This document summarizes an issue with the guard wire mismatch on the Discover 125ST motorcycle model. It presents the problem of the gear shift lever becoming sticky due to the wire coming out of the tube in the incorrect position. Two actions were taken to address the problem: 1) The bending die design was modified so that the wire length was corrected from 11mm to 7mm. 2) A reference sample was provided and inspection check points were added to the final inspection checklist. These actions resolved the issue as the percentage of defective gear shift levers dropped from 80% to 0% after implementation.

1. Problem Title - Sari guard wire mismatch Model-D125ST
Slide No : 1
Model Y/N Vendor
Platina 100
X
M/S Aurangabad electrical
Ltd
Unit –N1
Discover 125 X
Discover 150
X
Discover 125ST
√
Discover 100 (D-104)
X
Discover 100 (D-105)
X
APPLICABILITY MATRIX

2. Slide No : 2
EXPLANATION OF PROBLEM
Problem - Gear shift lever sticky.
Physical Phenomena -Wire come out from tube matching position
S. No. Observations
1. Wire come out from tube matching position
2. Gap between wire bending radius & tube outer dia
INITIAL OBSERVATIONS TEAM
Detail illustration/Pictorial view/Drawings
Wire come
out from tube
matching
position

3. Slide No : 3
DEFECTIVE GSL BEFORE ACTION
80% 80%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Aug.12 Sept.12

4. FTA
Slide No : 4

6. Slide No : 5
Sl.
No
Action
Target
date
Resp. Remark
1
Die Design modified & wire length get
corrected Observed 7.00mm in-place of
11.0mm
21.10.2012
PDPL-Mr.
Rajesh
AEL-Mr.
Narendra
Continue
2
Reference sample provided & check
point added in final inspection check
sheet
15.10.2012 Mr. Negi Completed
ACTION TAKEN –Process/Product/System side

7. Slide No : 7
DEFECTIVE GSL AFTER ACTION
80%
0%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Before Correction After Correction

8. Bending die design not
adequate causing more
length of wire (11.00mm)
Die Design modified & wire
length get corrected Observed
7.00mm in-place of 11.0mm

10. PREPARED BY-
Trouble Cases
Improvement cases
Basic Knowledge
Classific
ation
Date of
Preparation
ONE POINT LESSON
Theme
Metal Man Micro Turner ,Pant Nagar
Prepared by
22/08/12
गियर चेन्ज लीवर क
े चेगक
िं ि
पॉइिंट्स(Bush ID Undersize))
APPROVED BY-
Babita Joshi
Bush ID Pin Gauge ls
provided (100 %Pin Gauge
qualify )
Customer Complaint
Not Ok
Ok
Format No.: MMT/QA/F060
Rev. No. : 00
Eff. Date : 1.04.12
Slide No : 10

11. Reference sample
provided at
final inspection stage &
check point updated in SOP

12. Thank You
Slide No : 12