Auomotive Coaches & Component ltd

PROCESS FLOW DIAGRAM

Part Name: G45 Cabin Customer: Ashok Leyland

Part No: All models Rev No: PFD No : ACCL/QA/PFD/01

Inspection
Operation

Transport
Opn no.

Storage
Delay
Operation Description Product characteristic

Sheets & paint grade

10 Incoming
Inspection

Shearing As per drawing

Blaking As per drawing

Piercing As per drawing

20
Nibling As per drawing

Folding As per drawing

Forming As per drawing

30 Pretreatment As per SOP

40 Rear structure Assy Setting of child parts

50 Roof structure Assy Setting of child parts

60 Wind screen structure Assy Setting of child parts

70 Side structure (RH/LH) assy Setting of child parts

80 Assy. Of cabin structure Assy of structure assy

90 Door fabrication Door fabrication

100 Door lock fitting Door fabrication

Cabin panelling &
110 Paneling & Door mtg
mounting
Correction work
Cabin correction and
120 grinding
Inspection

Viscosity
130 Painting
Inspection

Trimming
140 Door trimming
Inspection
 Inspection
Operation

Transport
Opn no.

Storage
Delay
Operation Description Product characteristic

Trimming
150 Cabin Trimming
Inspection

160 Shower test Inspection

Trimming
170 PDI
Inspection & clearanc

Cabin storage & Packin

180 Dispatch
Inspection & Dispatch
Rev
Rev No / Date Details of revision No /
Date
000/18.12.2017 New Realse

Prepared by : V. Sridharan
Auomotive Coaches & Component ltd
PROCESS FLOW DIAGRAM
Ashok Leyland Prepared by Reviewed by Approved by

Rev ref: 0 V.Sridharan N.Sridharan K.Sridhar

Product characteristics Process characteristics

Sheets & paint grade Test certificate

Inspection Incoming inp. Checklist

As per drawing First off approval

First off approval/Inprocess

As per drawing inspection report
First off approval/Inprocess
As per drawing inspection report
First off approval/Inprocess
As per drawing inspection report
First off approval/Inprocess
As per drawing inspection report
First off approval/Inprocess
As per drawing inspection report
As per SOP Inprocess inspection report

Setting of child parts Inprocess inspection report

Setting of child parts Inprocess inspection report

Setting of child parts Inprocess inspection report

Setting of child parts Inprocess inspection report

Assy of structure assy Inprocess inspection report

Door fabrication Inprocess inspection report

Door fabrication Inprocess inspection report

Paneling & Door mtg Inprocess inspection report

Correction work Inprocess inspection report

Inspection Inprocess inspection report

Viscosity Inprocess inspection report

Inspection Final inspection

Trimming Inprocess inspection report

Inspection Inprocess inspection report

Product characteristics Process characteristics

Trimming Inprocess inspection report

Inspection Inprocess inspection report

Inspection Inprocess inspection report

Trimming Self certificate

Inspection & clearance Final inspection PDI report

Cabin storage & Packing

Packing standard
Inspection & Dispatch

Details of revision

Approved by : N.Sridharan
 Proto type Pre-launch Production Core team: B.Ramachandrapillai, Rajaram, Sunil Yadav, J.Manikandan,J.Arunkumar

- - a Plant Approval / Date:

Part Name: 60 TON PAYLOAD DOUBLE AXLE FLAT BED SKELTON CONTAINER Other Approval / Date:
SEMI TRAILER

Drg. / Part No: PRO-17-029-00 Key Contact Name: Mr. K.Pandiyan. Senior Manager

Drg. / Issue Level : # Key Contact Phone :

Characteristics

Part / Process Process Name / M/C Device No.

Number Operation Description
Sl.No Product Process

1 Sheets -

2 Sheet length -

3 Sheet width -

10 Incoming -
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

10 Incoming - 4 Sheet thk -

5 Paint colour -

6 Paint supply viscosity -

7 Components & Trim items -

-
Shearing Shearing 2 Length x width x thk
-

Blanking Shearing 1 Length x width x thk -

Hole I.D -
Piercing Piercing tool 3
20

Distance of holes -

Folding Press brake 5 Web length x flange height -

-
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

1 Overall girder length -

2 Girder width -

3 Front top flange length -

4 Rear top Flange Length -

5 Front web plate length -

6 Rear web plate width -

7 Front Bottom Flange Length -

40 Mani Girder Assy Manual Setting
8 Rear Bottom Flange Length -

9 Top Flange width -

10 Web plate width -

11 Bottom Flange width -

12 Top Flange Thickness -

Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

13 Bottom Flange thickness -

14 Web plate thickness -

1 -

2 -
50 Chassis Frame Assy Manual Setting
3 -

4 -

1 Bottom width -

Wind screen structure

60 Assy Fixture 2 Glass cut out width (By Template) -
Assy

3 Glass cut out length (By Template) -

1 Height -

2 Cant rail length -

3 Distance between 'B' & "C' post -

Side structure (RH/LH)
70 Assy Fixture
assy
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

Side structure (RH/LH)

70 Assy Fixture
assy
4 Distance of side waist rail from cant rail top -

Water bottle distance from 'B' post for RH

5 -
side struc. assy

6 "B" post to ABS mtg. stiffener no. -

1 Length of structure -

2 Width of structure -
80 Assy. Of cabin structure Assy Fixture
3 Height of structure-Rear -

4 Height of structure-Front -

5 Diagonal -

6 Door cutout width -

80 Assy. Of cabin structure Assy Fixture
Distance of AIP stiffner plate from structure
7 -
side

8 Distance b/w AIP stiffener plate -

1 Door outer height -

Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

2 Door outer width -

3 Door panel bending distance from bottom -

4 Door inner panel height -

5 Door glass cutout width inner/Outer -

6 Door glass cutout height inner/Outer -

Hinge support brkt distance from door inner

7 -
Welding machine & bottom
90 Door fabrication Bench drill Support plate bottom 1 from door inner
8 -
bottom
Door hinge distance from bottom support
9 -
plate

10 Door hinge hole drilling -

M8 Weld nut in door hinge hole -

11 Door hinge hole location marking -

12 Center distance between door hinges -

Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

Stiffener for proximity mirror & pull handle

13 -
hole

1 M8 Weld nut in lock brkt -

Welding machine, 2 Lock brkt welding -

100 Door lock fitting Drilling motor and
screw driver 3 Lock fitting -

4 Lock function -

1 Panel fixing -

2 Roof structure mtg -

3 Rear beading -

4 Front beading -

Cabin paneling & Hoist crane &

110 5 Cabin height at rear -
mounting Welding machine

6 Cabin height at front -

7 Door cutout width -

 Cabin paneling & Hoist crane &
110 mounting Welding machine
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

8 Door mounting -

9 Door lock -

1 Marker lamp stiffener -

2 Quarter glass paneling -

Cabin correction and

120 Welding machine 3 Quarter glass cutout -
grinding

4 Wind screen glass cutout -

5 Sandering -

1 Putty application -

2 Emery dressing -

3 Sealant application -

4 Paint application Viscosity -

5 Primer painting -
Pneumatic spray
130

Painting gun
Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

130 Pneumatic spray

Painting
gun
6 DFT -

7 Top coat painting -

8 DFT -

9 Adhesion -

10 Finish paint -

1 Door glass beading pasting -

Glass channel fixing in door glass cutout sides

2 -
& top

3 Door glass fixing into the glass channel -

Spanner, Drilling
140 Door trimming motor, screw driver
4 Regulator mechanism fixing -

5 Door glass winding function -

6 Door ABS pad fixing -

1 Glass work -

Spanner , Drilling
150

Cabin Trimming motor, screw driver

Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

2 Roof rexine -
Spanner , Drilling
150

Cabin Trimming motor, screw driver 3 ABS pad -

& Nut runner
4 Seat -

Trim parts(Floor matt, seats, sunvisor, handles

5 -
etc)
160

Shower test Shower test booth 1 Leak test -

1 Electrical -
Spanner , Drilling
170

PDI motor, screw driver 2 Main wiring harness routing -

& Nut runner
3 EDC & Telematics harness routing -

4 Clutch & Brake pedal free play -

Spanner , Drilling
170

PDI motor, screw driver 5 Steering column -

& Nut runner
6 AIP hole drilling -

1 Cabin cleaning -
 Part / Process Process Name / M/C Device No.
Number Operation Description
Sl.No Product Process

2 QR code -
180

Dispatch Fork lif

3 Door & Ignition key traceability -

4 Loose components packing -

5 Cabin loading -

Note1: All Dimension are in mm

Note 2: I - Inspector, O - Operator, C – Captain

Note 3: D – Reject the Lot & Inform Supplier For Necessary action
E – Stop & Segregate
F – Stop & Correct the Process.Raise INCR
G -- Stop & Segregate Move Rework Material for Non Conformance area
H – Hold the lot, Segregate / Reject, Inform Customer
R – Stop & Replace & Inform Supervisor for necessary action
Note 4 : FOA - First Off Approval , LOA - Last Off Approval , FIR - Final Inspection Report , DIR - Defect Intimation Report, INCR - Internal Non Conforman
Note 5 : During FOA, LOA stage 3 nos should be recorded in Inprocess check Sheet. Check 3 nos during Patrol Inspection and record 1 no in Inprocess ch

Prepared by: V. Sridharan Checked By : N. Sridharan

Date : 30.12.2017
* DIMENSIONS NOT LISTED ARE NOT CHECKED AS THEY ARE BEING CONTROLLED BY THE TOOLS. TOOLS ARE CERTIFIED BY TOOL ROOM / QUALITY .
· IN FINAL INSPECTION ONLY 5 REDINGS RECORDED.
 AUTOMOTIVE COACHES & COMPONENTS LTD

CONTROL PLAN

Manikandan,J.Arunkumar,R.Gowtham Control Plan No : Rev No :

Date (Orig) : Rev Date :

Customer Engg Approval / Date : Issue Date :

Customer Quality Approval / Date :

Other Approval / Date :

istics Methods

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- Against Specified grade Test certificate - - 1

- As per PO Measuring tape - - 1

- As per PO Measuring tape - - 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- As per PO Micrometer - - 1

- Paint shade Master sample visual - - 1

- 45±10 secs B4 Cup - - 1

- As per IPS Measuring tape/Micrometer/vernier - - 1

- As specified in drawing Measuring tape - - 1

- No shearing burr Visual - - 1

- As specified in drawing Measuring tape - - 1

- As specified in drawing Vernier - - 1

- As specified in drawing Measuring tape - - 1

- As specified in drawing Measuring tape - - 1

- No crack in bend line Visual - - 1

- No tool mark Visual - - 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- 14038 ±4mm Measuring tape - - 1

- 550 ±3mm Measuring tape - - 1

- 10000 ±5mm Measuring tape - - 1

- 3818 ±5mm Measuring tape - - 1

- 4548 ±3mm Measuring tape - - 1

- 10000 ±3mm Measuring tape - - 1

- 8400±5mm Measuring tape

- 5890±5mm Measuring tape

- 160 ±3mm Measuring tape

- 510 ±3mm Measuring tape

- 160 ±3mm Measuring tape

- 20 ±1mm Vernier
Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- 20±1mm Vernier

- 10±1mm Vernier

- 2250/2230/2210 ±4mm Measuring tape - - 1

- 538 ±2mm Measuring tape - - 1

- 425±2mm Measuring tape - - 1

- 460±2mm Measuring tape - - 1

- 2330±4mm Measuring tape - - 1

- 747 / 755 ±2mm Measuring tape - - 1

- 1017 / 1080 ±3mm Measuring tape - - 1

- 1315±3mm Measuring tape - - 1

- 1505±3mm Measuring tape - - 1

- 544±2mm Measuring tape - - 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- 825±2mm Measuring tape - - 1

- 140±1mm Measuring tape - - 1

- 110±1mm Measuring tape - - 1

- 1740±3mm Measuring tape - - 1

- 2382±4mm Measuring tape - - 1

- 1315±3mm Measuring tape - - 1

- 830±2mm Measuring tape - - 1

with in
- Measuring tape - - 1
10 mm

- 813±2mm Measuring tape - - 1

- 230±1mm Measuring tape - - 1

- 290±1mm Measuring tape - - 1

- 1405±3mm Measuring tape - - 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- 805±2mm Measuring tape - - 1

- 652±2mm Measuring tape - - 1

- 1367±3mm Measuring tape - - 1

- 640/675±2mm Measuring tape - - 1

- 479/495±2mm Measuring tape - - 1

- 130±1mm Measuring tape - - 1

- 240±1mm Measuring tape - - 1

- 235±1mm Measuring tape - - 1

- Ø 9mm Vernier - - 1

- No offset Visual - - 1

- Template marking Template - - 1

- 375±1mm Measuring tape - - 1

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- No offset Visual - - 1

- No offset Visual - - 1

- No offset Visual - - 1

- Full tight Visual - - 1

- Inner lock proper functioning Visual - - 1

- Proper seating and no damages Visual - - 1

- Proper seating Visual - - 1

- Proper seating and riveting Visual - - 1

- Proper seating and riveting Visual - - 1

- 1340±3mm Measuring tape - - 1

- 980±2mm Measuring tape - - 1

- 811±2mm Template - - 1
Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- Uniform gap with 'A' and 'B' post Taper gauge - - 1

- Proper locking Visual - - All

- No offset Visual - - 1

Proper seating of qtr glass cutout

- Visual - - 1
panel

- Proper seating of qtr glass frame Quarter glass frame - - 1

- As per template Template - - 1

- All weld slag & projections Visual - - 1

- Cover Grinding marks and dent Visual - - All

- 80 Grade Visual - - All

- Sealant in sheet joints Visual - - All

- 20 - 22 sec Stop watch - - All

- No uncoverage Visual - - All

Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

- 30-40 microns DFT gauge - - All

- No uncoverage Visual - - All

- 60-80 microns DFT gauge - - All

- No peel off Cross hatch cutter - - All

- No paint defects Visual - - All

- Proper pasting Visual - - All

- Proper fixing Visual - - All

- No damage Visual - - All

- Full tight Visual - - All

- Free movement Visual - - All

- Full tight Visual - - All

Proper seating and no damages to

- Visual - - All
glass
Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

Proper pasting of rexine & fitting

- Visual - - All
upholstery beading
Proper seating of pad and fitting
- Visual - - All
beading

- No damages Visual - - All

- Proper fitment of Trim items Visual - - All

- No leak Visual - - All

- All electrical items should work Electrical test - - All

- As per ESK Visual - - All

- As per ESK Visual - - All

- 3-5mm Visual - - All

- No wobbling Visual - - All

- No offset Visual - - All

- No dust Visual - - All

 Special chara. class Specification Evaluation Measurement Technique Error Proofing Maintenance SampleSize

Vendor code, Part no. & Name, Cabin

- Visual - - All
sl.no, Model, Drg. Rev, Date

Cabin sl.no plate tagged to respective

- key and ignition key no. written on Visual - - All
steering cover

- Covered by polythene cover Visual - - All

- As per TPH Visual - - All

Critical characteristics

Special Characteristics

Internal Non Conformance Report , IIR - Incoming Inspection Report

cord 1 no in Inprocess check Sheet.

: N. Sridharan
Rev Date :

Issue Date :

Methods

Reaction Plan / Corrective

Freq. Control Method Resp.
Action

Per lot Test certificate

Per lot Incoming insp.checklist

Per lot Incoming insp.checklist

D I
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Per lot Incoming insp.checklist D I

Per lot Incoming insp.checklist

Per lot Incoming insp.checklist

Per lot Supplier insp. chklist

per hour

per hour

per hour

per hour
Sampling inspection report G I
per hour

per hour

per hour

per hour
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif

First off / Inprocess insp.

Per shif R I
checklist

Per shif

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

First off / Inprocess insp. R I

checklist
Per shif

Per shif

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Per shif

Per shif

Per shif

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif

Per shif

Per shif

Per shif
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif

Per shif

Per shif

Per shif
First off / Inprocess insp. R I
checklist
Per shif

Per shif

Per shif
 First off / Inprocess insp. R I
checklist

Reaction Plan / Corrective

Freq. Control Method Resp.
Action

Per shif

100% Poke-Yoke R I

First off / Inprocess insp.

Per shif R I
checklist

Per shif Poke-Yoke R I

Per shif

First off / Inprocess insp.

Per shif R I
checklist

Per shif

100%

100% Self certificate R O

100%

100%

100%

Final insp. report R I

 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

100%

100% Final insp. report R I

100%

100%

100%

100%

100%

100%
First off / Inprocess insp. R I
checklist
100%

100%

100%

100%

Self certificate R O
 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

100% Self certificate R O

100%

100% Poke-Yoke R I

100% R O

100% Final insp. Checklist R I

100%

100% PDI report R I

100%

100%
PDI report R I
100%

100% Poke-Yoke R I

100% Packing list R I

 Reaction Plan / Corrective
Freq. Control Method Resp.
Action

100% Packing list R I

100% Poke-Yoke R I

100%
Packing list R I
100%

Approved By. N. Sridharan

PFMEA NUMBER. : PFMEA/ACCL/01

PART NUMBER : A0Y07400 PH31/PH52

PART NAME : 1618 & 2518 Cabin

SUPPLIER / PLANT : ACCL

MODEL YEAR / : Common

VEHICLE(S)

PROCESS RESPONSIBILITY :

Sev
Operation no Process Function REQUIREMENT Potential Failure Mode Potential Effect(s) of Failure

Not suitable for the further

No rust Rust 4
process

Not suitable for the further

As per Drawing Dimensional variation 2
process
10 Incoming
Component Rejection / Non
As per BOM Wrong material grade conforming product to next 8
operation

Page 38 of 77
 Sev
Operation no Process Function REQUIREMENT Potential Failure Mode Potential Effect(s) of Failure
10 Incoming

Not suitable for the further

No damage Damage 5
process

Shearing As per drawing Dimensional variation Rework / Scrap 5

Blanking As per drawing Dimensional variation Rework / Scrap 5

Piercing As per drawing Dimensional variation Rework / Scrap 6

20
Nibbling As per drawing Dimensional variation Rework / Scrap 6

Folding As per drawing Dimensional variation Rework / Scrap 5

Forming As per drawing Dimensional variation Rework / Scrap 6

30 Pre-treatment No scaling Scaling formation on panels Rework 6

40 Rear struc. Assy As per drawing Dimensional variation Rework / Scrap 4

50 Roof struc. Assy As per drawing Dimensional variation Rework / Scrap 4

Page 39 of 77
 Sev
Operation no Process Function REQUIREMENT Potential Failure Mode Potential Effect(s) of Failure

60 windscreen struc. Assy As per drawing Dimensional variation Rework / Scrap 4

Side structure (RH/LH)

70 As per drawing Dimensional variation Rework / Scrap 4
assy

80 Assy. Of cabin structure As per drawing Dimensional variation Rework / Scrap 5

90 Door fabrication As per drawing Door hinges taper Rework / Scrap 5

100 Door lock fitting As per drawing Secondary lock strucking Functional defect 7

Cabin paneling &

110 As per drawing Door uneven gap Aesthetic 5
mounting

Cabin correction and Quarter glass top panel seating

120 As per SOP Aesthetic 3
grinding gap

As per SOP Cabin bottom uncoverage Rust form in uncover place 5

130 Painting

Page 40 of 77
 Sev
Operation no Process Function REQUIREMENT Potential Failure Mode Potential Effect(s) of Failure

130 Painting
Paint defects like dribbling, peel
As per SOP off,uncoverage,Rough finish and Aesthetic affects & Rework 5
overspray etc

140 Door trimming As per SOP Winding function hard Functional defect 6

Trim parts may loosened and not

Improper fitting of trim parts 5
seated

Seat cushion damage Seat is not usable 7

150 Cabin Trimming As per SOP

Glass Improper seating Crack / Seating gap may occur 7

Roof Rexene tear Scrap 5

Page 41 of 77
 Sev
Operation no Process Function REQUIREMENT Potential Failure Mode Potential Effect(s) of Failure

Not meet the customer

160 Shower test As per SOP Water leakage 6
requirement

Steering height Variation Difficult in fitting st. column 4

Malfunctioning of electrical parts Safety related issue 9

Wiring may damage when in

Wire Hanging contact with rotating parts / Sharp 5
170 PDI As per SOP edges

Wiper motor overheating Motor may burn 8

Wiper blade misalignment Wiper arm blade foul 6

Page 42 of 77
 170 PDI As per SOP

Sev
Operation no Process Function REQUIREMENT Potential Failure Mode Potential Effect(s) of Failure

AIP Hole offset Not able to fitting AIP mtg brkt 7

Door key mismatch between the Difficult to find the respective

180 Dispatch As per packing standard cabins 6
cabin for the key

DISTRIBUTION Critical characteristics

LOCATION :

Special Characteristics

REV. REVIEWED AND REVISION

NO- APPROVED BY : DATE

A N. Sridharan 30.12.2017 REVISION HISTORY Format change

Page 43 of 77
 PROCESS FMEA

KEY CONTACT PERSON : Mr.S. Sekar - VP

KEY CONTACT PHONE : 9940161963

CORE TEAM : K. Sridhar, N. Sridaran, V. Sridharan, l..Kamalakannan, M. Karthikeyan,

R. Selvakumar, V.Sundarajan, Mohan

KEY DATE :

PRODUCT CODE :

SUPPLIER CODE : 7203487

CURRENT PROCESS CONTROLS

Potential Cause(s)/ Mechanism(s) of

Class

Failure D R
CONTROLS CONTROLS

Occur
e P
PREVENTION DETECTION t N

- Supplier Issue In coming Inspection 7 Incoming inspection report 2 56

Supplier inspection report and test

- Supplier Issue In coming Inspection 5 4 40
certificate

- Supplier Issue Material test Certificate 2 Grade wise raw material storage 2 32

Page 44 of 77
 CURRENT PROCESS CONTROLS

Potential Cause(s)/ Mechanism(s) of

Class

Failure D R
CONTROLS CONTROLS

Occur
e P
PREVENTION DETECTION t N

Supplier inspection report and test

- Supplier Issue In coming Inspection 4 3 60
certificate

First off approval / Sample

- Error in setting Setting approval 3 5 75
inspection

First off approval / Sample

- Error in setting Setting approval 5 3 75
inspection

First off approval / Sample

- Error in setting Setting approval 3 3 54
inspection

First off approval / Sample

- Error in template marking Setting approval 4 3 72
inspection

First off approval / Sample

- Error in setting Setting approval 3 5 75
inspection

First off approval / Sample

- Error in setting Setting approval 2 3 36
inspection

- Low PH level Monitor PH level of DM water 5 Inprocess inspection checklist 4 120

Error in setting and poor clamping in First off approval / Inprocess

- Setting approval 6 3 72
the fixture inspection checklist

Error in setting and poor clamping in First off approval / Inprocess

- Setting approval 5 3 60
the fixture inspection checklist

Page 45 of 77
 CURRENT PROCESS CONTROLS

Potential Cause(s)/ Mechanism(s) of

Class

Failure D R
CONTROLS CONTROLS

Occur
e P
PREVENTION DETECTION t N

Error in setting and poor clamping in First off approval / Inprocess

- Setting approval 6 3 72
the fixture inspection checklist

Error in setting and poor clamping in First off approval / Inprocess

- Setting approval 6 3 72
the fixture inspection checklist

Error in setting and poor clamping in First off approval / Inprocess

- Setting approval 5 3 75
the fixture inspection checklist

First off approval / Inprocess

- Error in setting and template marking Setting approval 4 3 60
inspection checklist

Excess pull out of secondary lock Nut welded in control lever to avoid 2 Poke-Yoke 1 14
control lever excess pull out

First off approval / Inprocess

- Error in door mount setting Setting approval 3 2 30
inspection checklist

Flat panel used at qtr glass cutout top 'L' section panel used instead of flat
- 2 Poke-Yoke 1 6
& bottom panel to avoid gap

Ground clearance less for cabin under Cabin kept on the height stand for
- 6 Final insp. report 4 120
painting cabin bottom checking

Page 46 of 77
 CURRENT PROCESS CONTROLS

Potential Cause(s)/ Mechanism(s) of

Class

Failure D R
CONTROLS CONTROLS

Occur
e P
PREVENTION DETECTION t N

1. Viscosity more or less

2. Poor surface cleaning Monitor & control process
- 5 Final insp. report 4 100
3. Poor sanding parameters and process
4. Spraying air pressure more or less

First off approval / Inprocess

- Error in door trimming Monitor & control the process 2 1 12
inspection checklist

- Fasteners not tightened properly Monitor & control the process 4 Self certificate 3 60

- No rack for storing seats Monitor & control the process 2 Poke-Yoke 1 14

- Cutout dimensional variation Monitor & control the process 4 Self certificate 3 84

Teared due to slipping of screw drivers

- when tightening beading end clip Monitor & control the process 2 Self certificate 4 40
screw

Page 47 of 77
 CURRENT PROCESS CONTROLS

Potential Cause(s)/ Mechanism(s) of

Class

Failure D R
CONTROLS CONTROLS

Occur
e P
PREVENTION DETECTION t N

Leaking through panel joints Monitor & control the process 4 Inprocess inspection checklist 3 72

Template used for setting steering

- Manual setting 3 PDI report 3 36
column

Loose/No connection,
Fuse problem Checking in electrical test rig 2 PDI report 2 36
Relay problem

- Wire routing not done as per ESK Following ESK 3 PDI report 3 45

Clearance maintained b/w link rod to

- Wiper arm link rod fouling 5 PDI report 2 80
avoid fouling

- Improper angle setup in wiper motor Identification done afer angle setting 4 PDI report 4 96

Page 48 of 77
 CURRENT PROCESS CONTROLS

Potential Cause(s)/ Mechanism(s) of

Class

Failure D R
CONTROLS CONTROLS

Occur
e P
PREVENTION DETECTION t N

Hole punching in cabin inner rear

- Error in manual marking and drilling 2 PDI report 1 14
panel in machine shop

- No traceability Key no. written on the door lock cover 3 Poke-Yoke 1 18

MFG QAD

Page 49 of 77
DATE (ORIGIN ) : 2/1/2013

DATE ( REVISED) : 30/12/2017

CUSTOMER ENGG. APPROVAL / DATE ( If Reqd. ) : NIL

CUSTOMER QUALITY APPROVAL / DATE ( IFREQUIRED. ) : NIL

PREPARED BY : V. Sridharan

PRODUCTION :

Action Results

O
S c D R
Responsibility and Target ACTION TAKEN
Recommended Action(s) e c e P
Completion Date COMPLETION DATE v u t N
r

Page 50 of 77
 Action Results

O
S c D R
Responsibility and Target ACTION TAKEN
Recommended Action(s) e c e P
Completion Date COMPLETION DATE v u t N
r

PH level to be monitor daily Production / Maintenance Monitored PH level daily 6 3 4 72

Page 51 of 77
 Action Results

O
S c D R
Responsibility and Target ACTION TAKEN
Recommended Action(s) e c e P
Completion Date COMPLETION DATE v u t N
r

Nut welded in control lever

Excess pullout to be avoided Production / Quality 6 2 4 48
to excess pull out

L' section used at qtr glass

Gap to be arrested Production / Quality 3 2 4 24
top & Bottom

Cabin kept on the height

Cabin stand height to be Production / Quality stand for under cabin 5 3 3 45
increased painting

Page 52 of 77
 Action Results

O
S c D R
Responsibility and Target ACTION TAKEN
Recommended Action(s) e c e P
Completion Date COMPLETION DATE v u t N
r

Training to be given to Production / Quality Training given 5 3 4 60

operators

Storage method to be Rack made for storing

Production / Quality 7 2 4 56
improved seats

Template to be validated every Validate template every 6

Production / Quality 7 2 3 42
6 months month

Page 53 of 77
 Action Results

O
S c D R
Responsibility and Target ACTION TAKEN
Recommended Action(s) e c e P
Completion Date COMPLETION DATE v u t N
r

Clearance to maintained b/w Link rod fitting orientation

Production / Quality 9 2 5 90
link rod to avoid fouling changed

Marking done afer setting

Identification to be done afer Production / Quality and checked in electrical 5 2 4 40
angle setting test rig

Page 54 of 77
 Action Results

O
S c D R
Responsibility and Target ACTION TAKEN
Recommended Action(s) e c e P
Completion Date COMPLETION DATE v u t N
r

Hole punching in cabin

Manual marking to be avoid Production / Quality inner rear panel in 5 3 4 60
machine shop

Cabin sl.no punched in

Traceability to be done Production / Quality identification plate and 4 2 4 32
tagged with door key

Page 55 of 77
Part No: All models

Part Name : G45 Cabin

Part / Process Process Name / Operation Sl.No

Number Description

40 Rear structure Assy 3

2
50 Roof structure Assy
3

60 Wind screen structure Assy 2

3
70 Side structure (RH/LH) assy
Part / Process Process Name / Operation Sl.No
Number Description

70 Side structure (RH/LH) assy

4

4
80 Assy. Of cabin structure
5

7
90 Door fabrication
8
Part / Process Process Name / Operation
90 Door fabrication Sl.No
Number Description

10

11

12

13

2
100 Door lock settinng
3

110 Cabin panelling & mounting 5

9
Part / Process Process Name / Operation Sl.No
Number Description

120 Cabin correction and grinding 3

5
130

Painting
6

10

3
140 Door trimming
4
Part / Process Process Name / Operation
140 Door trimming Sl.No
Number Description

2
150

Cabin Trimming 3

5
160

Shower test 1

3
170

PDI
4

2
180

Dispatch
3

4
 180
Dispatch

Part / Process Process Name / Operation Sl.No

Number Description

Inspected by: V. Sridharan

Conclusion: Accepted / Conditionally accepted / Rework / Rejection

 AUTOMOTIVE COACHES & COMPONENTS LTD

FIRST OFF APPROVAL REPORT IN CABIN SHELL

Insp. Date:

Shift: D / N

Characteristics Specification

Structure rear width top / Bottom 2176/2304

Distance between cant rail and rear channel 186

260
Distance between horiz. waist rail & struc. Angle
270

Distance between vertical waist rail 736

Distance between glass vertical runner 1195

Width - Front / Middle / Rear 2250/2230/2210

Distance between roof sticks from rear 538

Distance between roof runner 425

Distance of roof runner plate from runner 460

Bottom width 2330

Glass cut out width (By Template) 747 / 755

Glass cut out length (By Template) 1017 / 1080

Height 1315

Cant rail length 1505

Distance between 'B' & "C' post 544

 Characteristics Specification

Distance of side waist rail from cant rail top 825

Water bottle distance from 'B' post for RH side struc. assy 140

"B" post to ABS mtg. stiffener no. 110

Length of structure 1740

Width of structure 2382

Height of structure-Rear 1315

Height of structure-Front 830

with in
Diagonal
10 mm

Door cutout width 813

Distance of AIP stiffner plate from structure side 230

Distance b/w AIP stiffner plate 290

Door outer height 1405

Door outer width 805

Door panel bending distance from bottom 652

Door inner panel height 1367

Door glass cutout width inner/Outer 640/675

Door glass cutout height inner/Outer 479/495

Hinge support brkt distance from door inner bottom 130

Support plate bottom 1 from door inner bottom 240

 Characteristics Specification

Door hinge distance from bottom support plate 235

Door hinge hole Ø 9mm

M8 Weld nut in door hinge hole No offset

Door hinge hole location markinh Template marking

Center distance between door hinges 375

Stiffner for proximity mirror & pull handle hole No offset

M8 Weld nut in lock brkt No offset

Lock brkt welding No offset

Lock fitting Full tight

Lock function Inner lock function

Panel fixing Proper seating and no damages

Roof structure mtg Proper seating

Rear beading Proper seating and riveting

Front beading Proper seating and riveting

Cabin height at rear 1340

Cabin height at front 980

Door cutout width 811

Door mounting Uniform gap with 'A' and 'B' post

Door lock Proper locking

 Characteristics Specification

Marker lamp stiffner No offset

Proper seating of qtr glass cutout

Quarter glass paneling panel

Quarter glass cutout Proper seating of qtr glass frame

Wind screen glass cutout As per template

Sandering All weld slag & projections

Putty application Cover Grinding marks and dent

Emery dressing 80 Grade

Sealant application Sealant in sheet joints

Paint application Viscosity 20 - 22 sec

Primer painting No uncoverage

DFT 30-40 microns

Top coat painting No uncoverage

DFT 60-80 microns

Adhesion No peel off

Finish paint No paint defects

Door glass beading pasting Proper pasting

Glass channel fixing in door glass cutout sides & top Proper fixing

Door glass fixing into the glass channel No damage

Regulator mechanism fixing Full tight

 Characteristics Specification

Door glass winding function Free movement

Door ABS pad fixing Full tight

Proper seating and no damages to

Glass work glass
Proper pasting of rexine & fitting
Roof rexine upholstery beading
Proper seating of pad and fitting
ABS pad beading

Seat No damages

Trim parts(Floor matt, seats, sunvisor, handles etc) Proper fitment of Trim items

Leak test No leak

Electrical All electrical items should work

Main wiring harness routing As per ESK

EDC & Telematics harness routing As per ESK

Clutch & Brake pedal free play 3-5mm

Steering column No wobbling

AIP hole drilling No offset

Cabin cleaning No dust

Vendor code, Part no. & Name,Cabin

QR code sl.no, Model, Drg. Rev, Date

Cabin sl.no plate tagged to respective

Door & Ignition key traceability key and ignition key no. written on
steering cover

Loose components packing Covered by polythene cover

 Characteristics Specification

Cabin loading As per TPH

d / Rework / Rejection
TD

ELL

Form No: MR/8.1/CAB/FAR/01

Issue dt: 20.12.2017

Measurement Technique Acual Remarks

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape
Measurement Technique Acual Remarks

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape

M. Tape
Measurement Technique Acual Remarks

M. Tape

Vernier

Visual

Visual

M. Tape

Visual

Visual

Visual

Visual

Visual

Visual

Visual

Visual

Visual

M. Tape

M. Tape

M. Tape

Visual

Visual
Measurement Technique Acual Remarks

Visual

Visual

Visual

Visual

Visual

Visual

Visual

Visual

B4 cup & stop watch

Visual

DFT gauge

Visual

DFT gauge

Cross hatch cutter

(Adhesion test)

Visual

Visual

Visual

Visual

Visual
Measurement Technique Acual Remarks

Visual

Visual

Visual

Visual

Visual

Visual

Visual

Shower booth

Electrical test rig

Visual

Visual

Visual

Visual

Visual

Visual

QR code machine

Visual

Visual
Measurement Technique Acual Remarks

Visual

Aprroved by: N. Sridharan

 AUTOMOTIVE COACHES & COMPONENTS (P

GUMMIDIPOONDI - 601 201

SELF CERTIFICATION & IN - PROCESS INSPECTION REP
Model : G45 MKIII Imprvd. Cabin Type : Cabin
Part Name : REAR STRUCTURE ASSY Customer : M/S Ashok Leyland
Part No : B0Y07403 A SL No :

A) DIMENSIONAL INSPECTION
Measurement
S.No Parameters Spec, in mm
Technique

1 Structure rear width top / Bottom 2176/2304 M.Tape

2 Distance between cant rail and rear channel 186 M.Tape

Distance between horiz. waist rail & struc. 260 M.Tape

3
Angle 270 M.Tape
4 Distance between vertical waist rail 736 M.Tape
5 Distance between glass vertical runner 1195 M.Tape
B) VISUAL INSPECTION SELF CERTIFICATION
Measurement
S.No Welding Spec
Technique
1 Welding quality OK/NOT OK Visual
2 Surface free from spatter OK/NOT OK Visual

Operator sign Checked by Production Checked by Quality

 3 Welding distortion OK/NOT OK Visual
4 Blow holes in the weld bead OK/NOT OK Visual
C) PARAMETER CHECKING
Operator name / T No Specification 10am
Wire dia : 0.8mm OK / NOT OK
Setting :
5 Voltage : 18-22 V OK / NOT OK
Current:100-120 A OK / NOT OK
Welding : Gas flow:10 - 15
OK / NOT OK
lit/min
NOTE: Check for Dent,Damages,Waviness before welding and ensured painted components

Operator sign Checked by Production Checked by Quality

MPONENTS (P) LTD MR/8.1/16/C

01
ECTION REPORT
n Date :
Ashok Leyland D
Shift :
N

Actual / FES Sl.no

MR/8.1/54/B

OBSERVATION

Operator sign Checked by Production Checked by Quality

 11am 12am 2pm 3pm 4pm

Operator sign Checked by Production Checked by Quality