VEHICLE ASSEMBLY PRESENTITION BOARD DISPLAY

SR NO 1 2 3 3.1 3.2 3.3 TOPIC SHOP RESULT BOARD - PQCDSME LEVEL WISE TARGES - PQCDSME WIDELY + DEEPLY = KK THOROUGHLY NO ADJUSTMENT THEME NAGARE TESTING BEFORE ASSEMBLY A DRIVE CHAIN B CLUTCH CABLE 3.4 ELIMINATION OF GEAR SHIFTING HARD ISSUE 3.5 ELIMINATION OF ELECRICAL ISSUES IN HI-END BIKES 4 JN UPGRADE DESIGN DOCUMENT 5 JN UPGRADE VEHICLE DISPLAY WITH TAGS 6 JN UPGRADE BOARD DISPLAY 7 KAIZEN THEMES 7.1 AUXILIARY PETROL TANK FOR K3 7.2 OIL COOLER LEAK TEST ELIMINATION 8 Q ISSUES RESOLVED BY NEW WAY APPROACH - HI-END 9 KAIZENS AUTO BARCODE SCANNING ON NUMBER PUNCHING MACHINE 9.1 BY STATIONARY SCANNER - HI END 9.2 VACUUM LEAK TEST OF PETROL TANK PULSAR ONE BARCODE DELETION FOR PULSAR BY NUMBER PRINTING 9.3 ON CARD 10 KARAKURI ENGINE COOLING BY DYNO OPERATED FAN INSTEAD OF 10.1 COOLING BLOWER 10.2 PV CONVEYOR HALL SENSOR AUTO CANCELLATION 10.3 10.4 10.5 10.6 ENGINE SAFETY KARAKURI FAIRING TRANSFER DISCOVER BY SLOPE CONVEYOR CHASSIS DROP LIFT SAFETY KARAKURI AVENGER HANDLE BAR TRANSFER BY SLOPE ON TROLLEY TARGET DATE STATUS 31.05.08 TO BE UPDATED COMPLETED 28.05.08 INPROCESS COMPLETED INPROCESS PENDING PENDING PENDING PENDING INPROCESS INPROCESS INPROCESS INPROCESS INPROCESS TO BE DISCUSS PENDING PENDING INPROCESS

29.05.08 29.05.08

28.05.08 28.05.08 28.05.08 28.05.08 28.05.08

INPROCESS COMPLETED COMPLETED CORRECTION REQUIRED COMPLETED COMPLETED INPROCESS

30.05.08

YAMAGUCHI SAN VISIT POINTS - 12-13 JUNE'08.

SR NO. KAIZEN IDEA MACHINE CELL PQCDSM

WIDELY + DEEPLY 1 NO ADJUSTMENT THEME CO SETTING K3 HIGH/LOW BEAM SETTING DISCOVER ENGINE FOUNDATION BOLT TAPPER PULSAR HANDLE BAR SETTING MAIN KEY PLASTIC BAG SIZE 2 REDUCTION 3 SEAT PLASTIC BAG DELETION BALL CAGE PLASTIC TRAY 4 REPLACED BY REUSABLE BIN PETROLIEUM JELLY PLASTIC BOTTLE REPLACE BY 5 REUSABLE BARREL 6 TESTING BEFORE ASSLY DRIVE CHAIN ELONGATION CLUTCH CABLE ELONGATION DYNO TESTING ENGINE COOLING BY FAN INSTEAD OF COOLING BLOWER PV CONVEYOR - BLINKER AUTO CANCELLATION KARAKURI CHASSIS / ENGINE SAFETY KARAKURI FAIRING TRANSFER CONVEYOR INSTEAD OF TROLLEY AUXILIARY PETROL TANK FOR K3 VEHICLE DYNO TESTING

PULSAR K3 DSCOVER

P P P

PULSAR P PULSAR / DISCOVER C PULSAR/DIS COVER C PULSAR/DIS COVER C PULSAR/DIS COVER C PULSAR/DIS COVER Q PULSAR/DIS COVER Q

DYNO METER INSPECTION CONVEYOR DROP LIFT

PULSAR

8 9

PULSAR DISCOVER

Q S

10 11

DISCOVER HI END OIL COOLER LEAKAGE TESTING M/C BEARING RACE PRESSING M/C

P C

OIL COOLER LEAKAGE 12 TESTING BEARING RACE PLACING ON 13 MANDREL BY AUTOMATION BALL FILLING ON TOOL BY 14 AUTOMATION NO PRINTING ON PV CARD BY 15 BARCODE SCANNING PETROL TANK LEAK TEST BY 16 VACUUM

HI END HI END HI END PULSAR PULSAR

P P P Q P

CHASSIS NO PUNCHING BY 17 BARCODE SCANNING DESIGN DOCUMENTS - JN 18 UPGREAD HANDLE BAR TROLLEY 19 MODIFICATION - HOME WORK

NO PUNCNING MACHINE

HI END

OINTS - 12-13 JUNE'08.

PILLAR CONCEPT CURRENT STATUS

KK KK KK KK SHE SHE

NO ADJUSTMENT INPROCESS NO ADJUSTMENT COMPLETE NO ADJUSTMENT COMPLETE NO ADJUSTMENT COMPLETE COST REDUCTION INPROCESS COST REDUCTION INPROCESS COST REDUCTION COST REDUCTION

SHE

COMPLETE

SHE

COMPLETE

KK KK

PDI COMPLAINTS ZERO INPROCESS PDI COMPLAINTS ZERO INPROCESS

KK

KARAKURI

PENDING

KK SHE

KARAKURI KARAKURI

INPROCESS COMPLETE

KK KK

KARAKURI HIGH LEVEL KAIZEN

COMPLETE INPROCESS

KK KK KK KK KK

NAGARE NAGARE NAGARE POKAYOKE TIME SAVING

COMPLETE COMPLETE COMPLETE INPROCESS PENDING

KK

POKAYOKE

COMPLETE

SHE

YOTORI

INPROCESS