Action Plan For Wrong Clip Distance

Bajaj Wiring Harness

Date-21/02/2023
Complaint Background

Theme Analysis Report of Wiring Harness Clip Distance Wrong

Actual problem detail:-
While fitment harness clip positioning found mismatch leads to harness fitment issue in vehicle, clip
position vary against actual position.

Part name Rear harness & Front harness 

Part No. AL201161, BB201184
Engine No,/ Frame No. N/A
Model No. Maxima Cargo DSL
Type of Occurrence Fitment
Place of Occurrence Aurangabad
Condition of Occurrence Maxima Line IRS

Date of Occurrence 04.02.2023

No. of Cases in % 70%

Investigation

• Feedback received for Clip dimensions not Ok

• According to the batch code details found that, reported wiring harness LOT was made on
2nd of February 2023.
• Cable Tie Shift Details:
 BB201184 –
1) BTP1 To Clip4 Dimension observed 60mm against 90mm.
2) Clip4 To CLIP2 Dimension observed 220mm against 260mm.
 AL201161 –
1) Clip8 To clip9 Dimension observed 125mm against 160mm

• This cable Tie / Clip is fixed to its location on cable tie board with respect to drawing.
• Point No. 2) In BB201184 don’t found wrong as dimensions specified are 220 for clip4 to
clip2, check photo attached.
Simulation At Cable Tie Board
AL201161

Cable Tie Board Jig found Loose / Bend New cable tie Jig Installed
BB201184

4 Way Jig Bend / Tilted Replaced 4 Way Jig by new one

Analysis Study

Problem:
Wrong cable Tie Distance found in
wiring harness leads to fitment issue.
W/H Part No. :AL201161, BB201184
Description: Rear harness & Front harness
Analysis :
Why? Wiring harness Fitment issue to vehicle body
Why? Cable tie position is wrong as per drawing
specified.
Why ? Cable tie not positioned properly while fixing
against harness.
Why ? Cable tie board jig got loosen and misplace
from is designed position.

Containment Action: Permanent counter measure:

1. Bend case Jig is replaced with new jig 1. Defect Awareness training given to all operators.
also 4 way jig installed at node. 2. According to skill matrix operators working fixed on
2. ICA done & verified parts available at line.
MCL end. 3. Daily Jig / Fixture condition monitoring started and
3. After Verification of clamp distance as per as per breakdown sheet is maintained.
drawing marking started.

Target Date: 28/02/2023

Resp: Sunil Jadhav Resp. Sunil Jadhav
Cut of day: 12/02/2023 Cut Off Date – 24/02/2023
Status : Done Status : Done
 Fault Tree Analysis

Issue Cable Tie Distance NG

Man Machine Material Method

Sources of
variation

Unskilled Cable tie board CKT testing Cable Tie Cable Tie Board Cable Tie gun
manpower jig/Fixtures are EMDEP board material & Used For Cable used to cut
at proper validated dimensions as tie fitment excess portion
position per standard

All After Cable After SOP adhered Proper

Simulation

associates This process is tie detection investigation packaging

Method

working on done on Cable Harness pass found Cable tie std

line tie board at CKT board as per standard followed
observed
skilled/aut
horized.

Valid Valid  Valid Valid Valid Valid

Result

Invalid  Invalid Invalid  Invalid  Invalid  Invalid 

Skill Matrix / Training Record

7
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