8d corrective action report rev no. : 03 page no. 1 of 2

8D CORRECTIVE ACTION REPORT

Format no. : F-MRO-008

Rev no. : 03

Page No. 1 of 2

Ref. No.: Date: 05.06.2020

Customer Voice / Reported defect: VE8100 Door assly sealant crack & hemming open

Safety Failure rate high Post Cut off Fit/ Functional Aesthetic

D1: Team formation The Problem Solving Investigator, uses a multi-person approach to collect information from those directly associated with and/or impacted by the problem.

Team Leader: Aswin Kumar

Team Member Department Team Member Department

Dilip Rathore Manufacturing Sanket Chalmela Manufacturing

Girish Ranjan Kumar Product design Arun Jingound QA

Praveen Rathore Maintenance Sachin kumar Store

Piyush Gour SQA Atul Sinhal ME

D2: Describe the Problem Understand/Record the customer complaint, conversion into technical statement, Collect the data from those involved with the problem and produce a Well Formed inference. [5W1H, Histogram, 5G(Go to the spot, Examine object, Check

facts & figure, Refer to the theory, Follow operating std ) process flow chart, process map, customer complaint, problem statement, failure data, Data Inference ] D2.1 5W1H:-

5W1H Description Observation

What 1.Describe the problem in detail in

comparison with the OK part /

assembly/ operation/functioning

2. What is the effect of the

problem

1.Door assly sealant crack near lower hinge (LH &

RH) and during opening inner panel comes out of

hemming area ( Poor holding)

2. Door structure will disturb.

When

When did the problem occur?

Date: Time:_____ Ordinary Sequence During rework

maintenance Initial / shift end Online

Assly Testing Other _as per rework

100% problem

Where Where did you see the problem?

( Location / station)

WhatsApp Video 2020-06-02 at 5.12.24 PM.mp4 ( Field failure clip)

In model VE8100 both Door assly LH & RH near lower

hinge

Location: KNR, Telangana WhatsApp Video 2020-06-03 at 15.49.40.mp4 (Line observation clip)

Model: Pro 8031XM Hybrid

Sealant crack near lower hinge Sealant crack near lower hinge



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which Which trend (pattern) did you

see the problem? ( Monthly

trend/model/application/Dealer

All over INDIA, every month as per Service

Failed vehicle details:-

S. No

Chassis No Hrs Kms

S. No Chassis No Hrs Kms

1 MC2Y3LRC0LB000932 425 7422 6 MC2Y3LRC0LC000973 265 4173

2 MC2Y3LRC0LB000937 297 4740 7 MC2Y3LRC0LC000971 135 1721

3 MC2Y3LRC0LB000945 231 3198 8 MC2Y3LRC0LB000904 294 4112

4 MC2Y3LRC0LC000970 380 6745 9 MC2Y3LRC0LB000923 308 4592

5 MC2Y3LRC0LC000972 195 2884 10 MC2Y3LRC0LB000943 294 4543

Who Is the problem related to skill?

No

How 1. How the incident happened.

During door opening driver observed sealant crack & door

part moving near lower hinge of Both LH & RH door

assembly.

D3: Implement & verify containment Implement containment to control the situation and mitigate further negative effects of the problem. (Check sheet, Rework, Segregation, Visual check 100%, testing etc ) D3.1Interim action guide line video for field:-

VID_20200604_1246

10.mp4

Upper hinge area spot details Lower hinge area spot details



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D3.2Interim action validation report ( Not defined in drg )

Hemming flange clamping force report in Kgf

Side Precondition After brazing Remarks

LH 14 10 >33 >33 No deformation

RH 9 9 >34 >35 No deformation Note:- Above test concluded that Door assembly will sustain the door opening force & further RIG validation is planned by PDD

D3.4Interim action validation report

Location Material Sorted Quantities/Comments Resp Target Remarks

Customer Dealer: YES NO 10set of door dispatched DR 29/06/20 Dully brazed

Dealer YES NO Guideline attached AK 15/06/2020

Transit vehicle YES NO NIL

Stock yard YES NO 15 vehicle identified & rework under process

DR 17/06/2020

In house YES NO Checked & Brazing started

from plant

DR 06/06/2020 Started

Ware house YES NO NIL

Supplier YES NO NIL

D4: Root Cause Analysis Identify the Possible Causes of the problem for both occurrence and non-detection. Conduct a Root Cause Analysis to determine true Root Cause (Brain Storming session, C & E diag, FTA, Why-Why Analysis, process map, etc)

D4.1: Cause and Effect diagram:-



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D4.2: Model wise comparison report:-

Model wise outer to inner gap comparison report

Sr no Insp. Point

Pro3000/6000 Pro2000 Pro8000

Remarks

LH RH LH RH LH RH

Outer to Inner gap 1.5±1.5

Outer to Inner 1.5±1.5

Outer to Inner gap 1.9±1.5

Outer to Inner gap 1.9 ±1.5



1 Upper hinge

2.5 2 2 3 3.5 3.2 In pro8000 gap is higher side

2 Lower hinge

2.5 2 2 3.1 3.4 3.0

Model wise outer flange height comparison report

S no Insp. Point

Pro3000/6000 Pro2000 Pro8000

Remarks

LH RH LH RH LH RH

Outer flange Height

Outer flange Height

Outer flange Height

Outer flange Height

Outer flange Height 8.0± 1.0

Outer flange Height 8.0± 1.0

1 Upper hinge

11 11 11.5 11 7.8 7.9 As per drg OK in Pro8000 height observed lesser than other models

2 Lower hinge

11 11.5 12 11.5 8 7.8

Model wise Hemming thickness comparison report

S.NO. Insp. Point

Pro3000/6000 Pro2000 Pro8000

Remarks

LH RH LH RH LH RH

Hemming thickness 2.8+0.1






1 Upper hinge

3 3.0 2.44 2.46 2.7 2.9

Pro8000 & Pro3000 thickness more &

Pro1900 is OK 2

Lower hinge

3.05 2.96 2.4 2.44 2.6 2.7



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D4.2: Hemming overlap report (Total 5 reading taken )

Note:- 0.5 overlap @ LH12 problematic area against 1~3mm (calculated value)

Note:- 1.2 overlap @ RH12 problematic area against 1~3 (calculated value)



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D4.4: Door hemming thickness report(Total 5 reading taken).

Note:- LH side OK & RH side Hemming thickness is more by 0.1mm in some door mentioned area

4.5: Possible cause verification report.

S.no Variable Parameters Spec. Actual Status

1 Man

Unskilled operator Skill (L2-L4) L3 OK

Operator fatigue Visual OK OK

Wrong model run Not possible separate

line L3 OK

2 Machine

Clamping working condition Rigid clamping Found Ok OK

Bed surface waviness No deep marks Found OK OK

Inner locator worn out no step Found OK OK

Vacuum pads not effective Should be effective Found OK OK

Roller worn out no step Found OK OK

3 Method

Locator position not Ok Gap as per Design OK OK

Program disturbed Check visual OK OK

Heming flange overlap –LH 1.0~6.0mm 0.5~3.6mm OK

Heming flange overlap –RH 1.0~6.0mm 0.4~3.5mm OK

Heming thickness more –LH 2.54+0.1mm 2.65~2.7mm NOK

Heming thickness more – RH 2.54+0.1mm 2.7~2.9mm NOK

Door outer to inner gap more-LH 2.07+/-1.5mm 2.8~3.6mm OK

Door outer to inner gap more-RH 2.07+/-1.5mm 2.9~3.4mm OK



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Hemming bed outer locator LH 36 / 35.2 (-0.05/-0.1)mm 35.94/35.15mm OK

Hemming bed outer locator RH 36 / 35.4 (-0.05/-0.1)mm 35.94/35.35mm OK

Hemming bed inner locator LH 20(-0.05/-0.1)mm 19.96mm OK

Hemming bed inner locator LH 25(-0.05/-0.1)mm 24.95mm OK

Hemming bed inner locator RH 20(-0.05/-0.1)mm 19.95mm OK

Hemming bed inner locator RH 25(-0.05/-0.1)mm 24.95mm OK

Expired sealant As per mentioned As per

revalidated certificate OK

OK

Sealant qty less in Diameter 3.0mm 2.0mm OK

Sealant position not ok 5~6mm 02.0mm NOK

Program changed History No history OK

4 Material

Inner thickness LH 0.8mm 0.83mm OK

Outer thickness-RH 0.85mm 0.87mm OK

Inner thickness –LH 0.8mm 0.83mm OK

Outer thickness-RH 0.85mm 0.87mm OK

Door out flange height less-LH 8+1.0/-0.5mm 7.5~8mm OK

Door out flange height less-RH 8+1.0/-0.5mm 7.5~8mm OK

Inner flange wrinkles Wrinkle free Not Ok NOK

Outer flange wrinkles Wrinkle free Not Ok NOK

Flange height under size As per drg 7.4~8.0mm OK

4 Design Lower hinge stress area overlap less

1~3.0mm (value is similar in all model at same section)

Not ok NOK

Door tilting instruction missing Sticker Available OK

D4.6:Sealant Expiry study report



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D4.7: Sealant missing:-

Note:- Sealant dispensing done manually.

D4.8:Door panel inspection report

Door panel thickness inspection report

Sr no LH RH

Remarks Inner(spec 0.80) Outer(Spec0.85) Inner(spec 0.80) Outer(Spec0.85)

1 0.83/0.89 0.86/0.83 0.84/0.88 0.85/0.84

2 0.84 0.85/0.88 0.85/0.88 0.83/0.83

3 0.85 0.84 0.82/0.86 0.84

4 0.85 0.85/0.87 0.82/0.9 0.84

Avg 0.85 0.85 0.85 0.84

Hemming spec 2.54 2.54

Note:- At flange area heavy burr get folded found, wrinkle coming thickness variation from 0.83~1.7mm observed



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D4.9: Conclusion

Conclusion:- 1. Hemming thickness at hinge area 2.8mm against 2.54+0.1

2. Hemming overlap 0.5~1.2 mm observed against 1.0~3.0. 3. Hemming sealant position 0~2mm against 5~6mm.

D5: Develop Permanent Corrective actions Develop Permanent Solution(s) that address each Root Cause. Verify and test the Permanent Solution(s).

Defects phenomenon

Possible Root Causes

Action plan / Activity plan Dept. Resp Target date Status

Door hemming flange opening

during door assembly opening

Hemming thickness more

Robot program to be optimized Maintenance

PB 10/06/2020 G

Daily sample inspection to be started for Hemming thickness @ PDI

Mfg. SC 15/06/2020 G

Door hemming thickness spec tolerance to be increased after trial of new door inner from JBM

1. Hinge area2.54+0.2 2. Other area 2.54+0.3

PDD/QA GKR/ AAJ

15/07/2020 Y

Door overlap lower side

Door inner locally developed trial to be taken & Explore possibility of overlap increase

PDD/Mat/Mfg

GKR/ DK/SC

15/07/2020 Y

Brazing 7 spots started from line . SOP to be displayed near station Cut off no is A0000381

Mfg. SC 15/06/2020 G

With & without brazing door assembly to be provided for validation

Mfg SC 24/06/2020 G

With Brazing & without brazing RIG validation to be done

PDD GKR W2034 Y

After validation Drg to be updated

PDD GKR W2035 Y

Sealant qty less / missing

Sealant dispensing area to be ensured during sealant assembly SOP to be displayed near station

Mfg. SC 15/06/2020 G

Sealant position not Ok, manual application

Template to be provided ME AS 10/07/2020 Y

Door inner wrinkles

Local part to be implemented Purchase DK 30/07/2020 Y



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D5.2: Door hemming thickness report:-

.

Note:-

1. Hemming flange opening force with 2.7thickness, force is 20 kgf & with 2.55mm hemming thickness improved flange opening force till 28kgf.

2. Line mark observed in door outer side after hemming thickness of 2.55mm. Need to validate for line mark after painting if not OK, we will readjust to 2.7mm

3. Overal thickness is coming up to 2.9mm reason may be due to panel folded bur, wrinkles dust etc.

After set lower side-LH

Before Upper side-LH

After set lower side-RH

Before set Higher side-RH



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D5.3: Hemming overlap optimization report:-

Note:- 1.2mm overlap increased in problematic area

Note:- No major improvement

6: Validate Permanent Corrective Actions Validate that the chosen solution is effective [CAE, Validation, performance, Customer feedback]

D6.1: Door flange opening force before & after in kgf

After set -LH Before -LH

1.2mm

After set -LH Before -LH

1.2mm

0.4mm



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Hemming flange clamping force report in Kgf

Side Precondition hemming ht correction After brazing Remarks

LH 14 10 28 29 >33 >33 No deformation

RH 9 9 29 28 >34 >35 No deformation

D6.2 Brazing trial Slam test report awaited:-

D7: Prevent Recurrence Prevent recurrence of the problem at the problem site and across the organization

Related Document Updates Yes No Not

applicable Resp. Target

PFMEA Yes CFT 30/06/2020

PPAP

Poka yoke Sheet

Drawing

One point lesson

Process Flow

SOP Update Yes SC 20/07/2020

Control plan Yes AAJ 20/07/2020

Process Audit Sheet

Central Quality Audit Sheet

Quality Gate Check Sheet Yes SC 13/06/2020

Field Vehicle Resolution Reactive Proactive Selective

Address similar system horizontal Deployment Sr

no

Process /product item Resp Target status

1 Pro1000,Pro3000/6000 brazing implemented other than Pro2000

SC Already done

Green

2 Brazing to be added in the drg for above models

GKR W2036 Y



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Model wise Hemming thickness comparison report

S.NO. Insp. Point

Pro3000/6000 Pro2000

Remarks LH RH LH RH

Hemming thickness spec(2.8+0.1)




1 Upper hinge 2.85 2.84 2.44 2.46 All model ensured hemming thickness at lower side

2 Lower hinge 2.85 2.8 2.4 2.44

Conclusion:- Pro3000/6000 hemming thickness set ( no gap between outer to inner) @

lower side & flange deformation still observed. also heavy line mark is coming So set the

hemming thickness at higher side & brazing required to come out of the issue.

D8: recognize contributions

8d corrective action report rev no. : 03 page no. 1 of 2

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