Gabriel India Ltd,

Hosur
Interim Failure Analysis Report Date: 31.05.16 || Rev-00

Part Name : J101 RCU Part No : T11020KE0010N

Customer Voice:
Receiving/ Line/ Field
Sample no Defect Reported By
Complaint
Lock nut observed
1 Line Pratap Singh
loose

INITIAL OBSERVATIONS:

Sl.No Part Name Parameter Specification Observation Remarks

Nut should not be
1 Rear Shox Assy Visual Part yet to receive
loose
Defect Photo:

DIMENSIONAL CONFIRMATION :

Sl.No Part Name Parameter Specification Observation LH Remarks

1
2
Rear Shox Part Yet to
3
Assembly receive
4
5

Analysis:
PROCESS FLOW : -

Top Eyelet
Damper Top Plate Assy Length Checking and Spring Pre
Torquing
Assy load Adjustment
with Nuts

Dispatch Final Nut Tightening

Inspection

Immediate Action :
1. Checked the available parts found OK. Commitment mark provided after tightening of nut
2. Displayed One point lesson in line for Operator awareness
3. Furhter actions will be decided based on root cause analsyis

Root Cause :

Manual operation due to 4mm variation in Outer coil spring length and Pre Load adjustment . Operator can miss the tightening of Lock nut

Action plan :

Action Target Date Resp.

1. Feasibility study to be done to link torque wrench to the Plate
05.06.16 Anbarasu
assy machine to avoid manual error
2. Feasibility study to be done to convert Manual operation to
05.06.16 Anbarasu
Machine operation
Gabriel India Ltd, Hosur 31.05.2016

VCS - Lock Nut Loose

ISSUE : Customer Complaint PROBLEM : Lock Nut Loose

Acceptance Criteria : No loosening of Nut is allowed

Action:
100% parts to be verified for Lock nut tightening and put Commitment mark on Nut & Top
eyelet