Fasteners Final Pulsar

HOME WORK

DESIGN REVIEW MANUAL

Theme :- Design For Assembly

Cell :- Pulsar ( LHS )

Category

1.1

Pre

p

ara

t

ory

1 LH 1Chassis Loading

On ConveyorN

2 LH 2Rear Axle

InsertionRear axle DJ151032 N

Battery

BandDJ161247 N

Battery MF

Wet

Charged 9

AH

DJ201125 N

CDI DH111064 N

Hook -

Harness :-

LH

DJ161132 N

Bolt ( M6 ) 39168004 N

LH Engine

Hanging

plate

DJ161081 N

Bolts

(M8*65 &

M8*55)

39245504 N

3 LH 3 Battery Fitment

4 LH 4LH Harness

Clamp Fitment

Motion Loss

Applicability

Y / N

Activity / ProblemSr

No

Stage

NoStage Description Part Name DR Point For ReviewPart Number

5 LH 5 Engine Insertion

NPDS StageIdea Kaizen ID No

Category

1.1

Pre

p

ara

t

ory

Motion Loss

Applicability

Y / N


No

Stage

NoStage Description Part Name DR Point For ReviewPart Number NPDS StageIdea Kaizen ID No

Bolt 39241304 N

Rear LH

bracketDJ161114 N

LH center

bracketDJ161115 N

Allen bolt (

M 8 )39241404 N

8 LH 8

Engine torque

checking & chain

routine

Chain N

9 LH 9Rear wheel

alignment

Magneto

cable bandY a CPV_08_DR_009

Design _ Proto 2

4.3 _ 8bFixed clamp

LH 66

NMagneto

connectionLH 77

Engine bracket

bolt insertion

Fixed clamp to be

provided on chassis

itself to route magneto

cable

Separate band required to

tie up on chassis for holding

magneto cable

Category

1.1

Pre

p

ara

t

ory

Motion Loss

Applicability

Y / N


No

Stage


Upper &

lower chain

case

52DH0309 N

Bolts ( M 6 ) DH161283 N

washer Y a CPV_08_DR_011Design Basic

4.1 _ 4bCombine

Gear shift

leverDH101397 N

Rear cover

RR DJ101211 N

Bolt ( M6 ) 39167304 N

Metal ring

Rubber ring

M 6 Bolt N

To provide metal crimp

with rubber ring for

fitment

10 LH 10Chain case

fitment

Required to make s/a of bolt

& washer for chain case

fitment

Flange bolt provided

instead of separate bolt

& washer

11 LH 11Gear Shifter Lever

Fitment

Y aRequired to make s/a of

metal & rubber rings for

fitment

Design Basic

4.1 _ 4bCPV_08_DR_013 Combine

Category

1.1

Pre

p

ara

t

ory

Motion Loss

Applicability

Y / N


No

Stage


LH main

stepDJ161130 N

M8 Bolts 39231004 Y a CPV_08_DR_014Design Basic

4.1 _ 4bPre coated

Spring

washerN

13 LH 13Handle bar

fitmentHandle bar 52DH0169 N

Center Fork

bolts N

Washer N

Allen bolts (

M 8 )DG181008 N

Fork cap

rubber

grommet

DJ181009 N

AC Box clip DH121142 N

Carburettor DJ101232 N

Earthing

cable

grommet

N

17 LH 17A C Box clip

tighteningA C Box clip N

18 LH 18Accelerator

Connection

Accelerator

ConnectionN

19 LH 19LH Harness

Connection

LH side

harness

terminal

connection

N

LH side

decalDH161310 N

PT drain

pipe clipDH141002 N

21 LH 21Battery

ConnectionN

LH bellow

insertionN

Case meter

connectionN

Petrol Tank DJ710122 N

Bolt 39155604 N

14 LH 14

Fork Bracket

Center Bolt

Tightening

LH main step

fitmentLH 1212

23 LH 23Petrol Tank

fitment

22 LH 22LH Bellow

insertion

16 LH 16Carburettor

fitment

20 LH 20LH seat cowl decal

pesting

Precoated bolts

provided for LH main

step fitment

15 LH 15LH mud guard

fitment

Required to make s/a of

spring washer with bolt for

main step fitment

Category

1.1

Pre

p

ara

t

ory

Motion Loss

Applicability

Y / N


No

Stage


Washer 39074011 Y a CPV_08_DR_024Design Basic

4.1 _ 4bCombine

23 LH 23Petrol Tank

fitmentBolt with integrated

washer provided

Required to make s/a of PT

bolt with washer

Category

1.1

Pre

p

ara

t

ory

Motion Loss

Applicability

Y / N


No

Stage


Grab handle DJ161263 N

Bolt N

Side panel 52DK5506 N

Side lock

grommet33161018 N

Side panel

lockY a CPV_08_DR_025

Design Basic

4.1 _ 4bDesired thread length

Frame Sub

Assly K2 ES

UG3

52DJ0182 N

Bearing

Race Upper52DH0248 N

Bearing

Race lower52DH0248 N

Barcode

sticker 75261601 N

PV card 75118821 N

25 LH 25LH side panel

fitment

Grab Handle

fitmentLH 2424

Thread length to be

reduced for reducing

panel lock nut

tightening time.

More preparatory time

required for removing nut

from panel lock for s/a

26 LH 26Chassis Number

Punching

HOME WORK



Cell :- Pulsar ( RHS )

Category

1.1

Pre

para

tory

1 RH 1Rear Wheel

LoadingRear Wheel DJ151090 N

Rear wheel

spacerDJ151034 N

Rear brake

panelDH151060 N

Bearing ball Y a CPV_08_DR_027Design Basic

4.1 _ 4bSingle piece

Grease N

Fork 52DJ0130 N

Bearing

Cone DH181025 N

Cup

SteeringDH181014 Y a

Fork Nut 30181018 Y a

Metal &

rubber ringY a

CPV_08_DR_013 Design Basic

4.1 _ 4b

Combine

Mud guard 52DH0278 N

Brace

fenderDH161258 N

Allen bolts (

M 6 )DG181008 N

Painted set

loadingN

First to place stearing cup on

bearing cone & then

tightening fork with lock nut

Lock nut welded with

stearing cupCPV_08_DR_028 Combine

Metal ring with

rubber coating


metal & rubber ring for

fitment

Bearing ball is to place on

fixture for collecting with the

help of tool for fitment on

bearing races

Ball cage provided

instead of loose balls

Idea Kaizen ID No DR Point For ReviewNPDS StagePart Number

Motion Loss

Applicability

Y / N


No

Stage

NoStage Description Part Name

2 RH 2Rear wheel spacer

insertion

4 RH 4Mud guard

fitment stage

RH 33 Fork fitment stageDesign Basic

4.1 _ 4b

Category

1.1

Pre

para

tory


Motion Loss

Applicability

Y / N


No

Stage


Front

number

plate

52DH0317 N

Bolt Y aPlain

washerY a

Spacer Y aMagnet (

Self

cancellation

)

DH121130 N

Front axle

with grease

application

DJ151041 N

Front wheel N

Case meter DH151062 N

Spacer DS151058 N

Front axle

lock nut59150003 Y a CPV_08_DR_031

Design Basic

4.1 _ 4bCombine

Front axle

washer39078111 N

RH front

bracketDH161190 N

RH rear

bracketDJ161271 N

Hanging

plate nuts (

M 8 )

59150005 N

Split pin required to fit on

front axle

Lock nut introduced

instead of simple nut

6 RH 6Front wheel

fitment

7 RH 7Engine bracket

fitment stage

Required to make s/a of bolt ,

washer & spacerSingle piece CPV_08_DR_029 Combine

5 RH 5Front Number

Plate Fitment

Design Basic

4.1 _ 4b

Category

1.1

Pre

para

tory


Motion Loss

Applicability

Y / N


No

Stage


8 RH 8Engine fitment

stageN

Center

bracket bolt

( M12 )

39245504 N

Hanging

plate nuts (

M8 )

59150005 N

Rear axle

nutDH171019 N

10 RH 10Fairing Fitment

Stage

Fairing

AssemblyN

11 RH 11Front brake kit

routine stage

Bolt with

locktite

application

59150003 Y a CPV_08_DR_033Design Basic

4.1 _ 4bPre coated

Lock nuts DH161245 N

Simple nuts 59150005 N

RH step

holder52DJ0226 N

M13 bolts 39258204 N

Locktite to apply on bolt

before fitment

13 RH 13Front wheel

tightening stage

12 RH 12Engine tightening

stage

Pre locktite bolt

introduced for brake

kit fitment

9 RH 9Center bracket

tightening stage

Category

1.1

Pre

para

tory


Motion Loss

Applicability

Y / N


No

Stage


Rod end 15191026 N

M8 main

step bolt39231004 N

Spring

washerY a CPV_08_DR_034

Design Basic

4.1 _ 4bPre coated

Main step

RHDJ161131 N

Adjuster

nutDH191045 N

Spring 30191035 N

Plain

washer39019811 N

Brake padel DH191001 N

Flange bolt

(M12)39176904 N

Torque rod

bolt30151096 N

Spring

washer - T

Rod


4.1 _ 4bCombine

Center axle

nut (M22)DH171019 N

Torque rod

nut (M14)39079415 N

15 RH 15Brake padel

fitment stage


spring washer with bolt

14 RH 14Brake connection

stage

Spring washer required to

place on bolt before nut

tightening

Pre coated bolt to be

introduced for main

step fitment

Flange lock nut to be

introduced

16 RH 16Rear wheel

tightening stage

Category

1.1

Pre

para

tory


Motion Loss

Applicability

Y / N


No

Stage


Starter

motor

grommet

N

Spring


Design Basic

4.1 _ 4bCombine

Nut N


tightening stage

Upper lever

tighteningN

19 RH 19Seat cowl fitment

stageSeat cowl DK7303ZZ N

20 RH 20RH Harness

connection stageN

21 RH 21RH Harness

connection stageN

22 RH 22RH Harness

connection stageN

Starter motor on engine from

engine assembly with spring

washer & nut - During

connection spring washer &

nut has to take out then after

keeping terminal connection

to be done with placing

spring washer & nut

Instead of spring

washer , surreted nut

in loose condition

directly at final

assembly stage

17 RH 17Starter motor

connection stage

Category

1.1

Pre

para

tory


Motion Loss

Applicability

Y / N


No

Stage


Silencer DJ101259 N

Plain big

washer39242511 Y a CPV_08_DR_038

Design Basic

4.1 _ 4bCombine

Small

washer39024811 N

Lock nuts

(M17)DD161071 N

Flange bolts 39185004 N

Flange nuts 59150005 N

Gasket DJ101064 N

24 RH 24Silencer tightening

stageSnap pin DH151055 N

Flange bolts

(M6)39194304 N

Washers 39178924 Y a CPV_08_DR_040Design Basic

4.1 _ 4bCombine

26 RH 26Carburettor clip

tightening stageN

Big plain washer has to place

at rear mounting

Press fit bush with

washer introduced


plastic washer with

tightening bolt

Bolt with press

fitment plastic washer

23 RH 23Silencer fitment

stage

25 RH 25Seat cowl

tightening stage

Category

1.1

Pre

para

tory


Motion Loss

Applicability

Y / N


No

Stage


27 RH 27Clutch connection

stageN

Side panel N

RH side seat

cowl decalN

Side lock

grommetN

Side panel

lockN

29 RH 29 Vehicle inspection

Battery

terminal

removal

N

28 RH 28Side panel sub

assembly stage

HOME WORK

DESIGN DOCUMENT MANUAL

THEME :- DESIGN FOR ASSEMBLY (FASTENERS )

CELL :- PULSAR ( LHS )

Y / N

1 LH 2 Rear Axle Insertion Rear axle DJ151032 Y aAxle insertion should be

within 2 sec. instead of

6 sec.

Why 6 sec. required to axle

insertion ?

Axzle entry chafer 1X30 deg is not

sufficient for guiding whole stact-

up of rear wheel assembly

Provide 2.5X30 deg entry

chamfer for rear wheel axle

CPV_08_D

D_001

Design Basic

4.1 _ 4b

Upper & lower

chain case52DH0309 N

Bolts ( M 6 ) DH161283 N

washer Y a

Preparatory work of 4 sec.

should be ZERO sec. for s/a of

4 no of bolts & wahser for chain

case fitment

Why 4 sec. required ?

Due to 4 no. of bolts & washers

subassembly required to chain case

fitment.

Why subassembly required ?

Bolts & washers are separate parts

which need to preparatory work

before chain case fitment

Combine

(Provide flange bolt)

CPV_08_D

D_011

Design Basic

4.1 _ 4b

LH main step DJ161130 N

M8 Bolts 39231004 Y a

Preparatory work of 3 sec.

should be ZERO sec for s/a of

spring washer & main step

fitment bolt.

Required to make s/a of spring

washer with bolt for main step

fitment.

Precoated bolts provided for

LH main step fitment

CPV_08_D

R_014

Design Basic

4.1 _ 4b

Spring washer N

KAIZEN IDEAKAIZEN ID.

No.NPDS STAGEPROBLEM / WHY ? WHY ?

2 LH 10 Chain case fitment

STAGE

DESCRIPTION

SR.

NO.

PR

EC

OA

TE

D

CH

AN

GE

A/F

SIZ

E

EN

TR

Y C

HA

MF

ER

PA

SS

IVIA

TIO

N

PART

NAME

PART

NUMBER

CO

MB

INE

STAGE

NO.

MO

TIO

N L

OS

S

AP

PL

ICA

BIL

ITY

CATEGORY

LH 123

EXPECTATION

LH main step fitment

KAIZEN IDEAKAIZEN ID.

No.NPDS STAGEPROBLEM / WHY ? WHY ?

STAGE

DESCRIPTION

SR.

NO.

PR

EC

OA

TE

D

CH

AN

GE

A/F

SIZ

E

EN

TR

Y C

HA

MF

ER

PA

SS

IVIA

TIO

N

PART

NAME

PART

NUMBER

CO

MB

INE

STAGE

NO.

MO

TIO

N L

OS

S

AP

PL

ICA

BIL

ITY

CATEGORY

EXPECTATION

Allen bolts

( M 8 )DG181008

Fork cap

rubber

grommet

DJ181009 Y a

Fork cap rubber grommet fitment

should be within ZERO sec.

instead of

10 sec.

Why 10 sec. required for pressing

rubber cap on fork ?

Separate rubber cap requred to fit.

Why rubber cap required to fit ?

To fill cavity of allen bolt of

forkbracket.

Change A/F size

(Instead of allen bolt ,

hexagonal bolt to be provided

to cover cavity of fork bracket

)

CPV_08_

DD_016

Design Basic

4.1 _ 4b

AC Box clip DH121142


Bolt 39155604 N

Washer 39074011 Y a

Preparatory work of

2 sec.should be

ZERO sec. for s/a or bolt &

washer for petrol tank fitment

Why 2 sec. required for bolt &

washer sub assly. ?

Preparatory work sub assly before

fitment.

Why preparatory work is there ?

Bolt & washer is in separate

condition.

Combine

(Bolt with integrated washer

provide)

CPV_08_

DD_024

Design Basic

4.1 _ 4b

5 LH 23 Petrol Tank fitment

4 LH 15 LH mud guard fitment

Q1- Is entry chamfer sufficient for guiding

in sleeve ?

Q2- Is the entry chamfer provided onsleeve ID ?

Q3- Is the alignment of RHS bearing w.r.t.

sleeve ID axis is ensured in design?

Q4- Is the alifnment of brake panel bore axis

w.r.t. sleeve bore axis & RHS bearing axis

in design ?

Q1- Is there flange bolt provided for chain

case mounting ?

Q2- Whether the flange diameter is sufficient

to exert required clamping force ?

Q3- Is there integrated washer provided ?

CHECK POINT FOR DESIGNER

CHECK POINT FOR DESIGNER

Q1- Is there hexagonal flange bolt provided

instead of allen to cover cavity of fork

bracket ?

Q2- Is hexagonal bolt having entry chamfer

for easy of loacation ?

Q1- Is there flange bolt provided ?

Q2- Is there integrated bolt provided

HOME WORK




1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

1 RH 1Rear Wheel


Rear wheel

spacerDJ151034 N

Rear brake

panelDH151060 N

Bearing ball Y a CPV_08_DR_027Design Basic


Grease N

Fork 52DJ0130 N

Bearing

Cone DH181025 N

Cup


Fork Nut 30181018 Y a

Metal &

rubber ringY a

CPV_08_DR_013 Design Basic

4.1 _ 4b

Combine


Brace

fenderDH161258 Y a CPV_08_DR_015

Design Basic

4.1 _ 4bClamping from out side

Allen bolts (

M 6 )DG181008 N

Painted set

loadingN

Design Basic

4.1 _ 4bRH 33 Fork fitment stage


insertion

4 RH 4Mud guard

fitment stage

Category


No

Stage

NoStage Description Part Name Part Number

Motion Loss

Applicability

Y / N

Idea Kaizen ID No DR Point For ReviewNPDS Stage

Bearing ball is to place on

fixture for collecting with the

help of tool for fitment on

bearing races

Ball cage provided

instead of loose balls

Mud guard brace fender bolt

tightening is not easy due to

mounting from in side


metal & rubber ring for

fitment

Metal ring with

rubber coating

Mud guard with brace

fender mounting

provided from out

side

First to place stearing cup on

bearing cone & then

tightening fork with lock nut

Lock nut welded with

stearing cupCPV_08_DR_028 Combine

1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

Category


No

Stage


Motion Loss

Applicability

Y / N


Front

number

plate

52DH0317 N

Bolt Y aPlain

washerY a

Spacer Y aMagnet (

Self

cancellation

)

DH121130 N

Front axle

with grease

application

DJ151041 N

Front wheel N

Case meter DH151062 Y a CPV_08_DR_030Design Basic

4.1 _ 4bStrong design

Spacer DS151058 N

Front axle

lock nut59150003 Y a CPV_08_DR_031

Design Basic

4.1 _ 4bCombine

Front axle

washer39078111 N

RH front

bracketDH161190 Y a CPV_08_DR_004

Design Basic

4.1 _ 4b

Bold embossing with

colour filled

RH rear

bracketDJ161271 Y a CPV_08_DR_005

Design Basic

4.1 _ 4b

Bold embossing with

colour filled

Hanging

plate nuts (

M 8 )


4.1 _ 4bIdentification

Design Basic

4.1 _ 4b

Required to make s/a of bolt ,

washer & spacerSingle piece CPV_08_DR_029 Combine

5 RH 5Front Number

Plate Fitment

6 RH 6Front wheel

fitment


fitment stage

Bold embossing with

colour filling to be

provided on bracket

for clear identification

Passivation of nut be

change for clear

identification

Strengthening

required to improve

for the clip to avoid

bending

Bold embossing with

colour filling to be

provided on bracket

for clear identification

Lock nut introduced

instead of simple nut

Difficult to assemble case

meter in front due to clip

bending

Split pin required to fit on

front axle

Difficult to identify correct

bracket for fitment


bracket for fitment


nut for fitment

1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

Category


No

Stage


Motion Loss

Applicability

Y / N



stageN

Center

bracket bolt

( M12 )

39245504 N

Hanging

plate nuts (

M8 )

59150005 N

Rear axle

nutDH171019 N


Stage

Fairing

AssemblyN


routine stage

Bolt with

locktite

application


4.1 _ 4bPre coated

Lock nuts DH161245 Y a CPV_08_DR_032Design _ Proto 1

4.2 _ 8aIdentification

Simple nuts 59150005 Y a CPV_08_DR_032Design _ Proto 1

4.2 _ 8aIdentification

RH step

holder52DJ0226 N

M13 bolts 39258204 N

Center bracket

tightening stage9 RH 9

Passivation of simple

nut & lock nut to be

change

Passivation of simple

nut & lock nut to be

change

Pre locktite bolt

introduced for brake

kit fitment


stage


nut for fitment ( Lock nut &

simple nut )

13 RH 13Front wheel

tightening stage


nut for fitment ( Lock nut &

simple nut )

Locktite to apply on bolt

before fitment

1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

Category


No

Stage


Motion Loss

Applicability

Y / N


Rod end 15191026 N

M8 main

step bolt39231004 N

Spring


Design Basic

4.1 _ 4bPre coated

Main step

RHDJ161131 N

Adjuster

nutDH191045 N

Spring 30191035 N

Plain

washer39019811 Y a

Brake padel DH191001 Y a CPV_08_DR_035Design Basic

4.1 _ 4b

Square / Hexagonal

design instead of

serretion

Flange bolt

(M12)39176904 N

Torque rod

bolt30151096 N

Spring

washer - T

Rod


4.1 _ 4bCombine

Center axle

nut (M22)DH171019 N

Torque rod

nut (M14)39079415 N

16 RH 16Rear wheel

tightening stage

Brake padel mouting

boss to be modified ,

instead of surretion it

should be square or

hexagonal type.


introduced


introduced for main

step fitment


position of brake padel on

vehicle

Spring washer required to

place on bolt before nut

tightening


spring washer with bolt


stage

15 RH 15Brake padel

fitment stage

1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

Category


No

Stage


Motion Loss

Applicability

Y / N


Starter

motor

grommet

N

Spring


Design Basic

4.1 _ 4bCombine

Nut N


tightening stage

Upper lever

tighteningN


stageSeat cowl DK7303ZZ N

20 RH 20RH Harness

connection stageY a CPV_08_DR_020

Pre Pilot Production

5 _ 5

50mm more length for

every coupler

connection.

21 RH 21RH Harness



5 _ 5


every coupler

connection.

22 RH 22RH Harness



5 _ 5


every coupler

connection.


connection stage

Harness length

increased by 50mm

for easy access of

harness coupler for

connection

Harness length

increased by 50mm

for easy access of

harness coupler for

connection

Harness length

increased by 50mm

for easy access of

harness coupler for

connection

Instead of spring

washer , surreted nut

in loose condition

directly at final

assembly stage

Difficult to access required

coupler on harness for

connection



connection



connection

Starter motor on engine from

engine assembly with spring

washer & nut - During

connection spring washer &

nut has to take out then after

keeping terminal connection

to be done with placing

spring washer & nut

1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

Category


No

Stage


Motion Loss

Applicability

Y / N


Silencer DJ101259 N

Plain big

washer39242511 Y a CPV_08_DR_038

Design Basic

4.1 _ 4bCombine

Small

washer39024811 N

Lock nuts

(M17)DD161071 N

Flange bolts 39185004 N

Flange nuts 59150005 N

Gasket DJ101064 N

24 RH 24Silencer tightening

stageSnap pin DH151055 Y a CPV_08_DR_039


5 _ 5

Bend for thumb

support

Flange bolts

(M6)39194304 N

Washers 39178924 Y a CPV_08_DR_040Design Basic

4.1 _ 4bCombine


tightening stageY a CPV_08_DR_041

Design Basic

4.1 _ 4bSufficient access

25 RH 25Seat cowl

tightening stage

Difficult to access clip

tightening mounting head

due to chassis tube

Provide access for

tightening for

tightening.

Difficult to insert snap pin on

troque rod bolt hole due to

sharp bending

Bend provided on

snap pin round area

for getting grip to

thump fingure to

apply force for

insertion on torque

rod bolt hole


plastic washer with

tightening bolt

Bolt with press

fitment plastic washer


stage

Press fit bush with

washer introduced

Big plain washer has to place

at rear mounting

1.1

Pre

para

tory

1.2

. D

iffi

cult

To

Assem

ble

1.3

. D

iffi

cult

To

Access

1.4

. D

iffi

cult

To

Iden

tify

Category


No

Stage


Motion Loss

Applicability

Y / N



stageN

Side panel N

RH side seat

cowl decalN

Side lock

grommetN

Side panel

lockY a CPV_08_DR_025

Design Basic

4.1 _ 4bDesired thread length


Battery

terminal

removal

Y a CPV_08_DR_043Design Basic

4.1 _ 4bEasy access

Thread length to be

reduced for reducing

panel lock nut

tightening time.

Difficult to remove battery

negative terminal

Negative terminal

taken to front side of

battery

More preparatory time

required for removing nut

from panel lock for s/a


assembly stage

HOME WORK


Theme :- Defect Loss


Y CPV_08_DR_044Design Basic

4.1 _ 4b


4.1 _ 4b

3 LH 3Rear Axle

InsertionRear axle DJ151032 Y CPV_08_DR_046

Design Basic

4.1 _ 4b

Battery Band DJ161247 N

Battery MF

Wet Charged

9 AH

DJ201125 N

CDI DH111064 Y CPV_08_DR_047Design Basic

4.1 _ 4b

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CATEGORY

Activity / Problem Idea Kaizen ID No

2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR


On Conveyor

Sprocket

Assembly

2.2 MissingPossibility of rear wheel

rubber damper missing

Rubber damper in

single piece

2.5 Wrong part

assembly

Possibility of wrong part

assembly of sprocket

assembly ( K1 & K2 )

Sprocket passivation to

be change for sprocket (

Blue for K1 & Golder for

K2 )


2.5 Wrong part assemblyPossibility of CDI mis

match ( K1 & K2 )

Body colour to be

change for K1 & K2 CDI

for identification

2.5 Wrong Part assembly

Pulsar rear axle can be

interchange with JC or

JM rear axle

Passivation to be

different for Pulsar &

JC rear axle

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

Hook -

Harness :-

LH

DJ161132 N CPV_08_DR_048Design Basic

4.1 _ 4b

Bolt ( M6 ) 39168004 N

LH Engine

Hanging

plate

DJ161081 Y CPV_08_DR_004Design Basic

4.1 _ 4b

Bolts

(M8*65 &

M8*55)

39245504 N

Bolt 39241304 N

Rear LH

BracketDJ161114 Y CPV_08_DR_005

Design Basic

4.1 _ 4b

LH Center

BracketDJ161115 Y CPV_08_DR_006

Design Basic

4.1 _ 4b

Allen bolt (

M8 )39241404 N

8 LH 8Magneto

ConnectionY CPV_08_DR_049

Design Basic

4.1 _ 4b

9 LH 9Engine Torque

Checking

Chain

RoutineY CPV_08_DR_008

Design Basic

4.1 _ 4b

Possibility of LH side

hook fitted on RH side &

vice a versa

Common design for LH

& RH side harness hook5 LH 5LH Harness

Clamp Fitment

2.5 Wrong part assembly





2.5 Loose

2.1 Reverse

Possibility of wrong

hanging plate fitment

Bold embossing with

colour fill to be change

for hanging plates


bracket fitment

Bold embossing with


for hanging plates


bracket fitment

Bold embossing with


for hanging plates

Possibility of loose

connection of magneto

due to bullet type

terminal.

Coupler type terminal

introduced.

Possibility of reverse

direction of chain.

Yellow colour clip added

on chain link for

knowing correct

direction chain.

7 LH 7Engine bracket

bolt insertion

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

Y CPV_08_DR_009Design _ Proto 2

4.3 _ 8b


4.1 _ 4b

Upper and

Lower Chain

case

52DH0309 Y CPV_08_DR_052Design _ Proto 1

4.2 _ 8a

Bolts (M10) DH161283 N

Washer Y CPV_08_DR_011Design Basic

4.1 _ 4b

Gear Shift

LeverDH101397 Y CPV_08_DR_053

Design Basic

4.1 _ 4b

Rear Cover

(RR cover) DJ101211 N

Bolt ( M 6 ) 39167304 N


4.1 _ 4b

N


4.1 _ 4b

N

M6 Bolt N

2.2 Missing

2.6 Mis orientation

2.3 Loose

2.8 Adjustment Not Good

2.7 Not Matching

Fixed clamp to be on

chassis itself to hold

magneto cable firmly

Possibility of chain

adjuster marking

adjustment not done

correctly

Marking provided on

both side of chain

adjuster for easy and

correct adjustment.

Flange bolt instead of

washer.


positioning of gear shift

lever

GSL mouting boss to be

modified , instead of

surretion it should be

square or hexagonal

type for correct

position.

Possibility of upper &

lower chain case not

matching with each other

Relieve provided on

upper & lower chain

case to avoid touching

of chain case to swing

arm at welding gusset

for complete matching

Possibility of metal ring

missing.



fitment

Possibility of rubber ring

missing.



fitment

Rear Wheel

Alignment

11 LH 11Chain case

fitment

2.2 Missing

10 LH 10Magneto

cable band

Possibility of washer

missing

Possibility of loosening of

magneto cable due to

cable holding with band

2.2 Missing

Gear Shifter Lever

Fitment

Metal Ring

Rubber Ring

12 LH 12

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

LH Main

Step FitmentDJ161130 N

M8 Bolts 39231004 N

Spring

washerY CPV_08_DR_014

Design Basic

4.1 _ 4b

14 LH 14Handle bar

fitmentHandle bar 52DH0169 N

Center Fork

bolts N

Washer N

Allen Bolts

(M8)DG181008 Y CPV_08_DR_015

Design Basic

4.1 _ 4b

Fork cap -

Rubber

Grommet

DJ181009 Y CPV_08_DR_016Design Basic

4.1 _ 4b

AC Box Clip DH121142 N

Carburettor DJ101232 Y CPV_08_DR_018Design Basic

4.1 _ 4b

Earthing

Cable

Gromet

N

18 LH 18 A C Box Clip

TighteningN

19 LH 19Accelerator

Connection

Accelerator

ConnectionN

20 LH 20 LH Harness

Connection

LH side

harness

terminal

connection


4.1 _ 4b

21 LH 21Battery

ConnectionN

2.2 Missing

2.2 Missing

2.3 Loose

2.4 Not tightened fully


Possibility of spring

washer missingPrecoated bolts

Possibility of brace fender

mud guard bolt missing

Bolt mounting from out

side for clear visibility


carburettor fitment

Model identification

sticker on carburettor

cap

Possibility of fork cap

rubber grommet not

pressed fully

Instead of allen bolt ,

hexagonal bolt to be

provided to cover cavity

Possibility of loose

connection of harness

due to incomplete

pressing of bullet

Coupler type connector

provided instead of

bullet type connector

Carburettor

Fitment

LH Mud guard

fitment

LH main step

fitment

Fork Bracket

Center Bolt

Tightening

17

16 LH 16

13 LH 13

15 LH 15

LH 17

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

LH Side

DecalDH161310 N

Petrol Tank

Drain Pipe

Clip

DH141002 N

LH bellow

insertionN

Case meter

connectionY CPV_08_DR_055

Design Basic

4.1 _ 4b


Bolt 39155604 N

Washer 39074011 Y CPV_08_DR_024Design Basic

4.1 _ 4b

Grab Handle DJ161263 N

Bolt N

Side Panel 52DK5506 Y

RH Side Seat

Cowl DecalN

Side Lock

Grommet 33161018 N

Side panel

lockY CPV_08_DR_056

Design Basic

4.1 _ 4b

Frame Sub

Assly K2 ES

UG3

52DJ0182 N

Side stand

switchY CPV_08_DR_057

Design Basic

4.1 _ 4b

Bearing Race

Upper52DH0248 N

Bearing Race

lower52DH0248 N

Barcode

sticker 75261601 N

PV card 75118821 N


Punching

2.9 PDI / EFR

Side stand switch

mechanism not working

due to mud accumulation

on actuating button

Side stand switch

mechanism change

from mechanical type to

electromagnetic type

2.2 Missing

2.3 Loose

2.3 Loose

2.3 Loose

Possibility of incomplete

insertion of case meter

cable upper grommet in

number plate bracket

Number plate bracket

should be modified like

Discover brake kit

Possibility of PT washer

missing

Bolt with integrated

washer

Possibility of side panel

getting loose due to

bracket bend

Provided strengthened

bracket for side panel

locking.

22 LH 22

LH 25Grab Handle

Fitment

LH Seat Cowl

Decal Pesting

LH Bellow

Insertion23 LH 23

26 LH 26LH Side Panel

Fitment

24 LH 24Petrol Tank

Fitment

25

Combine

Identification

Identification

Identification

DR Point For Review

DR Point For Review

Commonisation

Bold embossing with colour

filled


filled


filled

Coupler type design

Identification for direction

DR Point For Review

Fixed clamp

Both side identification

Relieve to avoid fouling

Combine

Square / Hexagonal design

instead of serretion

Combine

Combine

DR Point For Review

Pre coated

Clamping from out side

Combine

Identification

Coupler type design

DR Point For Review

Wire type design

Combine

Strong design

Non contact design

HOME WORK


Theme :- Defect Loss


1 RH 1Rear Wheel


Rear Wheel

Spacer DJ151034 N

Rear Brake

Panel DH151060 N

Bearing ball Y CPV_08_DR_027Design Basic


Grease N

Fork 52DJ0130 N

Bearing Cone DH181025 N

Cup Steering DH181014 N

Fork Nut 30181018 N

Metal ring Y CPV_08_DR_013Design Basic

4.1 _ 4bCombine

Rubber ring Y CPV_08_DR_013Design Basic

4.1 _ 4bCombine

Rubber ring coating on

metal ring.

2.2 Missing

Possibility of rubber ring

missing.

Metal ring with rubber

coating.

RH 3 Fork fitment stage

2.2 Missing

Possibility of metal ring

missing.

Ball cage instead of loose

balls

3

2.2 MissingPossibility of bearing ball

missing


insertion

CATEGORY

Activity / Problem Idea Kaizen ID No DR Point For Review

2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N


Brace fender DH161258 N

Allen Bolts

(M6)DG181008 Y CPV_08_DR_015

Design Basic

4.1 _ 4bMounting from out side

Painted set

loadingN

Front

Number

plate

52DH0317 N

Bolt N

Plain washer Y

Spacer Y

Magnet (Self

canceling

indicator)

DH121130 N

Front Axle (

With grease

application )

DJ151041 N

Case Meter DH151062 N

Spacer DS151058 N

Front Axle

Nut59150003 N

Front Axle

Washer39078111 N

Split pin Y CPV_08_DR_031Design Basic

4.1 _ 4bCombine

Design Basic

4.1 _ 4b

Possibility of front axle split

pin missing

Lock nut instead of castle

nut & split pin

Possibility of number plate

plain washer missing

Single piecePossibility of number plate

spacer missing5 RH 5

Front Number

Plate fitment

2.2 Missing

2.2 Missing

4 RH 4Mud guard

fitment stage 2.2 Missing

Possibility of mud guard bolt

missing due to mounting

from inside

Mud guard mounting from

out side

2.2 Missing

CPV_08_DR_029 Combine

6 RH 6Front wheel

fitment

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

7 RH 7Engine Fitment

StageEngine DJ101231 N

RH Front

bracketDH161190 Y CPV_08_DR_004

Design Basic

4.1 _ 4b

Bold embossing with

colour filled

RH Rear

bracketDJ161271 Y CPV_08_DR_005

Design Basic

4.1 _ 4b

Bold embossing with

colour filled

Hanging

plate Nuts

(M8)

59150005 Y CPV_08_DR_032Design Basic


Center

Bracket Bolt

( M12 )

39245504 N

Plastic

washerN

Hanging

Plate Nuts (

M 8 )

59150005 N

Rear Axle

NutDH171019 N


Stage

Fairing

AssemblyN

11 RH 11Front Brake Kit

Routing Stage

Bolt ( with

loctite

application )


4.1 _ 4bPre coated

Lock Nuts DH161245 Y CPV_08_DR_032Design Basic


Simple Nuts 59150005 Y CPV_08_DR_032Design Basic


Possibility of wrong nut

fitment due to identification

Passivation of nut to be

change for simple & lock

nuts.

Possibility of loctite

application missing on boltPre loctite bolt

Possibility of wrong nut


Passivation of nut to be

change for simple & lock

nuts.

Possibility of wrong bracket



filling to be provided on

bracket for clear

identification




filling to be provided on

bracket for clear



Different passivation to be

provided to the nuts for

clear identification

12 RH 12Engine Tightening

Stage

2.2 Missing






RH 9Center Bracket

Tightening Stage

8 RH 8Engine Bracket

Fitment Stage

9

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

RH Step

Holder52DJ0226 N

M13 Bolts 39258204 N

Rod End 15191026 N

M8 Main

Step Bolt39231004 N

Spring

washerY CPV_08_DR_034

Design Basic

4.1 _ 4bPre coated

Main Step

RH DJ161131 N

Adjuster Nut DH191045 N

Spring 30191035 N

Plain Washer 39019811 N

Brake pedal DH191001 Y CPV_08_DR_035Design Basic

4.1 _ 4b

Square / Hexagonal

design instead of

serretion

Flange bolts

(M 12)39176904 N

Torque Rod

Bolt30151096 N

Spring

Washer - T

Rod


4.1 _ 4bCombine

Center Axle

Nut (M 22)DH171019 N

Torque Rod

Nut (M 14)39079415 N

14 RH 14Brake Connection

Stage

13 RH 13Front Wheel

Tightening Stage

15 RH 15Brake Pedal

Fitment Stage

16 RH 16Rear Wheel

Tightening Stage


provided instead of spring

washer

Possibility of spring washer

missing during torque rod

bolt fitment

Possibility of brake padel

orientation wrong wrt main

step

Brake padel mouting boss to

be modified , instead of

surretion it should be

square or hexagonal type.


introduced

Possibility of spring washer

missing during main step

fitment

2.6 Mis orientation

2.2 Missing

2.2 Missing

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

Starter

Motor

Gromet

N

Star Washer Y CPV_08_DR_037Design Basic

4.1 _ 4bCombine

Nut N

18 RH 18 Front Brake Kit

tightening Stage

Upper lever

tighteningN

19 RH 19Seat Cowl Fitment

Stage

Seat Cowl

insertionDK7303ZZ N


4.1 _ 4b


every coupler

connection.


4.1 _ 4bCoupler type design


4.1 _ 4bCommonisation


4.1 _ 4b


every coupler

connection.






4.1 _ 4b


every coupler

connection.





Possibility of harness wire

connection loose

Harness length increase by

50mm with introduction of

coupler type connection

instead of bullet type.

Possibility of blinker bullet

connection not pressed fully

RH Harness

Connection Stage22 RH 22

2.3 Loose


RH Harness

Connection Stage21 RH 21

20 RH 20RH Harness

Connection Stage

17 RH 17Starter Motor

Connection Stage

Coupler type connection

introduced instead of bullet

type.

Possibility of wrong harness

fitment on chassisCommon harness introduce.


connection loose








type.







connection loose

Instead of star washer ,

surreted nut to be

Possibility of star washer

missing


2.3 Loose



2.3 Loose

2.2 Missing



type.

2.5 Wrong part assembly Possibility of wrong harness


2.5 Wrong part assembly Possibility of wrong harness


CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

Silencer DJ101259 N

Plain Big

washers39242511 Y CPV_08_DR_038

Design Basic

4.1 _ 4bCombine

Small

washers39024811 N

Lock Nuts (M

17)DD161071 N

Flange Bolts

(M 14)39185004 N

Flange Nuts

(M 12)59150005 N

Gasket DJ101064 N

24 RH 24 Silencer

Tightening StageSnap Pin DH151055 Y CPV_08_DR_039


5 _ 5Bend for thumb support

Flange Bolts

(M 6)39194304 N

Washers 39178924 Y CPV_08_DR_040Design Basic

4.1 _ 4bCombine

26 RH 26Carburetor Clip

Tightening StageY CPV_08_DR_041

Design Basic

4.1 _ 4bSufficient access

RH 25Seat Cowl

Tightening Stage

23 RH 23Silencer Fitment

Stage

25

2.2 MissingPossibility of plain washer

missingPress fit bush with washer

Bend provided on snap pin

for better contact area on

thumb for insertion

2.2 MissingPossibility of plastic washer

missing

Bolt with press fit plastic

washer


Possibility of incomplete

insertion of snap pin on

torque rod bolt due to

Provide access for tightening

for tightening.2.4 Not tightened fully

Possibility of carburettor clip

not tightened fully due to no

access

CATEGORY


2.1

. R

evers

e

2.2

. M

issin

g

2.3

. Loose

2.4

. N

ot

tigh

ten

ed f

ully

2.5

. W

ron

g p

art

assem

bly

2.6

. M

is o

rien

tati

on

2.7

. N

ot

matc

hin

g

2.8

. A

dju

stm

en

t n

ot

good

2.9

. PD

I / E

FR

NPDS StageSr

No

Stage


Defect Loss

Applicability

Y / N

CPV_08_DR_042Design Basic

4.1 _ 4bStrong Design

Side Panel DK730822 Y CPV_08_DR_053Design Basic

4.1 _ 4bStrong Design

RH Side Seat

Cowl DecalDH161013 N

Side Lock

Grommet 31161018 N

Side panel

lockN

Y

28 RH 28Side Panel Sub

Assembly Stage

27 RH 27Clutch

Connection Stage

2.3 Loose

Possibility of side panel lock

coming out of chassis

bracket

Provided strengthened

bracket for side panel

locking.


Possibility of incomplate

insertion of clutch cable

grommet on cable

Clutch bracket design

change for easy insertion of

grommet

HOME WORK


Theme :- Cost Reduction


3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d

Frame Sub

Assly K2 ES

UG3

52DJ0182

Side stand

switch

Bearing Race

Upper52DH0248

Bearing Race

lower52DH0248

Barcode

sticker 75261601

PV card 75118821


On Conveyor

Sprocket

Assembly

3 LH 3Rear Axle

InsertionRear axle DJ151032

Battery Band DJ161247

Battery foam Y a

Foam required for

resting battery on

metallic surface

from back side

AC Box design

change for resting

battery on AC Box

itself

Impl

AC Box design for

accomodating

battery.

Battery MF

Wet Charged 9

AH

DJ201125 Y aSeparate bracket

required for battery

fitment

AC Box design

change for

accomodating

battery on AC Box

itself

Impl

AC Box design for

accomodating

battery.

CDI DH111064

Sr

No

Stage

NoStage Description Part Name Idea Cost saved by ( Rs ) Status DR Point For ReviewPart Number

Cost Loss

Applicability

Y / N

Category

Activity / Problem


Punching


Rs …… / Veh

Rs …… / Veh

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Hook -

Harness :- LHDJ161132

Bolt ( M6 ) 39168004 Y aCost involved by

using M6 bolt

Bolt can be

replaced with

smalle size

Plan

Provide harness

hook tightening bolt

with size ……

LH Engine

Hanging plateDJ161081

Bolts (M8*65

& M8*55)39245504

Bolt 39241304

Rear LH

bracketDJ161114

LH center

bracketDJ161115

Allen bolt ( M

8 )39241404

8 LH 8Magneto

connection

9 LH 9

Engine torque

checking & chain

routine

Chain

10 LH 10Rear wheel

alignment

Magneto cable

band

Upper & lower

chain case52DH0309 Y a

Extra material

provided on chain

case

Chain case width

reducedImpl

Bolts ( M 6 ) DH161283

washer Y a

Separate bolt &

washer required

for chain case

fitment

Flange bolt

introduced instead

of separate bolt &

washer

Impl

Use flange bolt of

dimension ……… for

chain case fitment

Cost saved

By………

Cost saved

by……….

Engine bracket

bolt insertion

Rs….. / Veh

11 LH 11Chain case

fitment


7 LH 7

5 LH 5LH Harness

Clamp Fitment

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Gear shift

leverDH101397

Rear cover RR DJ101211

Bolt ( M6 ) 39167304

Metal ring

Rubber ring

M 6 Bolt

LH main step DJ161130

M8 Bolts 39231004

Spring washer

Main key

grommetY a

Rubber grommet

used on main key

switch

Grommet deleted Impl

Provide main key

with out rubber

grommet

Handle bar 52DH0169 Y aSeparate cable

required for choke

connection

Choke lever

included in

carburettor body

itself

Impl

Provide carburettor

with choke lever

itself

Center Fork

bolts

Washer

Allen bolts ( M

8 )DG181008

Fork cap

rubber

grommet

DJ181009

AC Box clip DH121142

Carburettor DJ101232 Y aCarburettor

metallic diaphragm

cover

Cover change from

metallic to fybreImpl

Provide fyber

material cover for

diaphragm inplace

of metallic cover

Earthing cable

grommet

Handle bar

fitmentLH 14

Cost saved by Rs

………..

Cost saved by

Rs………..

Cost saved by Rs

………..

14

12 LH 12Gear Shifter Lever

Fitment

13 LH 13LH main step

fitment

17 LH 17Carburettor

fitment

15 LH 15

Fork Bracket

Center Bolt

Tightening

16 LH 16LH mud guard

fitment

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

18 LH 18A C Box clip

tighteningA C Box clip Y a

Separate

bolt,washer &

spacer required for

AC Box fitment

Step bolt

introducedImpl

Provide step bolt for

AC Box fitment

19 LH 19Accelerator

Connection

Accelerator

Connection

20 LH 20LH Harness

Connection

LH side

harness

terminal

connection

LH side decal DH161310 Y aSeat cowl decal

with size………….

Size reduced

to…………….Impl

Provide seat cowl

decal with

size……………

PT drain pipe

clipDH141002

22 LH 22Battery

Connection

LH bellow

insertion

Case meter

connection

Petrol Tank DJ710122

PT cap inner

screwY a

Anti theft screw

required on inner

side of petrol tank

cap

Screw deleted Impl

Provide PT cap with

out anti theft screw

mounting

Drain pipe Y aMore length of PT

drain pipePipe length reduced Impl

Provide drain pipe

with reduced length

of …..mm

Bolt 39155604

Washer 39074011

Cost saved by

Rs……….

Cost saved by

Rs………

Cost saved by

Rs………

Cost saved by

Rs…………

23 LH 23LH Bellow

insertion

24 LH 24Petrol Tank

fitment

21 LH 21LH seat cowl decal

pesting

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Grab handle DJ161263 Y aGrab handle of

material………….

Grab handle

material change

from……….to……….

Impl

Provide grab handle

with

material…………….

Bolt

Side panel 52DK5506

Side lock

grommet33161018

Side panel

lock

Cost saved by

Rs…………..25 LH 25Grab Handle

fitment

26 LH 26LH side panel

fitment

HOME WORK


Theme :- Cost Reduction


3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d

1 RH 1Rear Wheel

LoadingRear Wheel DJ151019

Rear Wheel

Spacer DJ151034 Y a

Rear wheel spacer

with yellow

passivation

Passivation change

from yellow to green.Plan

Provide rear wheel

spacer with green

passivation

Rear wheel

damperY a

6 groove rear wheel

damperSingle piece Impl

Provide 4 groove

damper for rear

wheel

Rear Brake

Panel DH151060 Y a a

1] Platted sprocket

on brake panel

2] Platted rear brake

arm

3] Sprocket

mounting on 6 bolts

1] Instead of platting ,

green passivation

provided

2] Passivation change

3] Sprocket mounting

on 4 bolts

Impl

1] Provide green

passivated sprocket

2] Provide green

passivated rear

brake arm

3] Provide sprocket

mounting on 4 bolts

Rear shock Y a

Separate dome nut ,

plain washer &

spring washer

required for shock

lower fitment

Bracket addd on swing

arm for mounting

shock lower with flange

bolt

Impl

Use flange bolt for

rear shock lower

mounting instead of

dome nut , plain

washer & spring

washerBearing

ball

Grease

2 RH 2

IdeaCost saved by ( Rs

)Status

Rear wheel spacer

insertion

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d


)Status

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Fork 52DJ0130 Y a More threaded length Thread length reduced Impl

Provide fork with

thread length …..

Mm

Friction

PlateY a

Friction plate

requiredFriction plate deleted Impl

Fork side

bracketY a

Separate bolt & nut

required for side

bracket fitment

Allen bolt introduced Impl

Bearing

Cone DH181025

Cup


Black passivation for

cup stearing

Passivation change

from black to greenImpl

Provide cup stearing

with green

pasivation

Fork Nut 30181018

Metal ring

Rubber

ring

Mud guard 52DH0278 Y a

1] Mud guard

mounting from inner

side - required bolt &

washer assembly

2] Rubber grommet

on LH side of mud

guard

1] Mud guard mounting

from outer side with

allen bolt

2] Rubber grommet

deleted

Impl

1] Provide mud

guard mounting

from out side with

allen bolt

Brace

fender DH161258 Y a

Separate clamp

required to fastened

with brace fender for

brake kit hose

grommet fitment

Brace fender with

clampImpl

Provide clamp

welded with brace

fender for brake kit

hose grommet

fitment.

Allen Bolts

(M6)DG181008

Painted set

loading

4 RH 4Mud guard

fitment stage

RH 3 Fork fitment stage3

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d


)Status

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Front

Number

plate

52DH0317 Y a

Separate bracket is

to fastened with

number plate for

brake kit hose clamp

pipe.

Front number plate

with bracketImpl

Provide welded

bracket to FNP for

brake kit hose.

Bolt

Plain

washer

Spacer

Magnet

(Self

canceling

indicator)

DH121130

Front Axle (

With grease

application

)

DJ151041

Front wheel

Case meter DH151062 Y aCase meter cost

more due to

magnetic type

Case meter design

change from gear type

to magnetic type

ImplProvide case meter

with magnetic type

Spacer DS151058

Split pin Y aCastle nut & split

pin required for front

wheel fitment

Instead of castle nut &

split pin - lock nut

used

Impl

Provide lock nut of

size ………. For front

wheel fitment

Front axle

lock nut59150003

Front axle

washer39078111

5 RH 5Front Number

Plate fitment

6 RH 6Front wheel

fitment

Cost saved By

Rs………

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d


)Status

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

RH front

bracketDH161190

RH rear

bracketDJ161271

Hanging

plate nuts (

M 8 )

59150005


stage

Center

bracket

bolt ( M12 )

39245504

Plastic

washer

Starter

relay &

OEN relay

Y aSeparate starter

relay & OEN relay

required

Starter relay combined

with OEN relayImpl

Provide single piece

device to functon for

starter & OEN relay

Hanging

plate nuts (

M8 )

59150005

Rear axle

nutDH171019


Stage

Fairing

Assembly


routine stage

Bolt with

locktite

application

59150003

Lock nuts DH161245

Simple

nuts59150005


fitment stage

9 RH 9Center bracket

tightening stage


stage

Cost saved by

Rs……….

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d


)Status

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

RH step

holder52DJ0226 Y a

Pillion step fitment

on step holder with

"O" ring , plain

washer & split pin

Pillion step mounting

with circlipImpl

Provide circlip of

size…… for pillion

step fitment

M13 bolts 39258204

Rod end 15191026

M8 main

step bolt39231004

Spring

washer

Main step

RHDJ161131

Adjuster

nutDH191045

Spring 30191035

Plain

washer39019811

Brake

padelDH191001

Flange bolt

(M12)39176904

Torque rod

bolt30151096

Spring

washer - T

Rod

39078912

Center axle

nut (M22)DH171019

Torque rod

nut (M14)39079415

13 RH 13Front wheel

tightening stage


stage

15 RH 15Brake padel

fitment stage

16 RH 16Rear wheel

tightening stage

Cost saved by

Rs………

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d


)Status

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Starter

motor

grommet

Spring

washer

Nut


tightening stage

Upper lever

tightening


stageSeat cowl DK7303ZZ

20 RH 20RH Harness

connection stage

21 RH 21RH Harness

connection stage

22 RH 22RH Harness

connection stage

Silencer DJ101259 Y aSilencer with

platting………..

Platting change

from…………..to………

…….

ImplProvide silencer with

platting………….

Plain big

washer39242511

Small

washer39024811

Lock nuts

(M17)DD161071

Flange

bolts39185004

Flange nuts 59150005

Gasket DJ101064

24 RH 24Silencer

tightening stageSnap pin DH151055


connection stage


stage

Cost saved by

Rs………….

3.1

. M

ate

rial

Change

3.2

. Length

Reducti

on

3.3

. E

lem

ent

Dele

tion

3.4

Yeil

d


)Status

Sr

No

Stage


Cost Loss

Applicability

Y / N

Category

Activity / Problem

Flange

bolts (M6)39194304

DG Screw Y aDG screw required

for seat cowl fitment

Bolt introduced for seat

cowl fitmentImpl

Provide bolt for seat

cowl fitment

Washers 39178924


tightening stage


stage

Side panel

RH side

seat cowl

decal

Side lock

grommet

Side panel

lock


Battery

terminal

removal

25 RH 25Seat cowl

tightening satge


assembly stage

Cost saved by

Rs…………..

Fasteners Final Pulsar

Documents

Transcript of Fasteners Final Pulsar