Monthly Data collection- Based on Major Causes

MAJOR QUALITY CONCERNS Vs MONTHS

180 140

155
160 • Part miss & Hole miss issues reduced . 153
120
• Rusty tubes issues prevented from the Supplier. 144
140 • Fitment issues – 4x4 New fixture made & Falcon
side fixtures upgraded . 124 100
120 • JIT parts issues reduced – Process controlled &
No.of concerns

Inspection improved .
100 80

80 60

59
60 53
40
40 34
27 28
24
20 20 20
20
10 10
7 5
4 2
0 0 0
0 0
Part miss Hole miss Rusty tubes Thickness issues Fitment / Profile issues Kit Part issues Welding - Miss/ Poor welding

List of Months

May June July Trent Line

AUTOBUS LASER LLC, RAK, UAE.

 Monthly Data collection- Based on Major Causes

DISTRIBUTION CHARTS FOR THE JULY’21 - FITMENT ISSUES

4, 4%
16, 15%
17, 16%

8, 7%

16, 15%

23, 21%

12, 11%
12, 11%

Front to Side structure Front to Roof Structure Side to Roof structure - Waviness Rear to Roof structure

Roof L angle Waviness Falcon LH side str- E.D up & Down level Weist Rail Up & Down issues Fuel tank levelling issues

AUTOBUS LASER LLC, RAK, UAE.

 ACTION- FALCON REAR TO SIDE FITMENT ISSUES

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

Verify the Structure

Check the Profiles to Profile with Outer
Make the Outer Falcon Rear
1 understand the exact Siva / Dinesh 18.07.2021 Completed template and find
profile templates Structure
cause of the issues. gap , where need to
be corrected .

1. Provide the
stoppers to
Verify the Stoppers arrest the Gap.
and Clamping To make correct profile, Completed
Falcon Rear 2. Welding
2 method . Welding And eliminate the welding Dinesh / Saurabh 19.07.2021
Structure sequence,
sequence shall to be distortions .
changed Clamping
method change
if required .

Result of the action : Effectiveness will be verified at AL Line

3
 ACTION- FALCON FRONT TO SIDE FITMENT ISSUES

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

Verify the Structure

Check the Profiles to Profile with Outer
Make the new Outer Falcon Front
1 understand the cause of Siva / Dinesh 18.07.2021 Completed template and find
profile templates Structure
the issues. gap , where need to
be corrected .

1. Provide the
stoppers to
Verify the Stoppers arrest the Gap.
and Clamping To make correct profile, Completed
Falcon Rear 2. Welding
2 method , Welding And eliminate the welding Dinesh / Saurabh 19.07.2021
Structure sequence,
sequence shall to be distortions .
changed Clamping
method change
if required .

Result of the action : Effectiveness will be verified at AL Line

4
 ACTION – SIDE STRUCTURE WAVINESS – Roof to Side Fitment issue

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

1.Upgraded the
Falcon fixtures to
Eliminate the eliminate 2nd stage
To control the Side
second stage of of welding.
structure waviness by Falcon side
1 Welding process by Siva / Dinesh 18.07.2021 Completed
reducing Process structure LH & RH 2. Check conditions
Incorporate all parts
movement internally of all stoppers.
fitting in 1ST Stage .
Replaced the new
one if damage.

Effectiveness of the Found in AL line

Support tubes to be 20mm Width excess
improved . Falcon side b/w LH & RH at the
Support tubes will Completed middle. So to
2 Dinesh / Saurabh structure LH & RH 19.07.2021
be provided inner control support
side Control transport & tube location
Handling effect for the changed from outer
Waviness . to inner.

Result of the action : Effectiveness will be verified at AL Line

5
 ACTION – Horizontal Tube up & down – Bottom Panel fitment issues

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

1.Upgraded the
Falcon fixtures to
provide the
Verify the levelling & To eliminate the
stoppers to control
Provide the stoppers dimension variations in Falcon side
1 Siva / Dinesh 18.07.2021 Completed the dimension
to maintain in side structure LH / RH. structure LH & RH issues
fixture .
2.Ensure the
levelling after the
correction.

Verify the Falcon side Make the inspection

To make sure the Completed
Dimension in all the structure LH & RH report for the
2 dimension meets as per Dinesh/ Suresh 19.07.2021
height related to respective Falcon
the Drawing .
corrections LH & RH structure.

Result of the action : Effectiveness will be verified at AL Line

6
 ACTION – Falcon E.D Door Up / Down – Passenger foot step fitment issue

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

1.Upgraded the
Falcon fixtures to
Verify the Up & To eliminate the Up/
provide the
Down levelling in Down levelling issues in
Falcon side stoppers to control
1 E.D door & Provide Emergency LH and RH Siva / Dinesh 18.07.2021 Completed
structure LH the levelling issues.
the stoppers to pillar.
maintain in fixture . 2.Ensure the
levelling after the
correction.

Ensure all the E.D

Provide the Support To control the waviness Completed
Falcon side inner side support
2 tube at inner side of due to the handling , Dinesh/ Suresh 19.07.2021
structure LH tubes are fitted
Emergency door Transport .
before sent to AL.

Result of the action : Effectiveness will be verified at AL Line

7
 ACTION – Roof can’t rail up & down – Roof fitment issues

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

1. provide the
To eliminate the Up / stoppers at the
Verify the levelling & Down issues in Falcon bottom of Cant
Provide the stoppers roof cant rail at the Falcon Roof rail joining .
1 Siva / Dinesh 18.07.2021 Completed
to maintain in joining areas. structure
fixture . 2. Ensure the
levelling after
the correction.

1. Ensure the
To make sure the Clamping is used
Verify the C clamps Falcon Roof
Levelling from the top Completed for every joints.
2 condition & Provide Dinesh/ Suresh structure 19.07.2021
where as control bottom 2. Ensure the
new if requires.
by Stoppers . levelling is
controlled .

Result of the action : Effectiveness will be verified at AL Line

8
 ACTION – FUEL TANK LEVELLING ISSUES

SL CUT OFF
WHAT WHY WHO WHERE STATUS HOW
NO DATE

Remove the excess

Fuel tank sub assy
spatters and ensure
fixtures excess To make the levelling of L
Falcon Side Ensure the flatness
1 spatters removal & angles for the fuel tank Siva / Dinesh 18.07.2021 Completed
structure RH of the fixture by
Stoppers need to assy at the Joining areas.
providing stoppers
provide if required.
at the bottom.

Falcon Side Introducing the tick

Training should be To educate the Completed
structure mark in PDI for the
2 conducted to the consequences of mis Dinesh / Saurabh 19.07.2021
Fuel tank levelling
welding operator's levelling of fuel tank assy
for time being .

Result of the action : Effectiveness will be verified at AL Line

9
Thank you