KAY JAY FORGING PVT LTD

Revision-B
KJFPL Code: TSF/CC/01
CUSTOMER COMPLAINT REGISTER
Review Status
Nature of Complaint
Customer QDH/Receipt (3 Months) Status
Sr. Complaint Type Plant Part No. Item Description By Root Cause CP Action Standardisation detail Target Date Signature Remarks
Name Date Closed/Open
New Repeated 1st 2nd 3rd

Occurrence - Broach Bend bend during

running because M2 grade material used for Occurrence - M35 grade material(Cobalt 6 to 8%) used instead of
broach M2 material to avoid the bend during production
20.09.2022 & 0103AZ102920N/ Gap Problem Req. 4.5-5.5 Not Not Not
1 Mahindra & Mahindra
01.10.2022
Assembly Chakan
0103AZ103020N
Assy Hinge Side Dr Top LH / RH
observed 6mm
Ö Sap Control Plan, PFMEA
Repeated Repeated Repeated
27.10.2022 Closed
Out Flow -Due to Inspector not ok piece Out Flow - Training given to the inspector not ok piece kept on the
kept on the working table instead of rework rework box instead of working table
box

Occurrence :- No method / system for

Occurrence - Thread operation done after the plating process
protect the part form plating inside the thread
instead of before plating process
20.09.2022 ,23.09.2 Thread Slip issue (No Go gauge Not Not Not
2 Mahindra & Mahindra
022
Assembly Chakan KJ18015 Assy Hinge Side Dr Top LH / RH
answering ) / Rust
Ö Sap
Out Flow -Due to no instruction given to
Control Plan, PFMEA , PFD
Repeated Repeated Repeated
27.09.2024 Closed
Out Flow -100% inspection started at incoming stage regarding
inspector for 100% inspection with no go
the Thread with no go thread plug gauge
thread plug gauge

Occurrence - Poka yoke Implemented in the process i.e M6 Thread

Occurrence :- Due to side milling operation
operation done after the Side milling operation and Side milling
done after the CNC turning operation i.e Side
operation reference during M6 opartaion(.Without side milling
milling operation was last operation so
Side Milling missing on Hinge operation not sit in the fixture) Control Plan, PFMEA , PFD, Not Not Not
3 Mahindra & Mahindra 27.09.2022 Assembly Chakan KJ18015 Assy Hinge Side Dr Top RH
locator
Ö Sap chances of part skipped
Eye Sequence Chart Repeated Repeated Repeated
27.09.2022 Closed
Out Flow -100% inspection started at incoming stage regarding the
Out Flow -Due to no instruction given to
side milling operation and Training provided to all the inspectors
inspector for 100% inspection
about the defect

Occurrence :- Due to no any system/

Method to detect the actual torque applied Occurrence -Bolt tight only with the torque wrench at (18NM)
on the part with torque gun instead of torque Gun to avoid less/ extra torque on the part
0103AZ102920N/ Axial Play observed (Torque Not Not Not
4 Mahindra & Mahindra 27.09.2022 Assembly Chakan
0103AZ103020N
Assy Hinge Side Dr Top RH/LH
less/ More)
Ö Sap Control Plan, PFMEA , W.I
Repeated Repeated Repeated
28.09.2022 Closed
Out Flow - Inspector not aware about the Out Flow -Training given to the inspector Bolt tight with toque
method to check the actual torque on the wrench at lower side torque i.e 18NM
part

Occurrence -Training provided to all the inspector regarding the

Occurrence :-Due to Inspector negligence
proper tight the nab pin in the piece
0103AZ102920N/ Not Not Not
5 Mahindra & Mahindra 27.09.2022 Assembly Chakan
0103AZ103020N
Assy Hinge Side Dr Top RH/LH Nap pin not insert properly Ö Sap Out Flow - Due to no instruction given to the
Out Flow -Training given to the inspector regarding the 100%
Work Instruction
Repeated Repeated Repeated
29.09.2022 Closed
operator for 100% inspection of part after the
inspection of the part regarding the nab pin proper tight in the piece
packing
before packing of material

Occurrence :-Due to no dedicated space/ Occurrence -Red binprovided on the machine for keeping the
red bin available for keeping the machine machine setting piece
NAB PIN OD OVERSIZE
setting piece at supplier end Not Not Not
6 Mahindra & Mahindra 19.10.2022 Assembly Chakan KJ18015 Pin Locator Hinge FOUND 14.23 MM AGAINST Ö Sap
Out Flow -100% inspection started at final stage at Surindera
Control Plan, PFMEA
Repeated Repeated Repeated
21.10.2022 Closed
13.70-13.90
Out Flow - Due to no instruction given to industries regarding the OD dia and Training provided to all the
inspector for 100% inspection inspectors about the defect

Occurrence :-Due to more play between

Occurrence -Play eliminated between broach pilot dia and broach
broach pilot dia(9.90±0.02) and broach
cavity. i.e size will be maintain in braoch cavity (10.02±0.02)
0103AZ102920N/ Gap Problem Req. 4.5-5.5 cavity10.14 i.e 0.24 mm play Not Not Not
7 Mahindra & Mahindra 10.12.2022 Assembly Chakan
0103AZ103020N
Assy Hinge Side Dr Top LH / RH
observed 5.8 mm
Ö Sap Control Plan, PFMEA
Repeated Repeated Repeated
21.12.2022 Closed
Out Flow -On weekly basis taper scale life checked from standard
Out Flow -Due to no monitoring of taper
room
scale life

Occurrence :-Due to manual chamfering

done on all the hole at one machine to avoid Occurrence -Chamfering operation done on VMC machine during
the burr 2nd facing operation instead of manual chamfering
0103AZ103050N/ Not Not Not
8 Mahindra & Mahindra 19.12.2022 Assembly Chakan
0103AZ102960N
Assy Hinge Side Dr Lower LH/RH Burr problem Ö Sap Control Plan, PFMEA
Repeated Repeated Repeated
06.01.2023 Closed
Out Flow - Due to Inspector not ok piece Out Flow:- Training given to the inspector not ok piece kept on the
kept on the working table instead of rework rework box instead of working table
box

Occurrence :- Due to no Macro code (Poka

Occurrence -Macro Code (700) (Poka Yoke ) added in part program
Yoke) in the machine program to avoid the
for power cut failure to avoid the without complete the operation
without complete the operation piece unlock
Side Chamfering operation piece not unload the part and the program start from the initial stage. Not Not Not
9 Mahindra & Mahindra 07.06.2023 Assembly Chakan 0103AZ103020N Assy Hinge Side Dr Top RH
missing
Ö Sap from the machine Control Plan, PFMEA,W.I
Repeated Repeated Repeated
09.06.2023 Closed
Out Flow :- 100% inspection started at final stage regarding the side
Out Flow - Due to no instruction given to
chamfering operation missing
inspector for 100% inspection

Occurrence :-Due to dia of pins size in the

fixture was lower side Occurrence -Position controlled in 0.15mm instead of 0.2mm by
changing the size of pins from 14.48-0.02, 10.85-0.02 and 14.80-
Gap Problem Req. 4.5-5.5 Out Flow - Due to kay jay gauge not 0.02 to 14.55-0.02, 11.05-0.02 and 14.90-0.02mm Not Not Not
10 Mahindra & Mahindra 30.08.2023 Assembly Chakan 0103AZ103050N Assy Hinge Side Dr Lower LH
observed 5.8 mm
Ö Sap
matched with M& M and 0.4mm variation in
Control Plan, PFMEA,SOP
Repeated Repeated Repeated
07.09.2023 Closed
the both the gauge (i.e 4.6mm gam in kay Out Flow -Kay Jay Gauge matched with with the M&M gauge to
Jay gauge then same part in Mahindra avoid the variation of both the gauges
Gauge 4.2mm ) (Spec-4.5-5.5mm)

Occurrence :-Due to the part side milling

width at higher side i.e 16.20mm ( spec16 ±
0.20) mm and riveting machine setting
Occurrence -Side milling width tolerance changed from 16±0.2mm
according to the lower side dimension
to 16±0.1mm and also riveting pin length tolerance also changed
15.83mm .And pin length also variation also
0103AZ102920N/ Assy Hinge Side Dr Top RH/LH from 16.86±0.2mm , 7.6±0.2mm to 16.86±0.1mm , 7.6±0.1mm Not Not Not
11 Mahindra & Mahindra 12.09.2023 Assembly Chakan
0103AZ103020N and Lower RH / LH
Tight Movement Ö Sap in the part Control Plan, PFMEA,SOP
Repeated Repeated Repeated
20.09.2023 Closed
Out Flow:- Auto checking torque force machine will be installed to
Out Flow - Due to manual checking variation
avoid the manual checking variation and instrument variation
during inspection and instrument variation
(Force meter not commonization with M &
M)
 Occurrence :-Due to design of clamp was
not proper ( Clamp was hold on the forging Occurrence:- Design of clamp changed for the part proper rest in
edge instead of the plain area) the fixture (Clamp rest on the plain area instead of forging edge)
12 Mahindra & Mahindra 10.09.2024 Assembly Chakan 0103AZ102920N Assy Hinge Side Dr Top RH Machining surface not ok Ö Sap Control Plan, PFMEA,W.I 14.09.2024 Closed
Out Flow - Due to no instruction given to Out Flow:- 100% inspection started at inprocess stage as well as
inspector for inspector for 100% visual final stage regarding the machining surface not ok
inspection on that particular area