Customer Complaints Register

Sl.No. Description of Complaint Root Cause Corrective Action

1 Phone & Email 25.08.09 Studs and bolts should not machined or reworked. Standard studs to be only used

2 Dantal Phone & Email 12.12.09 Inner dia oversized during Heat treatment.

3 Direct 12.12.09 This is due to fouling of Bearing cover with pump Bearing cover CD 41 +0.1 was modified as 39 +0.1

4 Drive Gear Damage at edge in GBS 40 PA PTO (2 nos) WIPRO Phone 10.01.10

5 MLK V1 shifting shoe worn out in 45 days (qty:2 nos) Mahindra Phone 12.01.10

6 Leakage of oil in GBS 40 PA PTO WIPRO Phone 20.01.10 - Redesigning of U cup and O ring to be done.

7 Breakage of Bearings and Gears in G 600 V2 PTO Hyva E mail 04.03.10

8 Oil leakage from input shaft in MLK V1 PTO Mahindra E mail 05.06.10 To avoid this,O Ring groove to be made and O Ring to be fitted in

9 ZF Alpha drive gear breakage (3 nos) WIPRO E mail 14.06.10

10 Pump cannot be fitted into G 750 V2 PTO Hyva 17.11.2010 1 Sliding Gear internal spline depth under size. Sliding Gear to be tested 100 % using plug gauge before assembly.

Complaint Issued by

Mode of Complaint

Complaint Received on

Qty Rejected

Damage of thread in M12x115 Cut Length Bolt and M12x90 Hex head bolt. The cut length bolt and Hex head bolt are assembled instead of stud. (Qty : 25 nos)

Maruthi Sharma, WIPRO

Ring Gear ID found over size upto 225 +0.05 +0.2 against 225 +0.046

1. The bends / ovaulty after Teeth cutting / Tuffriding to be measured and removed.2. Plug gauge / Snap gauge to be introduced to measure

the ID

In G 600 V2 PTO, mounting of pump is difficult. Before mounting filing is being done

Hyva, Bangaluru

This is because of PTO is engaged before the gear box stops. This is operator's mistake.

PTO operating instruction leaflet to be prepared and supplied along with every PTO

Shifting shoe material is Brass which not a good wear resistance material

Shifting shoe material changed to Phospher bronze, because it has higher wear resistance

This is because of PTO is engaged before the gear box stops. This is operators mistake.

We sent our service person to Delhi to attend this problem. PTO operating instruction leaflet to be prepared and supplied along with

every PTO

This is due to damage of O Ring in the input shaft. When the input shaft along with O ring is inserted into housing

hole during assembling, the sharp edge in the hole damages the O ring.

Microstructure is tested and found OK.The Hardness of the drive gear is tested and found OK. The case depth is

checked and found 2.5 instead of 0.6 - 0.8. This is the reason for the breakage.

This is discussed with M/s Sri Heat treatment and M/s Best heat Treatment. 1 sample tested in ASTER from Sri Heat treatment and

found 0.8. SOP for Heat treatment process to be made. Supplieaudit to be conducted.

11 ZF Alpha PTO oil leakage Palfinger 27.11.2010 1

12 G600 MPH leakage due to O Ring Worn out Hyva 25.11.2010 1

13 ZF 9S 1C oil leakage WIPRO E mail 07.12.2010 1

14 G 600 V2 Nylon Dummy breakage Hyva E mail 20.12.2010 1 Material to be changed

15 AMW E mail 10.02.2011 NA

16 Pump not entering into G600 MPH spline coupling WIPRO E mail 26.04.2011 NA

17 Bearing Damage in EATON 6306 PTO MNAL E mail 20.06.2011

17 PTO Pump Oil Leakage in ZF Alpha 6S PTO AMW E mail 29.07.2011 1

18 PTO Pump Oil Leakage in ZF Alpha 6S PTO - Qty 2 nos AMW E mail 29.07.2011 2

This is due to Hardening of U cup where the PTO was operated without oil.

The PTO is designed to use only in tipping purpose and the failure is happened in crane application which is not suitable for our PTO

This is due to O ring damage. Damage may happened because of sharp corners.

1. Before assembling it is to be ensured no sharp edges.2. Damaged O rings are to be replaced by VITON O ring. 1. In future VITON O rings only to be used 2. Piston O Ring subassembly is to be redesigned.

Failure of O Ring caused by hardening of rubber leading to premature wear.

Nitrile O rings fitted on PTOs were replaced with Viton O rings. The O ring material to be changed to a compound which is resistant to water,

heat and air.

This is due to Blow holes in the nylon dummy. During inward inspection 10 nos of dummy to be broken to find

any blow holes present.

1.Studs to be fitted on the PTO instead of sending separately.

2.Mounting the PTO using M12x100 stud is difficult and instead of the stud Hexagonal head bolt to be used.

3.Pump cannot be fitted with the PTO because the length of the M12 x 115 stud is not sufficient. M12 x 130 mm stud to be used.

AD Engineers visited WIPRO and found that this is due to burrs in pump shaft & the pump shaft is not made by

Alpha Drives

This might happened while assembling the bearing in inclined position. This might also happened by improper

method of disassembling of bearing. Rubbing mark is due to contact of face of grinding wheel during cylindrical

grinding. This might happened by improper method of disassembling of adaptor. Bearing failure.

To avoid these 1.Bearings are fitted into the housing using hydraulic press to ensure proper alighnment. 2.Face out 0.05 max is

permissible.3. Intially JSK Brand were used and now we are using INA Brand which is a higher quality.

Thread length in M12 stud is less and so it could not be tightened enough to prevent oil leakage.

Instead of M12x115 mm stud M12 x 130 mm stud are supplied. BOM to be modified

This is because Thread length in M12 stud is less and so it could not be tightened enough to prevent oil leakage. To avoid this Instead of M12x115 mm stud M12 x 130 mm

stud are supplied.BOM to be modified

Instead of M12x115 mm stud M12 x 130 mm stud are supplied. BOM to be modified

18A Spline Wear out in GBS 40 PA PTO WIPRO / KVUL E mail 13.08.2011

19 Noise while engaging in GBS 40 PA PTO WIPRO / KVUL E mail 13.08.2011 This will be ensured only verifying the defective PTO after receiving.

20 Mounting holes in GBS 40 PA Flange not matching. WIPRO / KVUL E mail 13.08.2011 During assembly of PTO, customer should not dismantle the PTO.

21 WIPRO / KVUL E mail 13.08.2011

22 WIPRO / KVUL E mail 13.08.2011

23 WIPRO / KVUL E mail 13.08.2011

24 AMW E mail 26.11.2011 Old model quill shafts in customer end to be replaced.

This may be due to mix up of pump gear which has been sent separately along with each PTO. This will be ensured

only by verifying the defective PTO after receiving. The defective PTO is replaced as an interim action.

28 teeth Drive Gear and 23 teeth Pump Gear sets to be stored in different place and clearly identified.

This may be due to mix up of 22 and 23 teeth pump gear which has been sent separately along with each PTO.

The PTO and the flange are assembled together before despatch. During assembling the PTO is disassembled by

the customer and again fitted in the vehicle gear box. During disassembling the holes may be shifted.

PTO Pump fitment becoming hectic job and time consuming job

At body building stage before fitment they are dismantling the PTO to put one mounting bolt and

fitment done on gear box in three separate parts. Which is killing min half hour time for every vehicle and it is

hectic job.

Inserting one mounting bolt and washer before assembling the PTO flange and PTO so that PTO can be directly fitted on the gear box. Time and energy can be saved at Body builder and original fitment will not

to be disturbed.

Receiving two different PTO gear sets with different gear ratios. Gear mismatching and fitment problem

This may be due to mix up of 28 teeth Drive Gear and 23 teeth Pump Gear set, because earlier 28 teeth Drive Gear and 23 teeth Pump Gear set was used in GBS 40 PA PTO. For the past 18 months 29 teeth Drive Gear and 22 Teeth

Pump Gear Combination set is being used.

All the Drive Gears at customer end having 28 teeths to be replaced by 29 teeth Drive Gear and all the Pump Gears having 23 teeths to be replaced by 22 teeth Pump Gear. 1. Only 29 teeth Drive Gear and 22 Teeth Pump Gear Combination set to be used for WIPRO. 2. 28 teeth

Drive Gear and 23 teeth Pump Gear sets to be stored in different place and clearly identified.

GBS 40 PA Drive Gear not engaging with gear box shaft

1.New Counter shaft is bought from M/s ABT TATA Motors and the shaft smoothly enters into the spline of

Drive Gear.2. Gauge used for inspection and the Counter Shaft dimensions are same. 3. Design and Manufacturer

parameters are found OK.

Spline end bore depth is 16.5 instead of 14.5 in 6209 Quill Shaft

1. Spacer thickness under size. (Measured 11.4 - 11.6 against 11.4 -0.05 in store stock). 2. Bore depth over size.

(Measured 26.0 - 26.2 against 26.0 ± 0.05 in store stock).3. Mix up of old model quill shafts. These quill

shafts are having excessive step length. The bore is 2 mm deeper than current quill shafts.1.

25 AMW E mail 30.11.2011 This is due to blow hole in Ø13 mm hole.

26 G750 MPH Spline Shaft teeth damage in the rear end AMW E mail 18.01.2012 2 Circlip to be provided in spline shaft to avoid slippage.

27 Instead of M10 x 1, 1/8 BSP tap is done in housing TAL Direct 28.03.2012 Ther is no clear drawing

28 Breakage of Bearings in G 750 V2 PTO MGB Motors E mail 20.04.2012 2 This is due to fitment of Pump in inclined position. Francis visited MGB Motors. 1no replaced.

29 GBS 40 PA Drive Gear Damage WIPRO E mail 22.04.2012 1 This is due to improper clutching before engaging PTO.

30 Mahindra E mail 22.04.2012 1

31 Missing of Pump Gear, Circlip WIPRO Direct 01.06.2012 Packing is not verified before despatch

32 Dummy Breakage in G 750 V2 WIPRO Direct 14.06.2012 1

33 Shifting Fork Breakage in MLK V1 Mahindra Direct 20.06.2012 3 This is due to more gap between spacer and Drive Gear While assembling the PTO the Gap to be maintained 0.2 max

34 Cannot assemble pump in G750 V2 PTO WIPRO E mail 12.08.2012 5 Pump Flange size variation. & Improper pump fitment Pump drawing to be prepared and sent to HYVA,WIPRO

36 WIPRO E mail 21.09.2012 1

EATON 6209 Oil leakage from stud hole due to blow holes in the hole

1.Vacum Impregnation to be done on all housings. 2. 100 % Visual Inspection to be done on all housings before assembly.

This is due to slippage of spline shaft into the coupling. Slippage may be due to : 1. Spline shaft outer diameter

under size.1. We have checked the spline shaft outer diameter in our stock and found OK.CAPA can be given

only after inspecting the failed PTO

Leakage between Oil seal bore and Adaptor shaft in MLK V1 PTO

This is because 1. Oil seal bore over size. 2. Oil seal damage

Oil seals are checked for any damages in Alpha Drives Stock and no damaged oil seals. Assembling operators are instructed to sepatrate

the damaged oil seals if any during assembling of PTOs.

Francis visted WIPRO and segregated the lot and found Pump Gear missing in 6 PTOs. 6 nos of Pump Gear sent to WIPRO

This is supplied on 8th month of 2011. This is due to blow holes in Nylon Dummy. The material is changed to

HDPE(High Density Poyethelene).

While operating GBS 40 PA PTO, it makes a improper meshing noise.

This is because of Drive Gear damage. Damage occurred while PTO is continuously tried to engage before the gear

box stops

Mr.Venakatesh of Alpha Drives visited PRERANA Motors on 24.09.2012 and replaced the damaged Drive Gear. Before engaging

PTO, driver has to press clutch pedal properly and wait for 5 seconds which failing will finally damage the drive gear spline and counter

shaft. The root cause and preventive action is discussed with Mr.Jagadish of Prerana Motors by Mr.Venkatesh of Alpha Drives

37 GBS 40 PA PTO Housing fouling with Gear Box Flange WIPRO E mail 21.09.2012 1

38 No PTO Name in Name Plate in GBS 40 PA PTO WIPRO E mail 20.10.2012 PTO name to be punched in name plate by assembly person

39 WIPRO E mail 20.10.2012

40 WIPRO E mail 20.10.2012

41 Blow hole in G750 MPH Housing WIPRO E mail 03.11.2012 1 no

42 Drill holes found in flange aea of G750 MPH WIPRO E mail 03.11.2012 1 no

43 WIPRO E mail 26.11.2012

44 G 550 Not disengaging after engaging Bafna E mail 02.12.2012 1 no

44 Leakage in GBS 40 R2 PTO (X174190000) WIPRO E mail 14.12.2012 10 nos 10 nos of Piston sub assy sent as free replacement.

45 TAL E mail 28.12.2012 20 nos This is due to Confusion and communication mistake.

46 WIPRO E mail 29.12.2012 1 no Pneumatic bore 40.1 is damaged

Problem identified by Prerana Motors, Mysore. Outer milling operation is missed in this Housing

PTO replaced. An attachement is fitted on Test rig so that Housing that missed outer milling cannot be tested. Casting to be modified so that

outer milling can be eliminated.

Not Rejected

No stock of name plate with printed PTO name. Stores issued empty name plate and assembly missed to punch

PTO name

Packing Slip is not verified and signed for GBS 40 PA PTO

Not Rejected

This is discussed with Francis. This is due to enough time is not given to him for assembling and packing.

100 % verification to be done by packing person and sampling inspection to be done by quality inspector.

G 750 PTO cannot be assembled with P408 pump using M12 x 50 mm stud because the non threaded

portion length of the stud is high.Not

Rejected

Same stud is used for all WIPRO PTOs for last two years and there is no such problem reported. The problem is only with G750 V2 PTO. Customer might have changed

their pump's flange thickness.

Stud design to be modified to meet customer requirement and this modified stud can be used for all other PTOs

1. Improper vent holes 2. Improper moulding 3. Presence of Humidity in moulding sand

100 % visual inspection to be carried out in inward inspection. Machining and assembly operators are instructed to separate and

identify if defective castings found.

This is old design PTO. Design was changed 2 years ago and there is no drills on flange are in our existing design.

Any design changes to be communicated to customers and get their approval

Instead of 4 nos of M12 nut, only 3 nos are packed and sent to WIPRO in 2 nos G600 MPH

Not Rejected

This is packed by new operator and he is not properly trained to do this job.

Packing instruction to be prepared and displayed. Understanding training to be given to ensure the operator is capable of packing .

Effectivness to be monitored.

These PTOs were supplied on Dec 2010 and kept ideal for 2 years before using. The rubber parts are damaged

which leads to leakage

G600 V2 PTO 20 nos despatched to TAL instead of G600 VO

ZF 9S 1110 PTO air leakage in Ashok Leyland which is supplied by WIPRO

47 Excess noise and vibration in Schenck 1 Gear Box Schenck E mail 29.12.2012 1 no

48 Pump fouling in G750 V2 PTO WIPRO Email 30.12.2012 1 no This is due to pump flange size varition.

49 MLK V1 Oil Leakage MNAL Email 09.01.2013 1 no

50 TATA Email 25.01.2013 1 no

51 Hyva Email 04.02.2013 1 no

52 Mounting Hole Under size in MLK V1 PTO MNAL Email 14.02.2013 2 nos Reaming not done.

53 G750 V2 Sliding Gear not entering into Pump Shaft Hyva Email 11.03.2013 1 no After heat treatment 100% Inspection to be carried out

54 WIPRO Email 26.03.2013 1 NA

55 WIPRO Email 10.04.2013 30 PO not clear & No proper communication

56 Pump Shaft not entering into G750 V2 Sliding Gear Hyva Email 22.04.2013 1 Sliding Gear Internal spline width o/s

57 M8 X 1.25 Thread damage in G550 Rear Housing BAFNA Email 25.072013 1 Coolant to be checked periodically

58 Shifting Sleeve missing in G550 PTO BAFNA 25.072013 1 Missed to fit the part during assembly

Need to request a pump from WIPRO. As per this pump we have to make a gauge.

G 550 Bearing Breakage and Transmission gear box damage

Suspected due to non availability of circlip,shaft has continuously pressed bearing while working

Abnormal sound coming from Transmission gear box. PTO Name : G600 V2

This is due to mounitng G600 V2 PTO in GB 750 Gear Box instead of GB 600 Gear Box

1. Internal spline damage. 2. Internal spline width o/s or u/s. 3. Major dia u/s. 4.Uneven Shrinkage during Heat

treatment

Drive Gear Damage & Leakage in GBS 40 PA PTO from Dummy side.

In this PTO the flange is old type i.e without slot. During fitment of the PTO in vehicle Gear box the screw might be

pressed the dummy into the bore

Wrong supply of PT0190009 PTO- Eaton 6S ES9306A instead of PT0190005 ZF9S2W.

Understanding PO requirement. Discuss with customers if PO is not clear

Sliding gear internal spline to be checked after Heat treatment 100 % using a gauge

Sticking of aluminium particles in M8 tap due to poor circulation or mixture of coolant.

1. PTO to be checked for engagement & disengagement before despatch. Test rig to be made. 2. Assembly instruction to be made.

59 Housing Breakage in G550 BAFNA 25.072013 1

60 Hyva E mail 03.08.2013 1 Replacement given.

61 WIPRO E mail 14.08.2013 2 NA

62 Pneumatic Leakage in G600 MPH WIPRO E mail 14.08.2013 1 This is due to O ring damage in piston sub assy

63 WIPRO E mail 14.08.2013 3

64 Dantal E mail 19.08.2013 1 Pump Shaft bore in Gear box is high Pump shaft to be modified by reducing the bore depth

65 Hyva E mail 10.10.2013 1

66 WIPRO E mail 10.10.2013 1

67 WIPRO E mail 10.10.2013 1

G 750 V2 Input shaft 11 teeth breakage, housing damage

This is due to bearing breakage. Damaged bearing is not received. During functioning any metal chips inside PTO

might damaged bearing.

PTO continuously in engaged position even air not supplied in ZF Alpha PTO

It is not ZF Alpha PTO. It is ZF 9S 2W with quill shaft. It is not our regular supply to WIPRO, it was given for sample

purpose. The quill shaft might not fitted properly in vehicle gear box. The PTO works properly.

Iron cap found but abnormal noise reported in GBS 40 PA PTO

Improper engagement of gear box counter shaft into PTO Drive Gear. After some time the drive gear will damage.

Engaging Gear box counter shaft in rotating condtion into PTO Drive Gear

Before engaging the PTO, vehicle driver has to apply clutch fully and wait for 20 seconds to stop the Gear Box counter shaft and try to

engage counter shaft into the PTO

Key Slipped off from pump shaft into pump shaft bore in Dantal 13 HP Gear box

G 750 V2 PTO damage, Cylinder damage & scratches on PTO body

Due to improper handling the packing damaged and finally parts damaged

Packing method to be improved by introducing special packing iside the cartoon box

Bearaing coming out & air leakage found in the piston in G 750 MPH (Sl.No.: 38263)

Rejected PTO checked in Alpha Drives and the PTO is in good condition. No air leakage & no bearing loose & this

is communicated to WIPRO

Eaton 6306 A PTO with quill shaft always in engaged postion even air not supplied

Rejected PTO checked in Alpha Drives and the PTO is in good condition. No engagement / disengagement

problem & this is communicated to WIPRO