-
18
member difficult to fit member
SCR harness clamp mounting bolt broken Battery torque controlled gun provided to avoid
19 on EATS bracket brekage
20 FES mounting delay Additional tackle provided
 Pending Closed
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 Sourcing issues June'20
Month Total issues Deviation
June 14 4

S.No Sourcing issues Action

Leafspring received in camber angle & Taken back by supplier and arranged with
1 halfspan mixup condition- to be received in matched set
batch
2 BC lever received in BS4 trolley- to be  Under progress- oneside matched with
received in vendor trolley  fabricated trolley
3 EATS not received in Trolley Movement  done with Fork lift instead of Jumbo
4 FES not received in trolley Bolts removed to take out cabin from
palletunder progress
5 Ad blue tank trollies to be multiplied  Managed with internal fabricated trolley
6 Fuel tank strap received in loose in place of Manual pressing done on strap & flap
sub assembly
Battery carrier stud received in damaged Special trolley fabricated for battery carrier
7
condition loading

8 Front FACIA mounting bracket shortgae- Delayed due to transit

MB502061, MB503034
9 All Cross members Part number Engraving Not Temporarily refereing to part number written on
done, Direction mark Not done X-member
10 FC404000 EATS cover shortage EATS cover fitment changed to plant scope

11 X8D00300- EATS cover mounting bracket EATS cover fitment changed to plant scope
shortage
12 2820 RMC propeller shaft IBTA part Matched with Axle IBTA
13 F6C05114- Fuel tank bracket late issue Delayed due to Fuel tank bracket inspection
Called separate part number FCF05514 for FCF05514 Rear closing X-member shortage-
14
2820 RMC MBA01155 fitted as alternate
 Pending Closed
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