0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant Engine Assembly Dummy Caps Fix/Remove Station Sl. No Photograph Operati on Total Dummy Caps Field / Customer Concern Control Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 1 FIP / HP Pump Install 3 Nos AE – 2 Nos. AE – 1 No  Fuel Leakage The part coming with dummy caps and QPS captured only assembly the FIP. Nowhere mentioned the Caps presence. NO CONTROL 2 Install Injector 1 & 2 6 Nos. 2 Nos. at Same Stn. AE – 2 Nos. AE – 2 Nos.  Mis-Firing  Compression Air leak.  Vacuum Fail  Injector will not fit properly. Nowhere mentioned the Caps removing process. NO CONTROL AE AE Z4

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant Engine Assembly Dummy Caps Fix/Remove Station Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 3 Install Injector 3 & 4 6 Nos. 2 Nos. at Same Stn. AE – 2 Nos. AE – 2 Nos.  Mis-Firing  Compression Air leak.  Vacuum Fail  Injector will not fit properly. Nowhere mentioned the Caps removing process. NO CONTROL 4 Vacuum Pump Install 1 No. AE – 1 No  Vacuum hardness not able to fix.  Turbo waste-gate will not work.  Power Loss  Engine Pick-up Issue. Nowhere mentioned the Caps presence. NO CONTROL Z4 AE AE Z4

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant Engine Assembly Dummy Caps Fix/Remove Station Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 5 Fuel supply tube 2 Nos. 1 No at Same Stn. AE – 1 No  Engine Not start.  Fuel Rail Pressure Low.  Fuel Leakage. QPS DCP 6 Leak of Pipe 6 Nos. 1 No at Same Stn. AE – 1 No AE – 4 Nos  Fuel Leakage. QPS DCP Z4 AE Z7

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant Engine Assembly Dummy Caps Fix/Remove Station Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 7 Oil Separator Cap 1 No.AE – 1 No  Engine white smoke  Oil consumption High  Oil Seal Damage  Oil Leakage  Engine Ceasing. Nowhere mentioned the Caps Install process. NO CONTROL 8 HP Pipe Install 2 Nos.2 Nos. at Same Stn.  Fitment Issue  Fuel Leakage  Injector Not work QPS Z4 Z7 AE AE

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant Engine Assembly Dummy Caps Fix/Remove Station Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 9 Fuel / Common Rail 5 Nos. 1 No at Same Stn. AE – 2 Nos. AE – 2 Nos.  Can't fix HP line Pipe  Engine Not start due to fuel supply not there DCP 10 HP Pipe 1 & 3rd 2 Nos. 2 Nos. at Same Stn.  Fitment issueQPS Z4 Z7 AE AE Z7

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z7 AE Z7 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 11 Fuel temp sensor 2 Nos. 1 no same station  Accommodate foreign particles  Choke the fuel system (contamination) QPS 12 Oil separator cap 1No.  Engine white smoke  Oil consumption High  Oil Seal Damage  Oil Leakage  Engine Ceasing. QPS

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z7 AE Z7 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 13 Turbo Cap -Bi Turbo 6 Nos. 1 No at same Stn. AE – 2 Nos. AE – 1 No. AE – 2 Nos. Remove & Re-fix)  Fitment Issue  Turbo parameter fail in cold test.  Accommodate foreign particles  Compressor vanes damage  Power Loss. QPS 14 Turbo Cap -Si Turbo 4 Nos. 1 No at Same Stn. AE – 1 No. AE.5130 – 2 Nos. (Remove & Re-fix)  Fitment Issue  Turbo parameter fail in cold test  Accommodate foreign particles  Compressor vanes damage  Power Loss. QPS

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z7 AE Z7 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 15 Bi Turbo Feed pipe 3 Nos.3 Nos. at Same Stn.  Fitment IssueQPS 16 Si Turbo Feed pipe 2 Nos.2 Nos. at Same Stn.  Fitment IssueQPS

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z8 AE Z8 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 17 TCOP sensor Cap 1 No1 No at Same Stn.  Fitment Issue Nowhere mentioned the Caps Removal process. NO CONTROL 18 TCOP sensor Tie 1 No1 No at Same Stn.  Sensor Not read any data (or) Malfunctioning QPS SPL (Not mentioned the removing tie)

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z8 AE Z10 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 19 Coolant Spigot cap 1 No1 No at Same Stn.  Fitment Issue Nowhere mentioned the Caps Removal process. NO CONTROL 20 EGR Cap1 No 1 No at same Stn.  Wiring Hardness fitment issue Nowhere mentioned the Caps Removal process. NO CONTROL

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z10 AE Z10 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 21 EGR pipe Waste gate Tie 1 No 1 No at same Stn.  Vacuum drop  EGR not work properly Nowhere mentioned the Tie Removal process. NO CONTROL 22 BI Turbo Caps Remove & Refix 2 Nos. Remove & Re-fix  Accommodate foreign particles  Power loss. DCP (Not mentioned the particular caps name)

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AE Engine Assembly Dummy Caps Fix/Remove Station Z4 Z10 AE Z10 Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 23 Fuel Inlet & Outlet Remove & Re-fix 2 Nos. Remove & Re-fix  Accommodate foreign particles  Fuel line block  Fuel filter choke  Engine will not start  Vibration due to improper fuel flow. DCP 24 AE Vacum cap Remove & Re-fix 1 No. Remove & Re- fix DCP

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant Turbo AU A Engine Assembly Dummy Caps Fix/Remove Station AU B Turbo Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 25 Coolant cap pipe remove 4 nos.  Fitment Issue Nowhere mentioned the Tie Removal process. NO CONTROL 26 Remove Temp. Sensor cap 1 nos.  Fitment IssueQPS

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AU1200.1A Engine Assembly Dummy Caps Fix/Remove Station Z4 Turbo AU B Turbo Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 27 Coolant pipe Cap 2 nos.  Fitment Issue 28 Remove Oil Drain Pipe fix Cap 1 no  Turbo Intake & Exhaust Oil leak

0 / 100 Mindset Sanand Engine Plant Go Further Sanand Engine Plant AU1200.1A Engine Assembly Dummy Caps Fix/Remove Station Z4 Turbo AU1200.1A Turbo Sl. No Photograph Operati on Total Dummy Caps Field / Customer ConcernControl Method Risk Priority Number Fixed / In Build RemovedRPNR*P*N 29 Remove Oil Drain Pipe Cap Each 1 No.  Turbo Intake & Exhaust Oil leak 30 Remove Oil Drain Pipe Cap Each 1 No.  Turbo Intake & Exhaust Oil leak SI BI