Team ID 21133

TEAM DEMONS RACING

MANUFACTURING REPORT
Copyright @ 2021 SAE BAJAINDIA
Author- Onkar Kamble
I: Assembly Sequence for overall (Department of Mechanical Engineering, Government
Vehicle Manufacturing : college of engineering Karad)

ABSTRACT Design of Vehicle

After market survey and data collection, designing team
The assembly line is a series of workstations which is used
starts working on product design with reference to above and
to assemble the different parts of vehicle and form it to one
present flaws in other competent products.
complete unit for efficient working. In the assembly line parts
are added to the various stations in order to form a complete
While starting with the methodology we initiated with study
assembly. Each station consists of various operations which
and research of elementary data of various materials used
are performed while doing the assembly. Objective is to
for their analyses. And made a final design according to
design an assembly line to reduce the manufacturing cost of
market requirement.
itself and increase the efficiency of production.

INTRODUCTION
This report describes the methodology followed by Team
Demons to analyse and prepare optimized mass
manufacturing of an all-terrain vehicle. The purpose of this
manufacturing is to manufacture an ATV with robust,single
seated off-road durable vehicle intended for sale to the
week-end off road enthusiast and off road routine
consumers. It also describes the BoM, assembly sequence,
Organization workflow, plant layout,etc.to highlight the
manufacturing unit.

Objective
 To increase accuracy and precision of assembled
product. 

 To reduce time required for assembling. 

 To make the process of assembling simpler in working.

 To make the complex products easy to assemble and

reduce the fatigue to operator. 

 To increase productivity and reduce human

interference/errors while doing assembly.  To reduce
the fatigue to operator.

Market survey and data Collection:

The prime objective of the data collection and market survey
is to gain the information of market requirement and which
type of product needed for off road enthusiasts to finalize the
product and its design followed by BoM.
 BOM for complete vehicle manufacturing
Part Number Part Name Material Types of material Quantity per Weight
Vehicle (in Kg)
B21-00-0001 Vehicle assembly complete
B21-10-1000 Roll cage 22 Kg
B21-10-1100 Firewall Al-Checkered Inhouse 1 2 Kg
B21-10-1200 Side panels Poly-propylene In house 2 1 kg
B21-20-1000 Powertrain
B21-20-1100 Engine - Vendor 1 28.57
B21-20-1200 CVT - Vendor 1 10
B21-20-1300 Half shaft / Axle OEM Hardware 4 3
B21-20-1400 Gearbox 20Mncr5 Vendor 1 8.5
B21-20-1500 Differential - Vendor 1 2.8
B21-20-1600 Propeller shaft - Vendor 1 0.5
B21-20-1700 Engine mounting table AISI 4130 Inhouse 1 2.5
B21-30-1000 Fuel system
B21-30-1100 Fuel tank Fibre Vendor 1 1
B21-30-1200 Fuel tank mount MS steel Inhouse 2 0.15
B21-30-1300 Fuel line Rubber Vendor 1 0.25
B21-30-1400 Splash shield Al Inhouse 1 0.2
B21-30-1500 Drip pan Al Inhouse 1 0.05
B21-40-1000 Seating system
B21-40-1100 Seat Mounting members AISI 4130 2
B21-40-1200 Seat FRP Vendor 1 0.75
B21-40-1300 Mounting clamps MS Steel Inhouse 4 0.3
B21-50-1000 Brakes
B21-50-1100 Disc Se420 Inhouse 3 0.5304
B21-50-1200 Pedal AISI 4130 Inhouse 2 0.556
B21-50-1300 Oil Dot 3 Hardware 1 0.5
B21-50-1400 CBX Calliper - Vendor 2 0.5
B21-50-1500 Brakes hose Steel braided Vendor 5m 0.3
B21-50-1600 Nikavi RTR calliper - Vendor 1 0.92
B21-50-1700 Mounting Clamps MS steel Inhouse 4 0.150
B21-60-1000 Assembly sus - steering
B21-60-1100 Assy Frt Wheel RH-joinary
B21-60-1101 Knuckle spindle RH Vendor 1 1.4
B21-60-1102 Ball bearing Chrome steel Hardware 1 0.2
B21-60-1103 Single Row cylindrical roller Chrome steel Hardware 1 0.2
bearings
B21-60-1200 Assy Upper A Arm RH AISI 4130 Inhouse 1 1.2
B21-60-1300 Assy Lower A Arm RH AISI 4130 Inhouse 1 1.1
B21-60-1400 Assy Tie rod Al Inhouse 1 0.2
B21-60-1500 Assy half shaft Hardware 1
B21-60-1600 Assy Hub-Rotor RH
B21-60-1601 Hub Frt Wheel RH Al-7075 T6 Inhouse 1 1.6
B21-60-1602 Disc Rotor Frt Wheel RH Se402 Inhouse 1 0.5
B21-60-1603 Hexagonal Flange bolt MS steel Hardware 2 0.01
M8*1.5*6
B21-60-1700 Assy brakes
B21-60-1701 Kbx brake calliper - Hardware 1 0.5
B21-60-1702 Brake pad Rubber Hardware 2 0.01
B21-60-1702 Brake line Steel braided Hardware 1m 0.1
B21-60-1801 Wheel Frt RH Vendor 1 2
B21-60-1900 Assy Frt Wheel LH-joinary
B21-60-1901 Knuckle spindle LH Al-7075 T6 Vendor 1 1.4
B21-60-1902 Ball bearing Chrome steel Hardware 1 0.2
B21-60-1903 Single Row cylindrical roller Chrome steel Hardware 1 0.2
bearings
B21-60-2000 Assy Upper A Arm LH AISI 4130 Inhouse 1 1.2
B21-60-2100 Assy Lower A Arm LH AISI 4130 Inhouse 1 1.1
B21-60-2200 Assy Tie rod Al Inhouse 1 0.2
B21-60-2300 Assy half shaft Hardware 1
B21-60-2400 Assy Hub-Rotor LH
B21-60-2401 Hub Frt Wheel LH Al-7075 T6 Inhouse 1 1.6
B21-60-2402 Disc Rotor Frt Wheel LH Se402 Inhouse 1 0.5
B21-60-2403 Hexagonal Flange bolt MS steel Hardware 2 0.01
M8*1.5*6
B21-60-2500 Assy brakes
B21-60-2501 Kbx brake calliper Hardware 1 0.5
B21-60-2502 Brake pad Rubber Hardware 2 0.01
B21-60-2503 Brake line Steel braided Hardware 2m 0.1
Assembly Line:
A. Press shop
The press plant provides the sheet metal and tube parts
for the bodywork. The manufacturing process begins
with extremely heavy tubes and rolls of steel and
aluminum sheet. The slots are initially cut to form boards
and then pulled with the most modern, fully automated
high-speed servo presses in several steps, bent and
punched. This results in molded parts such as side
frames, body frame, cockpit base, back panel, splash
shield and other covering parts,etc according to required
dimensions.The Demon motorsports uses a function-
oriented mix of proven deep-drawing steels and high
and higher strength materials.In the item production we
already lay the basis for the unique design and the
extremely rigid, but light weight bodies to make our
vehicle robust and durable with acquiring necessary
safety parameter to the passenger.
B. Body-Part assembly shop
The body part assembly shop consists of various sub-
assemblies attachments namely, chassis,transmission,
suspension, steering, Brakes,etc. Body shop means the
precise assembly of several hundred individual parts
made of steel and aluminum of different sizes and
thickness to a precision body. Depending on the vehicle
requirement besides steel and aluminum also some
carbon and fiber composites (SMC) are installed. With a
high degree of technical know-how resulting from
welding and joining techniques such as spot welding,
soldering, screwing and gluing, as well as the new laser
welding millimeter accuracy bodies. Most modern
technology skilled workers and robots perform these
serious and complex work with maximum precision,
while highly qualified employees control the machines
required.
1. Chassis Body: Base frame for Vehicle
First sub-assembly done in body shop is chassis formation by
using bend tubes and sheet metals of steel and aluminium. It
forms the base frame for the vehicle providing a support
structure to all elements of vehicle and mountings.
Chassis Material:As we know material selection is one of
the most important factor for vehicle point of view. So we
focused on material selection carefully. In material
selection we compared various material like AISI1018,
AISI4130, AISI4140 with their properties strength,
Young modules, machinability, chemical composition.
By this comparison we have selected AISI4130 because
it gives good yeild strength with good elongation
percentage and machinability also we selected better
chemical composition of AISI4130.
For welding fixtures are used to maintain angle of firewall and
length between members. In fixtures C- clamps are used to fix
the pipes at required position also we used L shaped clamps
to fix the pipe. And to maintain angles we designed fixtures.
2. Transmission assembly mounting
After welding a chassis successfully, transmission parts
like engine mountings, casings, etc. are assembled with
the chassis with allowing some tolerances for future
operations.

3. Suspension assembly parts
After transmission parts suspension control arms, H
arms and cambers link are attached with the chassis in
this stage, Allowing vehicle to move to the next
assembly line where side panels and cockpit-firewall
sheets are joined with them.
4. Steering assembly parts:
In this stage, after suspension parts mounting; the
steering parts like tie rod steering column get connected
with the remaining assembly with chassis.
Selection of material:
Metal base- Aluminium is used due to its light weight.
Plastic foam- Polyurethrene is used due to its properties
like light weight, abrasion resistant ,wear resistant and
complex shape capabilities.
Manufacturing process:
The metal base or internal support of a steering wheel is
a skeleton made of aluminium. The skeleton is then
covered with a very durable,
soft foam material,usually polyurethane (PU).
To form polyurethane foam, a process called Injection
Molding is performed. Before injecting the polyurethrene
the mould is covered with a release agent so that foam
will not stick on the mould.
5. Braking parts mounting:
Last parts on the partially complete assembly to be
mounted is braking parts and fluid lines.
Material selection for Brakes:-As we know material
selection is one of the most important factor for reliability
of vehicle. So we focused on material selection carefully.
In material selection we compared various material like
ss420, ss410, cast iron with their properties strength,
Young modules, machinability, Thermal properties (For
Disc) And for Pedal we compared Al 6061-T6, Al 7075-
T6, stainless steel. We chose ss420 for Disc Because it
has better overall properties and Al 7075-T6 For pedal
because it has better weight to strength ratio.
As per our design we deiced to laser cut disc. We chose
laser cutting because of its accuracy, speed, cost
effectiveness. After laser cutting by induction hardening
we hardened disc.  The hardened surface is ground on
both sides to achieve the required flatness and to control
disc thickness variation (DTV). Due to hardening we
decreased wear of disc due to brake pad, Which
translates to increase in life of disc.
 D. Paint Shop:

After QC check, the assembly goes for the paint where

the all necessary coatings and paints are done on the
assembly.

Final Assembly:

After this, it goes for the final assembly where all

remaining parts get attached with the vehicle including
engine and other parts. And final fittings are done to
forward it for inspection checklist.

C. Quality-control and Precision Check:

Once all parts are assembled the assembly goes for

precision and quality check line for maintaining the
precision throughout the slot and getting a desired
parameter acquiring vehicle.Once it is done, the vehicle
get the QC1 pass tag, assembly goes for the paint to
acquire aesthetic look.

Ovearll methodology

The assembly of a car: assume that certain steps in the assembly line are to install the engine, install the hood, and
install the wheels (in that order, with arbitrary interstitial steps); only one of these steps can be done at a time. In
traditional production, only one car would be assembled at a time. If engine installation takes 20 minutes, hood
installation takes five minutes, and wheels installation takes 10 minutes, then a car can be produced every 35
minutes.In an assembly line, car assembly is split between several stations, all working simultaneously. When a
station is finished with a car, it passes it on to the next. By having three stations, three cars can be operated on at the
same time, each at a different stage of assembly.

After finishing its work on the first car, the engine installation crew can begin working on the second car. While the
engine installation crew works on the second car, the first car can be moved to the hood station and fitted with a hood,
then to the wheels station and be fitted with wheels. After the engine has been installed on the second car, the second
car moves to the hood assembly. At the same time, the third car moves to the engine assembly. When the third car's
engine has been mounted, it then can be moved to the hood station; meanwhile, subsequent cars (if any) can be
moved to the engine installation station.

Assuming no loss of time when moving a car from one station to another, the longest stage on the assembly line
determines the throughput (20 minutes for the engine installation) so a car can be produced every 20 minutes, once
the first car taking 35 minutes has been produced.

Supplier Criteria for outsourcing materials and parts:

Workflow Organization:

MISSION: We Commit at providing quality products and unsurpassed

customer services and to Adapt vehicles to nature rather than Adapting
nature for vehicles

VISION: To be the most successful, trusted and respected all

terrain vehicle company in the world
 Production. This is the largest department, because it has hundreds of factory workers, and dozens of team
leaders. They do and oversee the work that happens on the factory floor. They keep the machines running, and
fix them when they break (unless it’s a problem for an engineer). However, both the workers on the floor and the
top production managers, and everyone in between, get direction from…

 Quality. This is the department that insures that every piece we make is at our standards. They run tests on all
the aluminum that comes in. They test pieces that our suppliers send us. They are in charge of designing and
implementing the system of checks that workers on the factory floor must run. They are also responsible for
maintaining the stock of thousands of calipers, each capable of micron-level measurement, and keeping all of
them properly calibrated. This department pulls a few pieces from every lot for testing, tests them with some very
sophisticated equipment, and doesn’t let the lot out unless those pieces pass those tests.The Quality department
also has the ISO 9001 officer, who is responsible for reading the materials from ISO 9001 and making sure that
we comply. However, the ISO qualification has to do with how the whole business is run, not just Quality, which
means that often the officer wants to give directions to the upper management that would otherwise be quite out
of line.

 Sales and Purchasing. There are surprisingly few of these people, because the parts we make more or less sell
themselves. Although they sometimes go to trade shows, they do almost no formal marketing. Their job is more
following orders through than it is trying to get people to buy, which is why they also do the buying. Finally, they
are the people who read our customer’s plans for the year, and it is based on those goals that sales goals and
initial production schedules are made.

 IT. These guys are like the plumbers of the company. If any computer has any sort of issues, they’re the guys
who will come and fix it.

 Environmental Health and Safety.Technical Planning (also known as Engineering). Before a new part goes into
production, a lot of design has to go into it. These guys work with our customers to develop test parts, which they
then send to the customers. Based on the customer’s response, they will then either redesign it, or send the
specifications to Production. Also, they are responsible for buying all of the equipment, ensuring that it can run to
our specifications, and training representative staff from Production.
 Corporate Support. All of the administrative support for the whole company. This includes…

 Translation and interpreting. A lot of the engineers are from Japan, and both our parent company and our
customers are Japanese. So a lot of interpreting has to happen, both between the engineers from Japan we
have, the tech reps who come for only a few months, the auditors who sometimes come from Japan, and the rest
of the company.

 Payroll. HR. The paperwork that has to be done when someone gets hired or fired. The cars that the guests from
Japan drive have to be bought, serviced, and fueled, and we pay for it. We liaise with the hotels that we put
Japanese guests in. We put up bulletin board displays. We answer the phones when someone calls. We do all of
those fiddly little things that keep the company running.

 Accounting. These people count up all the money spent anywhere in the company, and how much money we
have. They give the OK or the red light if any department wants to spend more than its budget for the month.
They calculate how much each piece costs to make, and at what prices we must sell them for. They read the tax
code every year and make sure that when we do our taxes, we do so in accordance with the law. If there’s any of
that reading or counting up they can’t do, they send the work to large accounting firms.

Company Financials :
 Annual production volume: 4000 no’s
 Production ratio(In-house : Outsource):1:5
 Manufacturing Cost before duties/taxes: Rs.4,50,000
 Annual sales turn over: 220cr
 Investment required-factory shed: Rs.1,26,00,000+Rs.21,00,000=1.47cr
 Investment required-capital equipment: Rs.102.42cr
 Material cost/vehicle: 100cr
 Estimated annual gross profit: Rs. 32.4cr
 Borrowed Loan capital: Rs. 63cr
 Advertisement cost and service cost: Rs.4.6cr
 Break even in units:12000
 Average inventory – 15days

Front wheel Assembly

BAJA 2021 – BOM for Front Wheel Assembly

Part Number Part Name Material Types of material Quantity per Weight
Vehicle (in Kg)

B21-60-1000 Assembly sus - steering

B21-60-1100 Assy Frt Wheel RH-joinery

B21-60-1101 Knuckle spindle RH Vendor 1 1.4

B21-60-1102 Ball bearing Chrome steel Hardware 1 0.2

B21-60-1103 Single Row cylindrical roller Chrome steel Hardware 1 0.2

bearings

B21-60-1200 Assy Upper A Arm RH AISI 4130 Inhouse 1 1.2

B21-60-1300 Assy Lower A Arm RH AISI 4130 Inhouse 1 1.1

B21-60-1400 Assy Tie rod Al Inhouse 1 0.2

B21-60-1500 Assy half shaft Hardware 1 3

B21-60-1600 Assy Hub-Rotor RH

B21-60-1601 Hub Frt Wheel RH Al-7075 T6 Inhouse 1 1.6

B21-60-1602 Disc Rotor Frt Wheel RH Se402 Inhouse 1 0.5

B21-60-1603 Hexagonal Flange bolt MS steel Hardware 2 0.01

M8*1.5*6

B21-60-1700 Assy brakes

B21-60-1701 Kbx brake calliper - Hardware 1 0.5

B21-60-1702 Brake pad Rubber Hardware 2 0.01

B21-60-1702 Brake line Steel braided Hardware 1m 0.1

B21-60-1801 Wheel Frt RH Vendor 1 2

B21-60-1900 Assy Frt Wheel LH-joinery

B21-60-1901 Knuckle spindle LH Al-7075 T6 Vendor 1 1.4

B21-60-1902 Ball bearing Chrome steel Hardware 1 0.2

B21-60-1903 Single Row cylindrical roller Chrome steel Hardware 1 0.2

bearings

B21-60-2000 Assy Upper A Arm LH AISI 4130 Inhouse 1 1.2

B21-60-2100 Assy Lower A Arm LH AISI 4130 Inhouse 1 1.1

B21-60-2200 Assy Tie rod Al Inhouse 1 0.2

B21-60-2300 Assy half shaft Hardware 1 3

B21-60-2400 Assy Hub-Rotor LH

B21-60-2401 Hub Frt Wheel LH Al-7075 T6 Inhouse 1 1.6

B21-60-2402 Disc Rotor Frt Wheel LH Se402 Inhouse 1 0.5

B21-60-2403 Hexagonal Flange bolt MS steel Hardware 2 0.01

M8*1.5*6

B21-60-2500 Assy brakes

 B21-60-2501 Kbx brake calliper Hardware 1 0.5

B21-60-2502 Brake pad Rubber Hardware 2 0.01

B21-60-2503 Brake line Steel braided Hardware 2m 0.1

B21-60-2600 Wheel Frt LH Vendor 1 2

Make or buy Decision

Sr. No. Components Make or Buy

1 Damper Buy

2 Wishbones Make

3 Disc Rotor Make

4 Knuckle Make

5 Hub Make
 6 Spherical ball joint Buy

7 Single row cylindrical bearing Buy

8 Brake calliper Buy

9 Nuts Buy

10 Bolts Buy

11 Steering arm Buy

12 Tie rod Make

13 Shaft Buy

Components to be manufactured Inhouse

Knuckle-Hub

Due to complex design and higher manufacturing cost, knuckle and hub were decided to manufacture inside our own facility.
Milling, turning and various operations will be performed in a CNC machine to produce the required parts. Various quality checks
and inspections will ensure proper manufacturing of the component.

Wishbone-Tie rod

Suspension and steering links are easy and inexpensive to manufacture which will reduce the overall cost of manufacturing
hence where decided to manufacture in house. Operations like notching and welding will be used for the manufacturing of the
components.

Direct buy components

Components like Dampers, Brake callipers, nuts and bolts etc are hard to manufacture but easily available outside at lower cost.
So, to reduce manufacturing burden, they were decided to buy from suppliers.

Supplier Selection Criteria

Identify key supplier evaluation categories

Weight each evaluation category

 Identify and weight sub categories

Define scoring system for Categories and sub categories

Evaluate supplier directly

Review evaluation results and make selection decision

Review supplier performance continuously

Operational Operational details Machine Tool used for Inspection gauges
machining
Sequence

1 Casting Inspection of Billet None None Vernier Calliper

2 Mounting and Clamping on CNC None None None

Fixtures

3 Face milling on both CNC Milling cutter Vernier Calliper

170mm*55mm surface to 35mm

3.1 Leaving the spindle face milling is CNC Milling cutter Vernier Calliper
done further 10mm

3.2 For calliper mounting, face milling CNC Milling cutter Vernier Calliper
on both 170mm*50mm surface to
6mm
 4 Turning spindle portion to 40mm CNC Turning cutter Vernier Calliper
diameter, h8

4.1 Turning operation for finishing with CNC Turning cutter Vernier Calliper
reduced feed

5 Drilling operation for UBJ and LBJ of CNC Drill bit of 12mm Vernier Calliper
12mm diameter

6 Drilling operation for calliper CNC Drill bit of 6mm Vernier Calliper
mounting of 6mm diameter

7 Chamfering operation at edges CNC Chamfer tool None

8 Deburring and polishing for surface CNC Abrasive nylon None

finish brushes

PROCESS SHEET FOR KUCKLE

Part Name: Knuckle Part no. Model no.

Material: Aluminium 7075 T6 Refer to draft of component

DRAFT FOR KNUCKLE

 PROCESS SHEET FOR HUB

Part Name: Hub Part no. Model no.

Material: Aluminium 7075 T6 Refer to draft of component

Operational Operational details Machine Tool used for Inspection gauges
machining
Sequence

1 Casting Inspection of Billet None None Vernier Calliper

2 Mounting and Clamping on CNC None None None

Fixtures

3 Face milling on 180mm*180mm CNC Milling cutter Vernier Calliper

surface up to 80mm

3.1 Face milling around 32mm bore at CNC Milling cutter Vernier Calliper
centre up to 55mm

3.2 Face milling around 40mm bore at CNC Milling cutter Vernier Calliper
centre up to 45mm

3.3 Face milling around 96mm bore at CNC Milling cutter Vernier Calliper
centre up to 10mm

4 Turning spindle portion to diameter CNC Turning cutter Vernier Calliper

32mm up to surface 35mm deep

4.1 Turning operation for finishing with CNC Turning cutter Vernier Calliper
reduced feed

5 Internal gear milling operation to CNC Gear cutter Vernier Calliper

23mm diameter for internal spline

6 Drilling operation for rotor CNC Drill bit of 8mm Vernier Calliper
mounting of 8mm diameter

7 Drilling operation for rim mounting CNC Drill bit of 10mm Vernier Calliper
of 10mm diameter

8 Chamfering operation at edges CNC Chamfer tool None

9 Deburring and polishing for surface CNC Abrasive nylon brushes None
finish
 DRAFT FOR HUB

PROCESS SHEET FOR DISC ROTOR

Part Name: Disc Rotor Part no. Model no.

Material: SS420 sheet of thickness 4mm Refer to draft of component

Operational Operational details Machine Tool used for Inspection gauges

machining
Sequence

1 Casting Inspection of Billet None None Vernier Calliper

2 Mounting and Clamping on None None None

CNC Fixtures

3 Laser cutting operation on Laser cutting machine Laser gun Vernier calliper
180*180*4 according given
drawing file

4 Deburring and polishing for CNC Abrasive nylon brushes None

surface finish
DRAFT OF ROTOR DISC

Process Flow Chart

CTQ Tree Diagram
SYSTEM FAILURE CAUSE EFFECT S O D RPN
CONTROL
 ENGINE Mechanical failure Mechanical Engine failure Use of OEM 10 3 4 120
failure of parts,
Performance
parts, choking
degradation Proper air
due to foreign
intake for
bodies
engine.

ROLL CAGE Structural failure, Axial stress Roll cage providing 9 5 8 360
bending and exceeds yield damage, proper
breaking strength due breaks and cross
to excess bends in roll members,
load/impact cage, driver’s effective
safety is design and
endangered analysis

RACK AND Mechanical failure Mechanical Inaccurate Proper 8 2 4 64

PINION linkage turning radius, material
AND TIE breakage due steering failure and
ROD to load and thickness
external
factors

KNUCKLE & Structural damage, Excessive Design failure, Material 7 4 6 168

CONTROL mechanical failure, impact at damage to with greater
ARM bending and cracks mounting, suspension, tensile
greater stress rough strength,
than yield operable Analysis
value vehicle

CALLIPER Structural/hydraulic Inaccurate Failure of Proper 6 5 4 120

failure fitting of breaks, mounting
valves, pad and fitting
greater
wear, less
braking
heat
distance
dissipation,
fluid leakage

ELECTRICAL Electric failure Water Endangers Proper 6 5 3 90

damage, driver’s safety insulation
CIRCUIT
electrical shot and
circuit covering

DFMEA:

PFMEA:
PROCESS FAILURE CAUSE EFFECT S O D RPN

ROLL CAGE WELDING Inaccurate welding, Poor strength, design failure, 5 3 4 60

fatal joints
AND BENDING Excessive electrode use

SUSPENSION ASSEMBLY Improper alignment, Poor performance, 6 3 2 36

Loose mounting System failure

MOUNTING COMPONENTS Dimensional inaccuracy Variation in expected results 5 3 2 30

ON CHASSIS

Checklist
Date Vehicle Checked by:

Dates of: Delivery _______________

ITEM OK NOT OK REMARKS

SAFETY BELTS

BRAKES

ENGINE

TRANSMISSION

STEERING
TURN SIGNALS

BRAKE LIGHTS
HORN

TIRES – TREAD/CONDITION

PROPER INFLATION
LUG WRENCH / JACK

FIRE EXTINGUISHER

FIRST AID KIT

LIQUIDS LEVEL CHECK:

ENGINE OIL
BRAKES OIL
GEARBOX OIL