Current rejection PPM at customer

70756
Defects
Qty
PPM
Tight
48
678
ZE Cylinder Head
33
466
Taping
23
325
piSTON Hit
22
311
Forigen Material
16
226
Crank shaft
10
141
Score Rod
9
127
LB
4
57
CC Problem
2
28
Tube Leak
1
14
CS Under size
1
14
Total
169
2388
160
2388

Crank case dents,rust

Crank shaft damages
valve plate (rust,dents)
Con Rod (Lines,porosity)
Piston (Dents, Damages)
OBB (Damages,Dents)

4697
Qty
1124
131
1092
98
98
259
2802

PPM
239302
27890
232489
20864
20864
55142
596551

70756
Defects
Tight
ZE Cylinder Head
Taping
piSTON Hit

Qty
48
33
23
22

PPM
678
466
325
311

Forigen Material
Crank shaft
Score Rod
LB
CC Problem
Tube Leak
CS Under size
Total

16
10
9
4
2
1
1
169

226
141
127
57
28
14
14
2388

60
50
40
30
20
10
0

48
33
23

22
16
10

48
33
23
20
14
10
7
4
2
1
1
163

Reduction
I
21
23
11
9
8
5
5
2
1
1
1
87
85
1194

Reduction
II
14
7
7
5
2
3
2
2
1
0
0
43
42
597

44%
70%
48%
41%
50%
50%
56%
50%
50%
100%
100%

29%
21%
30%
23%
13%
30%
22%
50%
50%

Reduction
III
9
3
4
4
3
2
0
0
0
0
0
25.0
25
358.2

1194
Reduction
1025
110
1100
98
98
225
2656

500
50
450
50
45
100
1195
254418

cumulative
% Qty
48
28%
81
48%
104
62%
126
75%

Reduction
44%
38%
41%
51%
46%
39%

678
1145
1470
1781

300
30
350
25
30
75
810
172451

Cumilative
PPM
28%
48%
62%
75%

Reduction
27%
23%
32%
26%
31%
29%

150
20
200
15
13
30
428
91122

142
152
161
165
167
168
169

84%
90%
95%
98%
99%
99%
100%

2007
2148
2275
2332
2360
2374
2388

84%
90%
95%
98%
99%
99%
100%

120%
100%
80%
60%
10

40%

Qty

20%

cumulative % Qty

0%

19%
9%
17%
20%
21%
20%

Reduction
IV
4
0
1
2
1
0
0
0
0
0
0
8
8
96

Reduction
13%
15%
18%
15%
13%
12%

75
10
100
8
10
20
223
47477
100
21290.1852

7%
8%
9%
8%
10%
8%

Tight
ZE Cylinder Head

48
33

678
466

Taping

23

325

Pisont Hit
Forigen Material

22
16

311
226

SNO
1

2
3

S.no
1

Defect
Tight

ZE cylinder head Lock pin hole out

Tapping

Defect
Crank case dents,rust

Crank shaft damages

valve plate (rust,dents)
Con Rod (Lines,porosity)
Piston (Dents, Damages)
OBB (Damages,Dents)

RootCause
OBB Perpendicularity out of spec
Crank Case OBB Squareness
OBB Alignment out of spec
Position of OBB Top Bush.
Con Rod Oil hole bur
Crank Shaft Short End damage
Piston Damages on OD while Washing,handling
Shifting of Crank case cylinder head Holes
Wrong selection of Gasket.
Double Suction Valve With Less gasket .
Shifting of OBB Holes

Root cause
Crank case Rust
Crank case Dents

Action Initated
100% freeness check at Kit testing & manual checking prior to packing
100% Squareness Checking Before Imeco Washing
Start of the shift and every 3 hrs Operator is inspecting OBB Alignment and
Maintaining record.
Special Tools initiated for removing burs in oil hole.
Before Washing
100% Checking

Will work with SQD to eliminate this defect as this is a supplier defect
100% checking being done before assembly with help of guage

Action Initated
Non Usage crank case need to apply Honilo oil and keep aside
Holding of Crank Case in soaking Area

2388
672255

100

Resp
Phani

Target Date
Immediate

Gangadhar/v
ivek
Immediate
phani

Maintaining
Record

Moosa

Maintaining

Vivek/Ganga
dhar

SQD/Phani
Phani

Resp
Target date
gangadhar/Vivek
phani

169
2802

Year 2016 TECUMSEH INDIA Supplier => AK KIT VENDOR SCRAP

Vendor
ScrapPeriod

Total

Qty

total

(ppm)

product.

reject

Total: 2005

21179

291,564

6175

1594

259

617

2991

Total: 2006

20906

227,542

4757

641

136

1331

Total: 2007

25340

260,060

6590

622

267

1070

Total: 2008

17946

199,096

3573

1304

418

73

738

Total: 2009

19702

125,621

2475

714

69

186

601

Total: 2010

15004

118,946

1683

93

55

31

291

Total: 2011

6975

75,264

525

223

26

159

Total: 2012

6101

120,633

736

228

44

403

Total: 2013

2964

129,541

384

26

26

151

Total: 2014

1020

115,705

118

15

11

18

Total: 2015

823

123,993

102

17

15

January

5659

7775

44

February

10606

March

1757

10243

18

April

1948

7700

15

May

3346

9565

32

16

June

6545

6545

22

July

2296

8710

20

August

1873

9612

18

September

#DIV/0!

October

#DIV/0!

November

#DIV/0!

December

#DIV/0!

Total

2388

70756

Defect Reason Scrapped :

9
10

14

169

16

48

23

total %

9%

28%

0%

14%

defect 1 = Piston Hit

Oil Ling Rejects

defect 2 = Tight

defect 15 = Piston Hit

defect 3 = Outboard Bearing defect

defect 4 = Tapping defect

defect 16 = Defet Valve Plate - (2) Leafs

defect 17 = Restricted

defect 5 = Crankshaft defect

defect 18 = Scored Rod

defect 6 = Crankcase machining operation

defect 19 = Scored OBB

defect 7 = Wrong Build-up (select fit)

defect 20 = Muffler Tube Leak

defect 8 = Leaking ValvePlate

defect 21 = Def. C/C

defect 9 = Miscellaneous (select fits)

defect 22= Damaged Piston

defect 10 = "ZE" Cyl. Head - Lock Pin Hole Off Location

defect 23 = .010 U.S. Shaft / Regular Rod

defect 11 = Rusty

defect 24 = Loose O.B.B.

defect 12 = Muffler Hole Undersized

defect 25= No Pump - Foreign Material Under V. Plate

defect 13 = No Stamp

defect 26 = Aluminum Muffler Off Flat

defect 14 = .010 U.S. Shaft / Regular Rod

defect 27 = Under Sized Long Journal

DEFECT REASON -- SCRAPPED KITS

5

169

131

132

124

97

475

53

2033

3293

1066

178

15

631

213

552

57

94

54

14

35

11

27

73

11

18

57

14

12
61

10

33

6%

1%

0%

2%

0%

20%

0%

0%

. Shaft / Regular Rod

p - Foreign Material Under V. Plate

ized Long Journal

11

33

lve Plate - (2) Leafs

um Muffler Off Flat

10

Comments / Remarks

Oil Line Rejects - Compr

13

14

15

16

17

11

74

240

15

159

67

977

27

19

47

13

18

19

20

10

30

1
1

3
1

0%

0%

4%

0%

0%

5%

0%

1%

Oil Line Rejects - Compressors

21

22

23

24

25

26

27

1
0
0

0
1

10

32

24

43

4
2

1
1

16

0%

0%

0%

0%

9%

0%

1%