This slide uses to find the root cause and responsible team for taking Countermeasure.

1. Initial Analysis Flow Method – TCF Shop
Warm Regards to Member.
Here JAGADEESH MC from ISUZU MOTORS. This is an attachment to do Initial Analysis
Flow (IAF) method.
Explains How to do an initial analysis to find Root cause for the Happened Issue. This Analysis
Flow Majorly Used for Automotive Industry. Helps to find Actual root cause of the issue to take
Effective Countermeasure to prevent the same issue in Future.
This Process flow helps to find basic Root cause of the Issue. Deep Drive Analysis (DDA)
Method needed to close those issue Permanently.
Regards;
JAGADEESH MC
+91 9786465675

2. A
B
C
D
NG Vehicle Part
OK Vehicle Part
New Part
Body
AA
Remove NG Vehicle Part & Re-
assemble in same NG Vehicle.
OK
NG
Assembly Process OK.
Assembly Process NG.
Assembly
Part
Body
Major Contribution
STEP -1
Initial Analysis Flow Method – TCF Shop
A
Remove OK Vehicle Part &
assemble in NG Vehicle to
Confirm PART & BODY
OK
NG
Suspected Body is NG.
Particular NG vehicle
Part is issue.
STEP -2 B
Assembly
Part
Body
Major Contribution
A
Assemble New (Un used) Part
in NG vehicle.
OK
NG
Confirmed Body is NG.
Dimension Level Variations
suspected in Parts . (A & C)STEP -3 c
Assembly
Part
Body Major Contribution
A
A C
2

3. A
B
C
D
NG Vehicle Part
OK Vehicle Part
New Part
Body
AA
Remove NG Vehicle Part & Re-
assemble in same NG Vehicle.
OK
NG
Assembly Process OK.
Assembly Process NG.
Assembly
Part
Body
Major Contributions
STEP -1
Example:
“LH” B’ Pillar Upper Trim to
Lower Trim More Gap.
Activity:
• Visually checked, there is no Abnormality.
• Checked actual value of the Gap. Spec (0 ~ 0.5mm) Actual – 2mm.
• Issue is confirmed and further study to be done.
• NG vehicle Part Removed and Re-Fixed in same vehicle.
If OK – Assembly Process to be verified.
If NG – No Abnormality in Assembly Process.
Conclusion:
• Further study to be done Suspecting (PART & BODY).
Initial Analysis Flow Method - TCF
3

4. A
B
C
D
NG Vehicle Part
OK Vehicle Part
New Part
Body
A
Remove OK Vehicle Part &
assemble in NG Vehicle to
Confirm PART & BODY
OK
NG
Suspected Body is NG.
Particular NG vehicle
Part is issue.
Assembly
Part
Body
Major Contributions
STEP -2
Example:
“LH” B’ Pillar Upper Trim to
Lower Trim More Gap.
Activity:
• Assemble OK vehicle Part in NG vehicle.
If OK – Part Found to be OK.
If NG – Suspected NG Body is an issue.
Conclusion:
• Further study to be done on NG Body.
Initial Analysis Flow Method - TCF
B
4

5. A
B
C
D
NG Vehicle Part
OK Vehicle Part
New Part
Body
A
Assemble New (Un used) Part
in NG vehicle.
OK
NG
Confirmed Body is NG.
Dimension Level Variations
suspected in Parts . (A & C)
Assembly
Part
Body
Major Contributions
STEP -3
Example:
“LH” B’ Pillar Upper Trim to
Lower Trim More Gap.
Activity:
• Assemble New (Un used) Part in NG vehicle.
If OK – Part has dimensional variations between part (A & C).
If NG – Confirmed NG vehicle BODY is Issue.
Conclusion:
• Body to be studied further (OK Body & NG Body) to find variations.
• Dimension check (Fitting, CMM, Panel Gap/Offset etc..)
• Visual Check (Damage, Dent & Panel Deformations etc..)
Initial Analysis Flow Method - TCF
c
5