Change point ppt - burgman coupler & terminal - 06.09.2024.pptx

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1. CHANGE POINT DETAILS FOR BURGMAN WIRING HARNESS ASSEMBLY 06.09.2024 CARV - Burgman coupler & Terminal

2. Contents 1. CARV details 2. Part details 3.Part number details of existing & proposed source 4.Comparison report - Coupler 5.Comparison report - Terminal 6.Comparison report - Part tooling details 7.4M Change management details 8.Dimensional comparison report - Wiring harness assembly 9. Dimensional comparison report - Coupler 10.Dimensional comparison report - Terminal 11.Comparison report - Pull out strength 12.Comparison report - MTC - Coupler

3. Contents 13.Comparison report - MTC - Terminal 14.ELV Report for Coupler & Terminal 15.Dimensional comparison report - Crimping height / Width / Compression ratio / Profile view. 16.Wiring harness identification for traceability 17.Fitment validation @ vehicle level 18.Comparison report - Insertion force 19.Comparison report - Holding strength 20.Comparison report - Performance test 21.Endurance test report 22.Cost impact details

4. (i) Sub-supplier change for Wiring harness coupler from “ S umitomo” to “Mass auto components” . (ii) Sub-supplier change for Wiring harness terminal lug from “Yazaki” to “Mass auto components”. Reason for CARV— Additional source for Coupler & terminal lug. Existing source : Sumitomo (Coupler) & Yazaki (Terminal) Proposed source : Mass auto (Coupler) & Mass auto (Terminal) Vendor name- LUCAS TVS Affected Model— BURGMAN SCOOTER Affected Part no – 31100M08K30 Affected part name— Motor assy,Starting Parts are common with SMG or not— Not applicable Parts are common with MSIL model— No (Only for burgman) ECN /ECR/LP/LR requirement detail- NA No of tools in case of duplicate tooling— NA No of shots old and new tool- NA 1. CARV detail- CARV/L059/ ---- / ----- .

5. 2.P art Details Part No : 31100M08K30 Part Name : Starter Motor

6. 3. Part number details of Existing & Proposed Parts Part Number details of Coupler and Connector Existing source Proposed source Coupler Sumitomo : 6410 - 4626 Mass auto components MAC20 - 0136 Connector Yazaki : 7114 - 3030 Mass auto components 30-0001

7. S. N o Existing part detail or tool detail Proposed part detail or tool detail Remarks Part no Part name 31100M08K30 (L059) MOTOR ASSY, STARTING 31100M08K30 (L059) MOTOR ASSY, STARTING No change Change child part detail COUPLER - SUMITOMO Part No : 6410 - 4626 COUPLER - MASS AUTO COMPONENTS Part No : MAC20 - 0136 Sub supplier change (New source) Picture - 4.Comparison : Existing & Proposed Part - Coupler

8. S. N o Existing part detail or tool detail Proposed part detail or tool detail Remarks Part no Part name 31100M08K30 (L059) MOTOR ASSY, STARTING 31100M08K30 (L059) MOTOR ASSY, STARTING No change Change child part detail TERMINAL - YAZAKI Part No : 7114 - 3030 TERMINAL - MASS AUTO COMPONENTS Part No : 30-0001 Sub supplier change (New source) Picture - 5.Comparison : Existing & Proposed Part - Terminal

9. S.no Existing part detail or tool detail Proposed part detail or tool detail Part design detail if any Terminal coil vertical feeding changed to horizontal feeding to eliminate the presence of thimble in terminal after cutting & crimping process . 6.Comparison : Existing & Proposed Part Tool Details

10. 7.4M Change management Change details Existing source Proposed source Remarks MAN Trained operators at MAC Trained operators at MAC No change MATERIAL Coupler material: Nylon Terminal material : Brass Coupler Material: Nylon Terminal material : Brass No change MACHINE Coupler : Injection moulding Terminal : Press tool Coupler : Injection moulding Terminal : Press tool No change METHOD Vertical feeding of terminal with end cutting & crimping Horizontal feeding of terminal with side cutting & crimping Change*

11. 8.Dimensional comparison report - Wiring harness assembly

12. 8.Dimensional comparison report - Wiring harness assembly S.NO. ITEM SPEC RANGE/TOLERANCE OBSERVATION Min. Max Mass auto components Sumitomo / Yazaki Judgment (O/X/ Δ ) Remark A APPEARANCE A1 Visual OK / NOT OK OK OK OK OK OK OK OK OK OK OK O B DIMENSIONS 1 Length 160 160 180 173 174 173 172 175 171 175 176 174 173 O 2 Length 90 90 100 95 95 96 96 95 94 93 95 95 94 O 3 AV5 Red / white OK / NOT OK OK OK OK OK OK OK OK OK OK OK O 4 Solder OK / NOT OK OK OK OK OK OK OK OK OK OK OK O 5 PVC Sleeve Black OK / NOT OK OK OK OK OK OK OK OK OK OK OK O 6 Red / White OK / NOT OK OK OK OK OK OK OK OK OK OK OK O 7 Green OK / NOT OK OK OK OK OK OK OK OK OK OK OK O 8 Length 75 75 85 81 81 81 81 81 79 79 79 79 79 O 9 Length 130 130 150 142 143 142 143 142 142 142 142 142 142 O 10 AV5 Green OK / NOT OK OK OK OK OK OK OK OK OK OK OK O Inference : There is no difference in specifications on wiring harness assy of both suppliers

13. 8.Specification comparison report - Wiring harness assembly Sumitomo / Yazaki Mass auto components S.NO. ITEM SPEC RANGE/TOLERANCE SPEC RANGE/TOLERANCE Min. Max Min. Max Judgment LTVS Explanations A APPEARANCE A1 Visual OK / NOT OK OK / NOT OK No difference OK B DIMENSIONS 1 Length 160 160 180 160 160 180 No difference OK 2 Length 90 90 100 90 90 100 No difference OK 3 AV5 Red / white OK / NOT OK OK / NOT OK No difference OK 4 Solder OK / NOT OK OK / NOT OK No difference OK 5 PVC Sleeve Black OK / NOT OK OK / NOT OK No difference OK 6 Red / White OK / NOT OK OK / NOT OK No difference OK 7 Green OK / NOT OK OK / NOT OK No difference OK 8 Length 75 75 85 75 75 85 No difference OK 9 Length 130 130 150 130 130 150 No difference OK 10 AV5 Green OK / NOT OK OK / NOT OK No difference OK Inference : There is no difference in specifications on wiring harness assy of both suppliers

14. 9.Dimensional comparison report - Coupler

15. 9.Dimensional comparison report - Coupler S.NO. ITEM SPEC RANGE/TOLERANCE OBSERVATION Min. Max MASS AUTO COMPONENTS SUMITOMO Judgment (O/X/ Δ ) Remarks A APPEARANCE Visual OK / NOT OK OK OK OK OK OK OK OK OK OK OK O B DIMENSIONS 1 Thickness 1.5 1.30 1.70 1.56 1.59 1.59 1.60 1.58 1.48 1.48 1.47 1.48 1.48 O 2 Length 16.2 16.0 16.40 16.17 16.17 16.16 16.14 16.15 16.31 16.32 16.31 16.31 16.32 O 3 Thickness 1.5 1.30 1.70 1.39 1.39 1.37 1.42 1.37 1.69 1.68 1.69 1.69 1.68 O 4 Width 16.1 15.90 16.30 16.29 16.30 16.30 16.29 16.29 16.12 16.12 16.12 16.11 16.12 O 5 Thickness 1.5 1.30 1.70 1.42 1.42 1.41 1.39 1.41 1.59 1.59 1.59 1.57 1.59 O 6 Length 34 33.60 34.40 33.98 34.02 33.97 33.95 33.98 34.02 34.04 33.98 33.98 33.98 O 7 Colour Natural OK / NOT OK OK OK OK OK OK OK OK OK OK OK O

16. 9.Specification comparison report - Coupler Sumitomo / Yazaki Mass auto components S.NO. ITEM SPEC RANGE/TOLERANCE SPEC RANGE/TOLERANCE Min. Max Min. Max Judgment Remarks A APPEARANCE Visual OK / NOT OK OK / NOT OK OK B DIMENSIONS 1 Thickness 1.5 1.30 1.70 1.5 1.30 1.70 OK 2 Length 16.2 16.0 16.40 16.2 16.00 16.40 OK 3 Thickness 1.5 1.30 1.70 1.5 1.30 1.70 OK 4 Width 16.1 15.90 16.30 16.3 16.2 16.4 5 Thickness 1.5 1.30 1.70 1.5 1.30 1.70 OK 6 Length 34 33.60 34.40 34 33.6 34.40 OK 7 Colour Natural OK / NOT OK OK / NOT OK Inference :

17. 10.Dimensional comparison report - Terminal (Mass auto)

18. 10.Dimensional comparison report - Terminal (Yazaki)

19. 10.Dimensional comparison report - Terminal (Mass auto Vs Yazaki) S.NO. ITEM SPEC RANGE/TOLERANCE OBSERVATION SPEC RANGE/TOLERANCE OBSERVATION Remarks Min. Max Mass auto terminal Min. Max Yazaki terminal A APPEARANCE 1 Visual OK / NOT OK OK OK OK OK OK OK / NOT OK OK OK OK OK OK B DIMENSIONS 1 Length 29.80 29.50 30.10 29.78 29.79 29.79 29.77 29.76 29.70 29.30 30.10 29.47 29.49 29.43 29.45 29.46 2 Length 16.45 16.25 16.65 16.41 16.42 16.42 16.40 16.40 16 15.70 16.10 15.76 15.72 15.76 15.73 15.74 3 Chamfer 1.50 1.30 1.70 1.66 1.67 1.67 1.64 1.65 1.40 1.20 1.60 1.53 1.49 1.52 1.56 1.51 4 Angle 40° 35° 45° 39°25' 38°57' 39°09' 39°02' 39°31' 30° 25° 35° 31°30' 32°27' 33°02' 31°51' 32°19' 5 Width 7.70 7.70 7.90 7.71 7.71 7.72 7.71 7.71 7.8 7.65 7.95 7.77 7.76 7.77 7.78 7.77 6 Length 15.10 15.00 15.20 15.02 15.10 15.15 15.02 15.09 15.2 15.00 15.40 15.08 15.07 15.09 15.07 15.08 7 Height 2.30 2.10 2.50 2.34 2.30 2.23 2.40 2.29 1.8 1.60 2.00 1.95 1.93 1.98 1.95 1.96 8 Thickness 0.40 0.38 0.42 0.40 0.40 0.40 0.40 0.40 0.40 0.38 0.42 0.39 0.39 0.39 0.39 0.39

20. 10.Specification comparison report - Terminal (Mass auto Vs Yazaki) S.NO. ITEM SPEC RANGE/TOLERANCE SPEC RANGE/TOLERANCE LTVS Explanations Min. Max Min. Max A APPEARANCE 1 Visual OK / NOT OK OK / NOT OK - B DIMENSIONS 1 Length 29.80 29.50 30.10 29.70 29.30 30.10 For mass auto coupler internal mating dimensions – Fitment verified and found OK 2 Length 16.45 16.25 16.65 16 15.70 16.10 3 Chamfer 1.50 1.30 1.70 1.40 1.20 1.60 4 Angle 40° 35° 45° 30° 25° 35° 5 Width 7.70 7.70 7.90 7.8 7.65 7.95 6 Length 15.10 15.00 15.20 15.2 15.00 15.40 7 Height 2.30 2.10 2.50 1.8 1.60 2.00 8 Thickness 0.40 0.38 0.42 0.40 0.38 0.42 Inference :

21. 11.Terminal Pull Out Strength - Mass Auto vs Sumitomo/Yazaki Inference : For both suppliers – Terminal pull out strength meeting the specifications.

22. 12.Sumitomo - Mass auto coupler -MTC Comparison Inference : There is no difference in material specification of both suppliers & verified OK.

23. 13.Yazaki - Mass auto connector -MTC Comparison Inference : There is no difference in material specification of both suppliers & verified OK.

24. 14.ELV Reports - Mass auto coupler & connector Inference : ELV reports verified and meeting the MSIL requirements.

25. 15.Crimping height / width / Comp ratio / Profile view – Comparison report Inference : Difference in crimping height / width due to terminal barrel sheet thickness difference. Why difference in crimping height & width – inference to be added

26. SUPPLIER IDENTIFICATION MARKING WITH CAVITY DETAILS 16.Wiring Harness identification For Traceability

27. 17.Wiring harness - Coupler & Connector Fitment Validation EXISITING SOURCE PROPOSED SOURCE Result: Wiring harness coupler & connector mating/fitment verified at vehicle level and No difference observed between existing source and proposed source - Found OK. SUMITOMO COUPLER - YAZAKI CONNECTOR MASS AUTO COMPONENTS - COUPLER & CONNECTOR

28. 17.Wiring harness - Coupler & Connector Fitment check Fitment check verified for 10 Nos at vehicle level using mass auto coupler & connector - found OK Verified : 1.Easy insertion / No hard fitment 2.Proper locking in mating part 3.Starter smooth operation

29. 18.Comparison report - Mating coupler insertion force Inference : No major difference in insertion force of both suppliers & met the specifications.

30. 19.Comparison report - Mating coupler holding strength Inference : No major difference in coupler holding strength of both suppliers & met the specifications.

31. 20.Comparison report - Performance test S.NO. ITEM SPEC RANGE/ TOLERANCE OBSERVATION Min. Max Mass auto components Sumitomo / Yazaki Judgment (O/X/Δ) Remarks D1 No load @ 11.6 V - Current 18 A - 18 11.640 12.340 12.270 10.750 11.980 11.469 13.211 10.678 12.027 12.468 O D2 No load @ 11.6 V - Speed 12500 rpm 12500 - 14972 15534 15005 14687 15316 13283 16077 15378 14984 15562 O D3 Load @ 10.3 V - Current 40 A - 40 30.240 31.100 31.310 29.990 30.470 31.826 32.548 31.797 29.666 32.513 O D4 Load @ 10.3 V - Torque 0.21 Nm 0.21 - 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 - D5 Load @ 10.3 V - Speed 8000 rpm 8000 - 11628 11906 11473 11421 11703 11274 12160 11933 12258 11551 O D6 Locked @ 5.7 V - Current 170 A - 170 117.15 116.30 129.83 116.97 128.96 127.998 120.421 131.668 127.702 118.467 O D7 Locked @ 5.7 V - Torque 0.7 Nm 0.7 - 1.110 1.050 1.060 1.080 1.140 1.085 1.121 1.088 1.052 1.074 O Inference : No major difference in performance test of both suppliers & met the specifications.

32. 21.Endurance test report :

33. 21.Endurance test report : Inference : Endurance test conducted using Mass auto coupler & connector – Found OK.

34. 22.Cost impact details : We would like to inform that there will be a cost reduction due to this change over which LTVS accepts to pass-on (Rs 1.40 / PCS) to MSIL.

35. Conclusion : For Burgman starter (31100M08K30) – CARV raised for Wiring harness assembly – Coupler & Connector(Sub-supplier change). Existing source : Sumitomo coupler & Yazaki connector. Proposed source : Mass auto coupler & Mass auto connector. Detailed specification/drawing comparison study done and fitment verified OK. Endurance test conducted using proposed source and no abnormalities observed. Hence, LTVS requested to MSIL to approve the proposed change in wiring harness assembly (Coupler & Connector). Based on MSIL feedback, LTVS would like to submit the updated C-outline drawings for MSIL/SMC approval.

36. Thanks