Professional Documents
Culture Documents
Customer Complaint Register
Customer Complaint Register
2017
Sr. No. Customer Name DATE PART NO. PART ISSUE REPORT MODE OF DEFECT DESCRIPTION REJECTION ROOT CAUSE ICA PCA Attachment
DESCRIPTION BY COMMUNICATION QTY
Flange stud M6x14 & M6x20 is chance to mixup in supplier Fuel tank mtg brkt stud length 100% inspection carriout by
90ltr Tank Assy 90ltr fuel tank stud length end, So all the current stock studs are checked & verified, All available parts in customer end 100 stock , 0 defects supplier end with commitment mark (All the flange stud in
2 Ashok Leyland 17.09.2019 172022VE1A -Fuel Kumar Mail short 1 and 100% visual inspection carried out with marking after and in-house 300 stock available checked 0 defects, stock checked ok on supplier end) Leyland\Sep 2019\2.JDI 90 ltr fuel tank flange height short.
the assembly 100% visual inspection done by PDI inspector with
commitment mark on tank assembly
Welding fixture modified to avoid the tire fix brkt slot under
size ( Pin type to Slot profile type will be modified)
SWC-Tire fix brkt Tire fix brkt slot size is less at mouth area due to handling All available parts in customer end 52 stock , 0 defects 1.100 % inspection carried out on PDI inspector by using T-bolt Leyland\Nov 2019\3.SWC - T BOLT NOT ENTRY.pptx
8 Ashok Leyland 20/11/19 572102VA0A Kumar Whatsapp group Tire fix brkt slot size less 1 damages , So slot type of checking is introduce in final and in-house 80 stock available checked 0 defects, inspection & do comitment mark..
inspection gauge (wedling shop) 2.Punch size will be corrected in tool Target date to complete
15/12/19.
SWC Assy - Height After tube bending , tube spring back issue, height variation After tube bending revising process added before welding, to
Carr. assy , inclinded All available parts in customer end 20 stock , 0 defects
10 Ashok Leyland 4/12/2019 572102VA0A sparewheel - Sankaran Whatsapp group variation/inclined 1 and in-house 25 stock available checked 0 defects arrest the spring back.100% visual inspection before welding , Leyland\Dec 2019\2.SWC IFS - HEIGHT VARIATION.pptx
seating of the tube, no up down movement.
Bull bar mtg brkt with After Spatter removal no self certiifying not done / near All available parts in customer end 40 checked 0 Awareness given to operator to ensure the free from spatter
11 Ashok Leyland 9/12/2019 620642VA0A Bull Bar Assy Thirumal Whatsapp group spatter near slot area 1 bracket area/ spatter not cleaed fully near slot area defect, ,and in-house 30 stock available checked 0 and selff certifying after spatter removal by the opertor. Leyland\Dec 2019\3.BULLBAR - RECT PLATE SPATTER.pptx
defects 1.100% ensure in welding line as well as final PDI.
at the time sample drawn in heating condtion in process, checking guge provide on both supplier & in-house.
which resulted shrinkage happen inbetwen time same not process awarness to given at supplier end same inhouse
ensured at supplier end 100% insepection not followed All available FG and child parts in our end 200 nos inspection awarness given.
18 Ashok Leyland 29-Sep-20 172442VE1B INSUL-FUEL TANK Sankaran Whatsapp group Rubber width Variation 3 effectively. checked found zero defects At the time of dispatch 100% Guage & visual inspection done
Leyland\Aug 2020\JDI Insul Rubber Strap Width Undersize.p
At DS PDI visual inspection not effective. and identfication mark provide.
20 Ashok Leyland 21-Sep-20 572102VA0B CARR ASSY - Sankaran Whatsapp group SWC Open out 1
SPARE WHEEL
22 Ashok Leyland 15.10.2020 130482VA2A PIPE ASSY COMP Sankaran Whatsapp group Bolt inclined entry due to 1
inclined retap done
25 Ashok Leyland 16-Nov-20 215372VA0B PIPE RAD LWR Sankaran Whatsapp group tube line mark/crack 1
26 Ashok Leyland 28-Nov-20 172022VA1A TANK ASSY - FUEL Sankaran Whatsapp group BOLT NOT ENTER, STUD 3
BROKEN
27 Ashok Leyland 28-Nov-20 172022VE1A TANK ASSY FUEL Sankaran Whatsapp group HEAVY BURR 1
Ashok Leyland 28-Nov-20 180202VE1A Brkt Accl Mntg Sankaran Whatsapp group WELD NUT MISS 1
Ashok Leyland
Ashok Leyland
Ashok Leyland
Ashok Leyland
Ashok Leyland
Sr. No. Customer Name DATE PART NO. PART DESCRIPTION ISSUE MODE OF DEFECT DESCRIPTION REJECTIO ROOT CAUSE ICA PCA
REPORT BY COMMUNICATION N QTY
Improper torque applied Inadequate checking method ,Final inspection Now Leak testing pressue increased 0.4 to 0.55 bar
in drain bolt due skipped,Seepage was unable to detect due to less Custromer End stock Check 25parts fround 4 and esure with soap water test twice. DICV\Jan 2020\Seepage issue
6 DICV- India 27.01.2020 A4004700601 ZB Fuel Tank/160L Vignesh Whatsapp group 1 part Not Ok
Drainplug seepage duration
ZB Fuel
7 DICV- India 27.01.2020 A4004701701 Tank/200L/Circular Vignesh Whatsapp group 1
ZB Fuel tank/200L/BS6
9 DICV- India 10.03.2020 A4004707001 Vignesh Whatsapp group Neck orientation shifted 16 Feb20 month rejection accounted at March'20 by customer , Reference Feb Attchement
Rv10
DICV Stock Check 18 nos found 1 nos NC Sandaring the GA coating over the shell jioning area
10 DICV- India 21.7.2020 A4004700801 ZB Fuel Tank Vignesh Whatsapp group Fuel seepage from end 1 Material outer GA coating affect the weld quality / @ D&S Stock checked 28 nos found Zero & endcover area of GA tank before the shell joining DICV\JUly 2020\0801 - End sea
seam welding Changes to Operator poor vision
Defect process to increase the weldability of GA tanks
fuel tank drain plug DICV Stock Check 16 nos found 2nos NC Job setup done on the smal sample cutpice instated of DICV\Aug 2020\1. 0801 drain
13 DICV- India 27.08.2020 A4004708401 ZB FUEL TANK Vignesh Whatsapp group welding/Pin hole welding 2 Job setup rework traning not effetive.
@ D&S Stock checked 17nos found Zero Defect tanks.
rework issue
Forming tool not re-polyished due to this crack Tool history card to be updated & Tool Re-polyishing to
DICV Stock Check 15 nos found 1nos NC
DICV- India 28.10.2020 A4004707001 ZB FUEL TANK Vignesh Whatsapp group Hose Bracket teared 1 generated while forming opertion same not ensured in @ D&S Stock checked 12nos found Zero Defect be done
PDI . Working level Awarness taning to given PDI inspectore
41
Isuzu Motors
1 6.9.2019 8974461061 Neck Saravanan Mail Fuel neck rust 1 Inside Painting not done Commerical issue- Mail Communication
India Pvt Ltd
Water contamination inside fuel tank due ICA-1:- Customer end stock checked 125nos + yard 1.After breather tube full welding self certified with tick mark. (Refer PPT)
to improper weld in breather pipe vehicle around 959 with VIN no details given to 2. Leak testing before and after powder coating commitment paint mark
customer, 0 nos defects observed. provided near breather tube after powder coating paint commitment mark
ICA - 2:- In D&S Stock - 92 nos checked provided. (Refer PPT)
Isuzu Motors zero defiects found. 3.In final PDI commitment provided every co2 welding area - full round
2 20.11.2019 8974497242 TANK ASM;FUEL,FO Saravanan Veribal Breather hose pipe welding miss 1 checked two lines on every co2 tube welding area. (Refer PPT) Izusu\2 .IMI PPRC 19-494 c
India Pvt Ltd
Suction tube was blocked due to dust
particles / mud found inside the tube.( see
pics below)
Isuzu Motors Small forign particle passed out from mesh Checked all hoses at Customer End and In house also. Introduced new size of mesh , whose cross section area is so less instead of Izusu\3.IMI PPRC 19-495 Br
3 22.11.2019 8974461072 NECK -Yacha Saravanan Veribal Hole on hose 1
India Pvt Ltd during to cover operation at supplier end old mesh, So small particle also filter easily.
ICA-1:- Customer end stock checked 35 nos , 1 nos 1. supplier end fallen part in plating tank to be checked visuall as any
defects observed.
Vehicle not getting start due to fuel forgine material presence.supplier rework procedure
Isuzu Motors ICA - 2:- In D&S Stock In final PDI area checked -
5 07.09.2020 8974497243 Tank Asm Fuel Saravanan Mail flow not in available from fuel tank 1 Izusu\5.IMI PPRC 20-068 (1
India Pvt Ltd 65nos OK, defect part-Zero
delivery hose 2. Before float unit assembly tube to be checked with air passing. (ensure
ICA- 3:-In supplier end all the parts checked no defect
free from foreign particles inside)
found
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd Seems there was more
dust particles present inside the fuel
tank ,during plating part fallen in platining
tank and dust accumulated and dried .
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd
Isuzu Motors
India Pvt Ltd