# Complete QA Checksheet Items (Extracted Master Repository)
**Source Documents:** `docs/qa checksheet.pdf` (signed ISO plant standard) and `docs/Inprocess checksheet  April. - 2026 - 2000bus.xls`.

## Cowl & Sub-Assembly Critical Clearances (CTC Format 4) (`QS_CTC_SUBASSY`)
- **Format No:** `AA/QA/CTC/04` | **Revision:** `05`
- **Description:** Critical to Quality (CTC) clearances for Driver Door & Emergency Door apertures

### Section 1: Driver Door Aperture CTC Clearances (10 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Clearance Gap at Location 'A' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 2 | Clearance Gap at Location 'B' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 3 | Clearance Gap at Location 'C' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 4 | Clearance Gap at Location 'D' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 5 | Clearance Gap at Location 'E' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 6 | Clearance Gap at Location 'F' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 7 | Clearance Gap at Location 'G' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 8 | Clearance Gap at Location 'H' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 9 | Clearance Gap at Location 'I' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 10 | Clearance Gap at Location 'J' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |

### Section 2: Emergency Door Aperture CTC Clearances (10 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 11 | Clearance Gap at Location 'A' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 12 | Clearance Gap at Location 'B' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 13 | Clearance Gap at Location 'C' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 14 | Clearance Gap at Location 'D' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 15 | Clearance Gap at Location 'E' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 16 | Clearance Gap at Location 'F' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 17 | Clearance Gap at Location 'G' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 18 | Clearance Gap at Location 'H' | CRITICAL | FEELER_GAUGE | 8 ±2 • [6.000 to 10.000 mm] | 1 bus / 10th bus lot |
| 19 | Clearance Gap at Location 'I' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |
| 20 | Clearance Gap at Location 'J' | CRITICAL | FEELER_GAUGE | 6 ±2 • [4.000 to 8.000 mm] | 1 bus / 10th bus lot |

---

## FAPS Fire Detection & Alarm Matrix Checksheet (`QS_FAPS`)
- **Format No:** `AA/QA/FAPS/CS-005` | **Revision:** `02`
- **Description:** Fire Alarm & Protection System Modelwise Matrix (Smoke detector, alarm, FDSS cylinder, water, nitrogen)

### Section 1: Fire Alarm & Protection System (FAPS) Matrix (7 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Smoke detector fitment, wiring connection and functional alarm test | CRITICAL | FUNCTIONAL | Operational | 1.0 |
| 2 | Audible alarm siren level and dashboard buzzer trigger test | CRITICAL | FUNCTIONAL | Audible >= 85 dB • [85.000 to — GU] | 1.0 |
| 3 | FDSS 6kg dry powder fire suppression cylinder mounting and pressure gauge in green zone | CRITICAL | VISUAL | Pressure Green Zone | 1.0 |
| 4 | Water spray cylinder mounting (85L for 20.75H, 115L for 20.90L) & bracket tightness | CRITICAL | VISUAL | 85L / 115L as per model | 1.0 |
| 5 | Nitrogen actuation cylinder (6.5L/4.5L/13.5L/6.8L) leak test & valve seal intact | CRITICAL | VISUAL | Seal Intact | 1.0 |
| 6 | Cylinder mounting on chassis rail / rear dickey bracket bolt torque | CRITICAL | TORQUE_WRENCH | 1.7 ~ 2.6 kgf·m • [1.700 to 2.600 kgf·m] | 1.0 |
| 7 | Thermal sensing tube routing and nozzle distribution quantity across engine bay | CRITICAL | PROD_REPORT | As per model matrix | 1.0 |

---

## Field Complaints & Quality Gate Checksheet (`QS_FIELD_ISSUES`)
- **Format No:** `AA/QA/FC/FM-013` | **Revision:** `00`
- **Description:** Starline / Skyline / Legacy Bus Complain Points & Field Defect Audit (Page 3 of QA Standard)

### Section 1: Starline / Skyline / Legacy Bus Field Complain Points (37 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Welding: mudguard chanda missing | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 2 | outer panel: LH Side skirt panel front welding broken on border | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 3 | FRP: Rear Dome corner side heavy waviness | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 4 | FRP: Bazzale ring minior crack found | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 5 | FRP: Rear Dome outer on air bubbles | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 6 | FRP: Front dome / bumper level not ok | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 7 | E Door: E door out ( off set with pillar) | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 8 | D Door: Driver side door not fitting properly. | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 9 | E hood: Hot air not pass from E hood bottom | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 10 | E hood: E hood sealant finish ok | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 11 | Dash board: Dash board crack Co driver side -Vecv bus | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 12 | Inner panel: Roof inner panel drumming during vehicle run | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 13 | Roof hatch: Roof hatch gap and leakage | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 14 | Rear  Door: Rear Dickey lock missing faps - skyline model | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 15 | Rear  Door: Rear dickey lock not works | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 16 | JK Door: J.K Door hinge bolt loose | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 17 | FAPS: Water leakage from FAPS Water tank | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 18 | FAPS: Nitrogen cylinder empty | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 19 | fire ext.: Fire Extingusher missing found-Not fit from here -mtg also missing | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 20 | window: 3-piece window noice-Tower bolt in gap | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 21 | window: window screw loose | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 22 | RVM: Right side upper mirror - Left side view is not visible after sitting on the seat. | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 23 | glass: Rear / front Glass Rubber Not Fitted Properly. | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 24 | Glass: Front / Rear glass fitment rubber resting ok | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 25 | ELECTRICAL: Side marker Cracked and damaged , tail light cover not crack | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 26 | ELECTRICAL: FRP Rear inner tail light cover in gap LH/RH side- Dust inserting - skyline | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 27 | VINYL: 1.Vinyl Broken on cowl area | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |
| 28 | Wiper: Wiper arm glass not clean - legacy camoflex | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 29 | seat: Driver seat forward & backward mechanism driver seat is not adjustable | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 30 | seat: LH side Seat leg spac differnet from other buses | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 31 | seat: Gangway pipe fitted in gangway center | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 32 | seat: Staff seat not mount on support | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 33 | AC: 1.Ply excess cut by AC pipe , AC not work , AC cover paint peel off , | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 34 | paint: Front panel received in various painted issues | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 35 | paint: Paint condition not ok - front facia | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 36 | GSL COVER: cover Missing | MAJOR | VISUAL | Free of defects / No complaints | 1.0 |
| 37 | leakage: Leakage fill sealant paint not touch up . | CRITICAL | VISUAL | Free of defects / No complaints | 1.0 |

---

## Final Vehicle Inspection & Shower Test (FVI) (`QS_FVI`)
- **Format No:** `AA/QA/FVI/IR-011` | **Revision:** `00`
- **Description:** Final Vehicle Quality Checksheet & Shower Water Leakage Test BS-VI

### Section 1: Under body (5 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | U bolt tight / Outrigger tight / not tapered | CRITICAL | MANUAL | — | 1.0 |
| 2 | Wiring not pinch in U bolt / wiring not foul on ETS tank | CRITICAL | VISUAL | — | 1.0 |
| 3 | Front / rear bumper bracket tight / Toe hook tight | MAJOR | VISUAL | — | 1.0 |
| 4 | Chassis number visible - | MAJOR | VISUAL | — | 1.0 |
| 5 | Under body paint ok Front / Rear / LH/RH side etc | MAJOR | VISUAL | — | 1.0 |

### Section 2: Door locking (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 6 | E door locking / level ok / Hazard function ok | CRITICAL | FUNCTIONAL | — | 1.0 |
| 7 | D door locking 1& 2nd lock ok / not level out with pillar | CRITICAL | FUNCTIONAL | — | 1.0 |
| 8 | JK door locking / hazard function ok | CRITICAL | FUNCTIONAL | — | 1.0 |
| 9 | Battery flap locking ok | MAJOR | VISUAL | — | 1.0 |

### Section 3: Fitment - Interior parts (10 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 10 | Dash board tight screw not loose , no gap front and co driver side  / glove box locking ok / E hood locking ok | MAJOR | VISUAL | — | 1.0 |
| 11 | Cluster meter tight CNG/DIESEL -function ok / no gap | CRITICAL | MANUAL | — | 1.0 |
| 12 | Switch plate tight / Driver fan not loose / sunvisor not loose / salooon mirror not loose | MAJOR | VISUAL | — | 1.0 |
| 13 | Front glass rubber rest proper / A pillar cover not loose | MAJOR | VISUAL | — | 1.0 |
| 14 | Driver / C o driver window glass sliding ok / Co driver handle fitted | MAJOR | VISUAL | — | 1.0 |
| 15 | All parttion jk door / D door  no extra hole and fitment ok | MAJOR | VISUAL | — | 1.0 |
| 16 | Powder coating ok hatrack , parttion , grab rail , window guard etc | MAJOR | VISUAL | — | 1.0 |
| 17 | Front and rear glass rubber seating ok , no gaps | MAJOR | VISUAL | — | 1.0 |
| 18 | All cutout fitment , Rear Tail light cover not gap | MAJOR | VISUAL | — | 1.0 |
| 19 | Grab rail / FAPS pipe fitment ok /Gola beading not short / cap not missing | MAJOR | VISUAL | — | 1.0 |

### Section 4: Exteriror fitment (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 20 | Window guard not missing / bkt not taper , rear tail light not crack / rear bumper sensor fitted / rear grab handle fitted not inclined / side indicator and replactor fitted not loose / RVM not loose | MAJOR | MANUAL | — | 1.0 |

### Section 5: Side skirt panel / stretch panel (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 21 | No waviness ,No line marks and No drummung | MAJOR | MANUAL | — | 1.0 |

### Section 6: Roof panel (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 22 | No dent in shoulder and rain gutter | MAJOR | VISUAL | — | 1.0 |

### Section 7: Interior panel (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 23 | No damage or dent , No scratches , Roof no drumming | MAJOR | VISUAL | — | 1.0 |

### Section 8: Floor Vinyl/Chequered plate (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 24 | No extra cut or gap with side and cabin area , chaqured plate no loose in cabin and hump , seat area | MAJOR | MANUAL | — | 1.0 |

### Section 9: Paint / Powder coat   Finish (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 25 | Cabin area - Dash board / E hood paint ok / sealant ok | MINOR | VISUAL | — | 1.0 |
| 26 | Paint ok window / hatrack / partition / Door aperture | MINOR | VISUAL | — | 1.0 |
| 27 | Dash board carpet / A pillar carpet pasting ok | MINOR | VISUAL | — | 1.0 |

### Section 10: Sealant filling at Window top, Height marker and tail lamp. (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 28 | Sealant filling ok all window / front / rear dome /height marker | MINOR | VISUAL | — | 1.0 |
| 29 | Rain guttter and A pillar area sealant finishing to be ok | MINOR | VISUAL | — | 1.0 |

### Section 11: Eicher horse and Emblum fitted properly (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 30 | Should not be loose, inclined and off set fitted . | MAJOR | MANUAL | — | 1.0 |

### Section 12: Door Beading (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 31 | E door / D door beading fitment ok not loose fitted / no light pass | MAJOR | MANUAL | — | 1.0 |

### Section 13: Wiper operation & Nozzle setting (5 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 32 | 1) Water nozzles pipe tight , Arm not  foul with fws rubber | CRITICAL | MANUAL | — | 1.0 |
| 33 | 2) Water tank not loose / linakge not foul with structure | CRITICAL | VISUAL | — | 1.0 |
| 34 | 3) wiper testing-Check all 3 speed  ok / water nozzle flow ok | CRITICAL | MANUAL | — | 1.0 |
| 35 | 4) Start washered and check glass cleaning by wiper at low speed | CRITICAL | MANUAL | — | 1.0 |
| 36 | 5) Check wiper blade mounting nut fully tighted | CRITICAL | MANUAL | — | 1.0 |

### Section 14: Electrical function (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 37 | All interior lights should be glowing/Working | CRITICAL | FUNCTIONAL | — | 1.0 |
| 38 | Head light not off set / working ok - grommer fitted | CRITICAL | FUNCTIONAL | — | 1.0 |
| 39 | Check all exterior light replacor and indicator / tail light  glowing / working | CRITICAL | FUNCTIONAL | — | 1.0 |
| 40 | Check buzzer working jk door / e door open | CRITICAL | FUNCTIONAL | — | 1.0 |

### Section 15: Dash board electricals. (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 41 | Telematic switch / ECO / ABS / Pom tom / cut off switch pin Not loose fitted | CRITICAL | VISUAL | — | 1.0 |

### Section 16: Service point (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 42 | Coolant oil , clutch oil , steering oil , easly Access | CRITICAL | MANUAL | — | 1.0 |

### Section 17: Battery aasembly (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 43 | Cut off work , terminal not loose , wiring not foul ETS and not loose | CRITICAL | MANUAL | — | 1.0 |

### Section 18: Body builder Plate & Chassis no VIN plate (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 44 | 1) Weight as per Body builder weight list  2) Position Should be straight and align | MAJOR | VISUAL | — | 1.0 |

### Section 19: Radiator (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 45 | Radiator not puncher / coolant level ok | MAJOR | VISUAL | — | 1.0 |

### Section 20: FOP setting (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 46 | FOP locking to be ok . No loose fitting | MAJOR | MANUAL | — | 1.0 |

### Section 21: Stepney tyre (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 47 | Check stepney tyre not loose / hole access to rod | CRITICAL | MANUAL | — | 1.0 |

### Section 22: Toe hook (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 48 | Check Front  Toe hook fitment ok | MAJOR | VISUAL | — | 1.0 |

### Section 23: CNG Bus cylinder details plate (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 49 | Cylinder number match with cng plate / service indicator fitted | CRITICAL | VISUAL | — | 1.0 |
| 50 | Check air in tank , Cng knob  filling feasible and  flap align ok , | CRITICAL | VISUAL | — | 1.0 |
| 51 | Cylender conncetion ok , hose pipe connection ok | CRITICAL | VISUAL | — | 1.0 |
| 52 | Dust panel welded ok , No gap with Body | CRITICAL | VISUAL | — | 1.0 |

### Section 24: AC buses (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 53 | AC bus drain pipe fitment ok , AC cooling properly , AC duc match with seat / Pvc beading not loose and short fitted , AC display fittted | MAJOR | VISUAL | — | 1.0 |

### Section 25: Pneumatic door (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 54 | Pnuematic door hydroulic tight / function ok / connection ok on air tank | MAJOR | VISUAL | — | 1.0 |

### Section 26: RLC / Dickey (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 55 | 1) Lagguage fitment ok , lader fitment ok , Dickey locking ok , Diekcy vinyl past ok , paint ok | MAJOR | MANUAL | — | 1.0 |

### Section 27: FAPS (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 56 | As per FAPS check sheet | CRITICAL | VISUAL | — | 1.0 |

### Section 28: Cleaning (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 57 | Engine hood cleaning ok | MAJOR | VISUAL | — | 1.0 |

---

## Inner Paneling In-Process Checksheet (`QS_INNER`)
- **Format No:** `AA/QA/IPS-IP/IR-007` | **Revision:** `00`
- **Description:** Inner Paneling BS-VI In-Process Checksheet (Grab rails, roof board, harness holes)

### Section 1: All support (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Graib rail support single line for normal staff bus and  (RP bus two line) | CRITICAL | VISUAL | — | 1.0 |
| 2 | Internal light support 20.90L-5 ,20.75-H-4nos /Speaker plate is welded in line.  25mm hole to be given for harness passing in structure. | CRITICAL | VISUAL | — | 1.0 |

### Section 2: Special features (7 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 3 | Root board - | MAJOR | PROD_REPORT | — | 1.0 |
| 4 | AC- | MAJOR | PROD_REPORT | — | 1.0 |
| 5 | Ac Type driver partition - | MAJOR | PROD_REPORT | — | 1.0 |
| 6 | Roof hatch -             / Driver cabin / | MAJOR | PROD_REPORT | — | 1.0 |
| 7 | Camera qty-         / Speaker -            / FDAS        /          FDSS /  FAPS | MAJOR | PROD_REPORT | — | 1.0 |
| 8 | Speaker- | MAJOR | PROD_REPORT | — | 1.0 |
| 9 | Inner panel - pvc/ pre coated/ ACP - | MAJOR | PROD_REPORT | — | 1.0 |

### Section 3: Wiring Harness (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 10 | 1)Harness Should not short in length. Driver fan , roof light , cabin light , rear height marker , front hieght marker . | MAJOR | VISUAL | — | 1.0 |
| 11 | 2) Grommate fit in wiring hole area | MAJOR | VISUAL | — | 1.0 |

### Section 4: Front / Rear inner Dome (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 12 | 1) Front /   Rear inner FRP dome fitment ok, Rivet proper butt | CRITICAL | VISUAL | — | 1.0 |
| 13 | 2) Front dome fitment middle  height skyline and starline 1147+/-2mm , Legacy 1220mm , Pro legend  1325mm ,  Leg gen 4 1140mm  , Pro amts VE0-31 -1280mm | CRITICAL | MEASURING_TAPE | 1147.0 ± 2.0 mm • [1145.000 to 1149.000 mm] | 1.0 |
| 14 | 3) Front  /rear inner FRP dome rivet( Al solid rivet 14mm )pitch 150 +/- 15mm. Rivet butt properly  check per day 1 bus | MAJOR | MEASURING_TAPE | 150.0 ± 15.0 mm • [135.000 to 165.000 mm] | 1.0 |

### Section 5: Sealant apply (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 15 | 40mm Thermacol fitted in all roof and side areas | MAJOR | MEASURING_TAPE | — | 1.0 |
| 16 | Sealant apply in roof tube and all plates for panel bonding | MAJOR | VISUAL | — | 1.0 |

### Section 6: Roof Panel (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 17 | 1) paneling - Check no scratch /dent / drill marks | MINOR | VISUAL | — | 1.0 |
| 18 | 2) Inner Roof panel beading Rivet (Steel Rivet 17mm)pitch  At middle- 125+/- 15mm At Radius - 85+/- 15mm check per day 1 bus | MINOR | MEASURING_TAPE | 125.0 ± 15.0 mm • [110.000 to 140.000 mm] | 1.0 |
| 19 | 3) Inner FRP dome joint(screw 6x25) properly with roof & no gap from sides | MINOR | VISUAL | — | 1.0 |
| 20 | 4) Plastic beading fit at Roof panel / caint rail  150+/-15mm screw pitch to be maintain. (Screw 6x19) | MINOR | MEASURING_TAPE | 150.0 ± 15.0 mm • [135.000 to 165.000 mm] | 1.0 |

### Section 7: Marking (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 21 | Check all interior supprot marking ok | MAJOR | VISUAL | — | 1.0 |

### Section 8: JK door & E door aperture (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 22 | 1)JK door & E door inner top Pre -coated GP panel No, dent, No damage, No scratch , No drumming | MAJOR | VISUAL | — | 1.0 |

### Section 9: Driver Door (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 23 | Cabin area No gap visible in door hinge area , A pillar area and Cowl LH/RH side no gap | MAJOR | VISUAL | — | 1.0 |

### Section 10: Side Panel (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 24 | 1) Inner side panel beading screw(6x19) pitch  At middle- 150+/- 15mm check per day 1 bus | MINOR | MEASURING_TAPE | 150.0 ± 15.0 mm • [135.000 to 165.000 mm] | 1.0 |
| 25 | 2) Side panel bottom rivet(steel 17mm) fitted at 275±25mm  check per day 1 bus | MINOR | MEASURING_TAPE | 275.0 ± 25.0 mm • [250.000 to 300.000 mm] | 1.0 |

### Section 11: Rear panel (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 26 | Rear panel not loose pasted and rivet ok , No gap with rear dome | MINOR | VISUAL | — | 1.0 |

### Section 12: Pillar Cover / waist rail,cant rail  angle (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 27 | Window pillar cover no dent /  sealant pasting proper and match on bottom area Z section sealant . | MAJOR | VISUAL | — | 1.0 |

### Section 13: Body clean (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 28 | No sheet metal chips on Engine area / body clean | MAJOR | VISUAL | — | 1.0 |

---

## Outer Paneling In-Process Checksheet (`QS_OUTER`)
- **Format No:** `AA/QA/IPS-OP/IR-006` | **Revision:** `00`
- **Description:** Outer Paneling BS-VI In-Process Checksheet (Legacy, New Starline, Skyline)

### Section 1: Special Features (13 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | FAPS- as per check sheet - | CRITICAL | PROD_REPORT | — | 1.0 |
| 2 | AC support - | CRITICAL | VISUAL | — | 1.0 |
| 3 | Window Fix glass - | CRITICAL | VISUAL | — | 1.0 |
| 4 | Ac Type driver partition - | CRITICAL | VISUAL | — | 1.0 |
| 5 | Roof hatch support - | CRITICAL | VISUAL | — | 1.0 |
| 6 | Camera support - | CRITICAL | VISUAL | — | 1.0 |
| 7 | Child foot step - | CRITICAL | VISUAL | — | 1.0 |
| 8 | Destination board  support - | CRITICAL | VISUAL | — | 1.0 |
| 9 | FDSS/FDAS support  - | CRITICAL | VISUAL | — | 1.0 |
| 10 | Rear / side dickey - | CRITICAL | VISUAL | — | 1.0 |
| 11 | RLC support - | CRITICAL | VISUAL | — | 1.0 |
| 12 | Grab rail support  - | CRITICAL | VISUAL | — | 1.0 |
| 13 | Hatrack support welded - | CRITICAL | VISUAL | — | 1.0 |

### Section 2: Cowl weld (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 14 | Cowl weld with body A pillar in 3 places | CRITICAL | VISUAL | — | 1.0 |

### Section 3: Chassis no (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 15 | Chassis number visible on chassis | CRITICAL | VISUAL | — | 1.0 |

### Section 4: Ply / Grinding (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 16 | ply joint should be level & grind & no uneven cutting & no chiping on ply .Cabin ply level match with cowl | MAJOR | VISUAL | — | 1.0 |
| 17 | Bolt (6x25 with lock nut) in side and middle Screw (12x25) pitch on ply require 200+/-20mm, 12X38MM Screw used in foot step ply . | MAJOR | VISUAL | 200.0 ± 20.0 mm • [180.000 to 220.000 mm] | 1.0 |

### Section 5: Front  FRP (7 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 18 | Parameter | MAJOR | VISUAL | Model legacy | 1.0 |
| 19 | Front FRP Aperture Center Height 'H' | CRITICAL | MEASURING_TAPE | 1218±2 • [1216.000 to 1220.000 mm] • Dynamic (7 models) | 1.0 |
| 20 | Front FRP Aperture Width Top | MAJOR | MEASURING_TAPE | 1980+/-5 • [1975.000 to 1985.000 mm] • Dynamic (7 models) | 1.0 |
| 21 | Front FRP Aperture Diagonals C & D | CRITICAL | MEASURING_TAPE | 2250± 7MM • [2243.000 to 2257.000 mm] • Dynamic (7 models) | 1.0 |
| 22 | Profile | CRITICAL | TEMPLATE | FRP match with Template top ,bottom ,and side | 1.0 |
| 23 | 1) Front angle  rivet pitch 150+/- 15mm and screw open /no high points | MINOR | MEASURING_TAPE | 150.0 ± 15.0 mm • [135.000 to 165.000 mm] | 1.0 |
| 24 | 2) Front FRP mesh fitment to be ok , No loose and gap with FRP | MINOR | MANUAL | — | 1.0 |

### Section 6: FOP/Toe hook (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 25 | Check FOP area pipe welding  , fop bolt not loose/ Toe hook access | MAJOR | VISUAL | — | 1.0 |

### Section 7: Front bumper (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 26 | 1) Front bumper should be level verticly & horizontaly match with side panel , Bolt tight | MAJOR | VISUAL | — | 1.0 |

### Section 8: D.door /E Door (14 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 27 | 1) Gap b/w driver door & aperture as per CTC Matrix-check 1 bus / 10th bus lot | MAJOR | VISUAL | Multi-point (10 pts: A, B, C, D, E, F, G, H, I, J) | 1.0 |
| 28 | Area | MAJOR | VISUAL | D door spec | 1.0 |
| 29 | A | MAJOR | VISUAL | 8 ±2 • [6.000 to 10.000 mm] | 1.0 |
| 30 | B | MAJOR | VISUAL | 8 ±2 • [6.000 to 10.000 mm] | 1.0 |
| 31 | C | MAJOR | VISUAL | 8 ±2 • [6.000 to 10.000 mm] | 1.0 |
| 32 | D | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 33 | E | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 34 | F | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 35 | G | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 36 | H | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 37 | I | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 38 | J | MAJOR | VISUAL | 6 ±2 • [4.000 to 8.000 mm] | 1.0 |
| 39 | 2) Cabin area covered steering / dash board / hand break etc | CRITICAL | VISUAL | — | 1.0 |
| 40 | 3) Door hinge no play  , Hinge bkt welding not missing , hinge bkt nut welded , flushness 2mm inside with aperture | CRITICAL | FUNCTIONAL | — | 1.0 |

### Section 9: Rear bumper (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 41 | Rear bumper mounting not loose / bkt welded , leveling ok with side and bottom skirt rail ,Aluminium strip cutting ok | MAJOR | MANUAL | — | 1.0 |

### Section 10: Rear dome (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 42 | 1) Rear dome not waviness LH/RH window area | MAJOR | VISUAL | — | 1.0 |
| 43 | 2) Rear dome proper rest side ,top and bottom | MAJOR | VISUAL | — | 1.0 |

### Section 11: Roof panel (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 44 | 1)Should be proper weld 80-100mm distance and front and rear pillar area 12-15mm weld | MAJOR | MEASURING_TAPE | 80.0 ~ 100.0 mm • [80.000 to 100.000 mm] | 1.0 |
| 45 | 2) Roof top front and rear  FRP rivet should be Steel sheild with 160+/-10 mm pitch | MINOR | MEASURING_TAPE | 160.0 ± 10.0 mm • [150.000 to 170.000 mm] | 1.0 |
| 46 | 3) Sealent should be finish and no hole in roof and gutter . | MAJOR | VISUAL | — | 1.0 |

### Section 12: Stretch panel (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 47 | 1) check No waviness/ No line marks visible | MINOR | VISUAL | — | 1.0 |
| 48 | 2) Stretch panel stretching min 0.8 to 1mm per meter | MAJOR | MEASURING_TAPE | Min 0.8 mm • [0.800 to — mm] | 1.0 |

### Section 13: Skirt panel (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 49 | 1)Panel level at bottom with front / rear bumper should be match. | MAJOR | VISUAL | — | 1.0 |
| 50 | 2) Skirt panel welding ok bottom area / wheel arch panel not loose | MAJOR | MANUAL | — | 1.0 |
| 51 | 4) Skirt panel side marker light hole below waist rail 870 +/- 5mm alignment to be ok   Side replactor hole  : 20.75H, 20.90L -3 Hole, 20.70E,20.50C,D = 02 . | MAJOR | MEASURING_TAPE | 870.0 ± 5.0 mm • [865.000 to 875.000 mm] | 1.0 |

### Section 14: All flaps (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 52 | 1)Fuel and Urea tank flap Not off set fitted and rubber stopper fitted | CRITICAL | VISUAL | — | 1.0 |
| 53 | 2) Battery / EATS tank flap rivet fitment ok | CRITICAL | VISUAL | — | 1.0 |

### Section 15: Volvo / Strip/ JK door (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 54 | 1) Volvo Al. section sealant pasting ok , leveling ok from jk door /E door area | MAJOR | VISUAL | — | 1.0 |
| 55 | 2) In front and behind jk door  volvo section should be in level . | MINOR | VISUAL | — | 1.0 |
| 56 | 4) Side strip rivet (Al. 19mm) pitch 150+/- 15mm maintain. | MINOR | MEASURING_TAPE | 150.0 ± 15.0 mm • [135.000 to 165.000 mm] | 1.0 |
| 57 | 5)  side Strip should not be wavi and taper and No short length | MINOR | VISUAL | — | 1.0 |

### Section 16: Rear panel/ tail lamp /rear dome (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 58 | 1)Rear panel No Loose and no drumming, side corner level ok | MINOR | VISUAL | — | 1.0 |
| 59 | 2) tail lamp cover selaant should be ok pasting / No inclined | MINOR | VISUAL | — | 1.0 |
| 60 | 3) Al. strip  Rivet pitch = 150+/-15 maintain. | MINOR | VISUAL | 150.0 ± 15.0 m • [135.000 to 165.000 m] | 1.0 |

### Section 17: Rear Dickey (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 61 | 1) Rear dicky Hinge bolt not loose and not fouling with aperture | MAJOR | VISUAL | — | 1.0 |
| 62 | 2) Hinge welding to be ok , catcher bkt welding ok,ply tight and no corner gap | MAJOR | MEASURING_TAPE | — | 1.0 |

### Section 18: Noise (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 63 | Skirt / streth panel no abnormal noise observed | MAJOR | VISUAL | — | 1.0 |

### Section 19: CNG (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 64 | 1) Roof exhuase welded all cylender / AC two exhause provision | CRITICAL | VISUAL | — | 1.0 |
| 65 | 2) Side flap all cylender  not off set / cylinder connect with pipe | CRITICAL | VISUAL | — | 1.0 |
| 66 | 3) Air in tank mesh fitted / Air in tank box welded | CRITICAL | VISUAL | — | 1.0 |

### Section 20: AC (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 67 | Ac bus structure aperture provide / RH window tube welded | CRITICAL | VISUAL | — | 1.0 |
| 68 | AC bus drain pipe  hole provide in structure | CRITICAL | VISUAL | — | 1.0 |

### Section 21: RLC (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 69 | 1)RLC Bkt.Should be straight fit and sealing thorugh out the bottom edge to be check ( As per requirement) No's Of RLC Bracket : 20.50D = 6, 20.70E = 8, 20.70H = 10, 20.90L = 12 | MAJOR | VISUAL | — | 1.0 |
| 70 | 2) RLC bkt weld as per matrix for modelwise | MAJOR | VISUAL | — | 1.0 |

---

## Pre-Delivery Inspection Checksheet (PDI) (`QS_PDI`)
- **Format No:** `AA/QA/PDI/IR-012` | **Revision:** `00`
- **Description:** Pre-Delivery Inspection BS-VI (Seat mounting, gangway 350mm, torque 1.7~2.6 kgf·m, VIN plate)

### Section 1: Check sheet (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | If material shortage , after fitment list to be varify | CRITICAL | VISUAL | — | 1.0 |

### Section 2: Paint (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 2 | Paint Finished ok - front /rear / cabin / side LH/RH | MAJOR | VISUAL | — | 1.0 |

### Section 3: Vin plate (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 3 | Chassis & Body builder Plate fitment at driver top properly | MAJOR | VISUAL | — | 1.0 |

### Section 4: Seat (9 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 4 | Seat type- | CRITICAL | PROD_REPORT | Capacity- | 1.0 |
| 5 | Gangway | MAJOR | MEASURING_TAPE | Min 350mm • [350.000 to — mm] | 1.0 |
| 6 | Leg Space | MAJOR | MEASURING_TAPE | Min 245mm • [245.000 to — mm] | 1.0 |
| 7 | E door seat clearance | MAJOR | MEASURING_TAPE | Min 280mm • [280.000 to — mm] | 1.0 |
| 8 | Rexine No cuts,not loose,, handle should not loose and damage, No scratch | CRITICAL | MANUAL | — | 1.0 |
| 9 | Seat pitch min 680mm school and 815mm pushback  to be ok , seat not inclined fitted | MAJOR | MEASURING_TAPE | Min 680.0 mm • [680.000 to — mm] • Dynamic (3 models) | 1.0 |
| 10 | Check if Passenger seat belt fitted then accesseble for locking | CRITICAL | MANUAL | — | 1.0 |
| 11 | Rear dickey seat not touch to rear glass in fitment | MAJOR | VISUAL | — | 1.0 |
| 12 | Seat leg not mount on stepny cutout . Co driver seat not Shift E hood area , Rear dickey Seat mount on support | MAJOR | VISUAL | — | 1.0 |

### Section 5: Under body (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 13 | Seat mounting on base frame seat support  .should not be taper | MAJOR | VISUAL | — | 1.0 |
| 14 | Seat bolt tightening at  1.7~2.6 kgfm (M8)  check 1 bus per day | MAJOR | TORQUE_WRENCH | 1.7 ~ 2.6 kgfm • [1.700 to 2.600 kgfm] | 1.0 |

### Section 6: Chassis part (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 15 | Chassis number visible - | CRITICAL | VISUAL | — | 1.0 |
| 16 | Stepney tyre not loose / any tyre not cut | MAJOR | VISUAL | — | 1.0 |
| 17 | Check all tyre should not cut | CRITICAL | VISUAL | — | 1.0 |

### Section 7: Battery (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 18 | Battery Cable fitment not loose , electronic cut off switch, maxi fuse  tight properly , Harness Not foul in  EATS tank | CRITICAL | VISUAL | — | 1.0 |

### Section 8: Stanchion  tube (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 19 | check  support mark check in roof and floor , No inclined and loose fitted , 20.90L-2 QTY ,20.75H & 20.70E,G - 1QTY fitted | CRITICAL | MANUAL | — | 1.0 |

### Section 9: Electric (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 20 | All Electrical function should be working | CRITICAL | FUNCTIONAL | — | 1.0 |

### Section 10: Cabin (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 21 | Clutch oil cap fitted , No scratched or polythnene marks in paint  E hood and dash bord | MAJOR | VISUAL | — | 1.0 |
| 22 | sealant filled proper . Steering not cut and damage and no fumes , No extra holes /dent | MAJOR | VISUAL | — | 1.0 |

### Section 11: Front face (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 23 | Front dome, FOP and Rear FRP dome Painting to be ok | MAJOR | VISUAL | — | 1.0 |

### Section 12: Check School bus/Legacy sticker/ CNG Sticker/ No smoke Sticker (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 24 | Not inclined and no air bubbles inside the sticker | MAJOR | VISUAL | — | 1.0 |

### Section 13: Functional (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 25 | Driver door / jk door / E  door locking ok / wiper function ok | CRITICAL | FUNCTIONAL | — | 1.0 |

### Section 14: Service point (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 26 | Check All flap - Diesel flap not off set , urea flap not off set | CRITICAL | FUNCTIONAL | — | 1.0 |

### Section 15: CNG (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 27 | CNG - cylender connection ok , Exhause fitted on roof ,service indicator fitted | CRITICAL | VISUAL | — | 1.0 |
| 28 | CNG - Air tank and Gas knob flap not off set | CRITICAL | FUNCTIONAL | — | 1.0 |
| 29 | CNG - plate fitted and cylender number match with actual chassis | CRITICAL | VISUAL | — | 1.0 |

### Section 16: AC (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 30 | AC bus drain pipe fitment ok , AC cooling properly , AC duc match with seat / Pvc beading not loose and short fitted , AC display fittted | CRITICAL | VISUAL | — | 1.0 |

### Section 17: Pnuematic door (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 31 | IF Pneumatic door- cover fitment ok , door working speed check . Pnuematic cylinder flow control valve nut should be tight | CRITICAL | MANUAL | — | 1.0 |

### Section 18: Shower (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 32 | Shower testing -OK / DA lite ok | MAJOR | PROD_REPORT | — | 1.0 |
| 33 | After shower sealant fill to be paint apply | MAJOR | VISUAL | — | 1.0 |

### Section 19: Cleaning (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 34 | 1) Driver seat stand clean not rusty .                                                                                                                        2) Cabin area clean . seat area clean, engine area clean | MAJOR | VISUAL | — | 1.0 |

### Section 20: Polishing (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 35 | Polishing properly with 2000 paper | MAJOR | VISUAL | — | 1.0 |

### Section 21: Part missing (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 36 | Acrilic sheet E door inside & outside , GSL cover / Steering cover / proximity  mirror in legacy  / Dash board switch not missing  / JK door & battery key not missing | MAJOR | VISUAL | — | 1.0 |

### Section 22: Covering (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 37 | Poly cover pasting at dashboard and enginehood area | MAJOR | VISUAL | — | 1.0 |
| 38 | Poly cover pasting at engine cutout and gangway area . | MAJOR | VISUAL | — | 1.0 |

---

## Material Shortage & Pending Points Checksheet (`QS_SHORTAGE`)
- **Format No:** `AA/QA/MSDO/OR-003` | **Revision:** `00`
- **Description:** Material Shortage & Defect Observation Log across stations

### Section 1: Material Shortage & Pending Points Log (5 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Verify all shortage parts from BOM are fulfilled before final gate sign-off | CRITICAL | LIST_VERIFY | 100% shortage items cleared | 1.0 |
| 2 | Verify all recorded defects from upstream stations are reworked and cleared | CRITICAL | VISUAL | 100% shortage items cleared | 1.0 |
| 3 | Final Vehicle Inspection (FVI) verification for shortage fitment completion | CRITICAL | LIST_VERIFY | 100% shortage items cleared | 1.0 |
| 4 | Inspect quality of reworked components and confirm no secondary damage | MAJOR | VISUAL | 100% shortage items cleared | 1.0 |
| 5 | Verify all station log sheets and checksheet approvals are signed | MAJOR | PROD_REPORT | 100% shortage items cleared | 1.0 |

---

## Surfacer Coating In-Process Checksheet (`QS_SURFACER`)
- **Format No:** `AA/QA/IPS-S/IR-008` | **Revision:** `00`
- **Description:** Surfacer Paint BS-VI In-Process Checksheet (Underbody epoxy, primer quality, door apertures)

### Section 1: Under body (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Under body epoxy ok in border tube , foot step , side diceky , rear dickey  cowl joint , base frame channel , front structure / rear structure | CRITICAL | VISUAL | — | 1 |

### Section 2: Front side /Dome area (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 2 | Front rear frp dome primer quality ok | MINOR | VISUAL | — | 1 |
| 3 | Front and rear bumper match with panel , No extra cutting. | MINOR | VISUAL | — | 1 |

### Section 3: RH / LH  Side (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 4 | Driver & Eme. Door,  aperture and frame no welding spatter | MINOR | VISUAL | — | 1 |
| 5 | Volvo gola no major waviness , Al. strip not short fitted | MAJOR | VISUAL | — | 1 |

### Section 4: Roof (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 6 | Roof shoulder not dent | MAJOR | VISUAL | — | 1 |
| 7 | Rain gutter joint ok | MINOR | VISUAL | — | 1 |

### Section 5: Floor (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 8 | Ply level match , joint properly grinding | MAJOR | VISUAL | — | 1 |

### Section 6: OUTPUT- OBJECT FOR SURFACER (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 9 | Painting Date | MAJOR | VISUAL | — | 1.0 |

### Section 7: Chassis cover (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 10 | Chassis parts diesel tank , urea tank, steering , handbreak,faps tank covering properly to avoid fumes / overspray | MAJOR | VISUAL | — | 1 |

### Section 8: Mansoon Tape (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 11 | Straight, edage pasting, no wrinkel | MAJOR | VISUAL | — | 1 |
| 12 | No hole on (panel & rain gutter) | MAJOR | VISUAL | — | 1 |

### Section 9: Under body (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 13 | Under body paint ok front show top and tubes | CRITICAL | VISUAL | — | 1 |
| 14 | Under body paint ok mudguard area and CNG pipe | CRITICAL | VISUAL | — | 1 |
| 15 | Under body paint coverage ok all over flooor | CRITICAL | VISUAL | — | 1 |

### Section 10: Degreasing (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 16 | Clean with cotton /tissue paper | MAJOR | MANUAL | — | 1 |

### Section 11: Dry sanding (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 17 | Metal with P180/P80 and FRP with P180 from all area. | MAJOR | VISUAL | — | 1 |

### Section 12: Primer (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 18 | Etch primer  / Wash primer,  No Coverage less | MAJOR | VISUAL | — | 1 |

### Section 13: PUPS surfacer (6 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 19 | Viscocity (18-24)sec. | MAJOR | VISUAL | 18.0 ~ 24.0 mm • [18.000 to 24.000 mm] | 1/ day |
| 20 | Baking tempreture 70-80⁰                                 ( 60-65⁰Effective on metal) | MAJOR | VISUAL | 70.0 ~ 80.0 mm • [70.000 to 80.000 mm] | 1 |
| 21 | DFT (50 +/-10)micron | MAJOR | VISUAL | 50.0 ± 10.0 mm • [40.000 to 60.000 mm] | 5th Bus |
| 22 | No Rundown, no coverageless | MAJOR | VISUAL | — | 1 |
| 23 | Film appearance - (X-cut Adhesion) Test | CRITICAL | MANUAL | — | per 5th bus |
| 24 | Stretch panel no line marks visible after surfacer | CRITICAL | MANUAL | — | 1 |

### Section 14: FRP (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 25 | Front / rear dome surface no air bubbles | CRITICAL | MANUAL | — | 1 |

### Section 15: Chassis part (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 26 | No fumes / over spray on steering / diesel / urea tank / hand break / faps tank | MAJOR | VISUAL | — | 1 |

---

## Top Coat Painting In-Process Checksheet (`QS_TOP_COAT`)
- **Format No:** `AA/QA/IPS-TC/IR-009` | **Revision:** `00`
- **Description:** Top Coat Paint BS-VI In-Process Checksheet (Putty fill, sanding P320/P400, sealant, gloss >=85%)

### Section 1: Putty Application (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Putty Fill on Dent area | MAJOR | VISUAL | — | 1 |
| 2 | Sanding with P80 and P180 | MAJOR | VISUAL | — | 1 |

### Section 2: Surfacer Sanding (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 3 | Surface Preparation on surfacer Sanding with P320 | MAJOR | VISUAL | — | 1 |
| 4 | Finishing with black Guide Coat P400 | MAJOR | VISUAL | — | 1 |

### Section 3: Sealant Finish (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 5 | Driver door Sealent finish proper surround door Aperture and rain gutter | MAJOR | VISUAL | — | 1 |
| 6 | Sealent finish proper at Rear both corner and Rear dicky area | MAJOR | VISUAL | — | 1 |
| 7 | Sealant finished in all flaps area / volvo gola | MAJOR | VISUAL | — | 1 |

### Section 4: Finished (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 8 | Front dome/ bumper joint finished | MAJOR | MANUAL | — | 1 |
| 9 | Rear dome / bumper joint finished | MAJOR | MANUAL | — | 1 |

### Section 5: Covering (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 10 | Steering /tyre/ diesel/ urea tank and UB Cylinder  covered | MAJOR | VISUAL | — | 1 |

### Section 6: OUTPUT- OBJECT FOR TOP COAT (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 11 | Painting Date | MAJOR | VISUAL | — | 1.0 |

### Section 7: Covering (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 12 | Steering /tyre/ diesel/ urea tank and UB Cylinder  covered | MAJOR | VISUAL | — | 1 |

### Section 8: Paint viscosity (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 13 | Top Coat Viscosity  (16 - 22) sec | CRITICAL | VISUAL | 16.0 ~ 22.0 mm • [16.000 to 22.000 mm] | 1/ day |

### Section 9: Tempreture (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 14 | Drying Tempreture 70-80⁰C / 30-35 minutes | CRITICAL | VISUAL | 70.0 ~ 80.0 mm • [70.000 to 80.000 mm] | 1 |

### Section 10: Colour shade (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 15 | As require match with master sample | CRITICAL | VISUAL | — | 1 |

### Section 11: Final  DFT            (90-130) micron (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 16 | LH Side | MAJOR | VISUAL | — | Every 5th /1 vehicle |
| 17 | RH side | MAJOR | VISUAL | — | 1.0 |
| 18 | Roof | MINOR | VISUAL | — | 1.0 |
| 19 | Rear | MINOR | VISUAL | — | 1.0 |

### Section 12: Topcoat Adhesion for FRP & Metal. (2*2)mm (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 20 | Film appearance - (X-cut Adhesion) check after 72 hrs of application. | CRITICAL | MANUAL | — | Every 5th /1 vehicle |

### Section 13: No Rundown / pin holes (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 21 | Strech panel ,Skirt panel | MAJOR | VISUAL | — | 1 |
| 22 | LH  / RH front and rear roof corners | MAJOR | VISUAL | — | 1 |
| 23 | All flape and bumper corners | MAJOR | VISUAL | — | 1 |

### Section 14: Grey / Black      paint at head lamp area, window area and rear wind shield ,tail lamp FRP . Rear dickey (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 24 | Should not be rundown, no orange peel , no peel off coverage should be even. | MAJOR | VISUAL | — | 1 |
| 25 | Masking tape use properly during Grey/Black graphics b/w window and stretch panel. | MAJOR | VISUAL | — | 1 |

### Section 15: Black graphics (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 26 | Seat rail dust cleaning and paint ok | MAJOR | VISUAL | — | 1 |
| 27 | Rear dickey , side flap , battery flap black paint coverage should be ok | MAJOR | VISUAL | — | 1 |
| 28 | Black graphics should be ok as defin modelwise | MAJOR | VISUAL | — | 1 |

### Section 16: D Door/E Door (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 29 | 1) Black Paint finish at Driver / Emergency  door aperture area | MINOR | VISUAL | — | 1 |

### Section 17: Roof (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 30 | Roof panel paint proper /  Mansoon tape paint proper | MAJOR | VISUAL | — | 1 |

---

## Interior Trimming In-Process Checksheet (`QS_TRIM`)
- **Format No:** `AA/QA/IPS-TR/IR-010` | **Revision:** `06`
- **Description:** Interior Trimming BS-VI Checksheet (Tyres, handbrake, radiator, windshield, wiring, dashboard)

### Section 1: Check All Tyre (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | No cut marks no damage | MAJOR | VISUAL | — | 1.0 |

### Section 2: Toe hook (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 2 | Check front toe hook fitted | MAJOR | VISUAL | — | 1.0 |

### Section 3: Hand brake (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 3 | Hand brake Not Damage , pipe not open , No fumes | CRITICAL | MANUAL | — | 1.0 |

### Section 4: Floor cutouts (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 4 | Stepny cutout check spinner acess , Diesel and urea cutout position to be ok | CRITICAL | MANUAL | — | 1.0 |

### Section 5: Rediator area (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 5 | Radiator covered Open | CRITICAL | VISUAL | — | 1.0 |
| 6 | No leakages from radiator area , coolant oil level ok | CRITICAL | VISUAL | — | 1.0 |

### Section 6: Chassis part (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 7 | Coolant level ok . , starter relay ok , steering not cut marks | CRITICAL | VISUAL | — | 1.0 |

### Section 7: Toe Hook (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 8 | Check Toe hook provision from front | CRITICAL | VISUAL | — | 1.0 |

### Section 8: Fuel Tank , Urea tank (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 9 | check fuel and urea  tank align with  flap ( Not off set) | CRITICAL | VISUAL | — | 1.0 |

### Section 9: Battery Cable fitment on terminal. (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 10 | Clamping weld / no loose mounting , Grommate fitment ok | CRITICAL | VISUAL | — | 1.0 |
| 11 | Battery cable terminal not loose & Earth cable  should be tight | CRITICAL | MANUAL | — | 1.0 |
| 12 | Electronic cut off switch , maxi fuse tight properly | CRITICAL | FUNCTIONAL | — | 1.0 |
| 13 | Harness not pintch & not foul with ETS tank | CRITICAL | VISUAL | — | 1.0 |

### Section 10: Spare tyre (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 14 | Spare tyre fitment tight ok  , Not loose / hole access to rod | MAJOR | FUNCTIONAL | — | 1.0 |

### Section 11: Window Fitment (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 15 | Window not damage in fitment , powder coating ok , Both window gap even vertically , Bottom level not off set . | MAJOR | VISUAL | — | 1.0 |
| 16 | Driver / co driver window glass not gap / sliding ok | MAJOR | MANUAL | — | 1.0 |

### Section 12: Window Guard rail fitment (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 17 | Bkt not tilt fitted , powder coating ok , distance ok 100mm | MAJOR | MEASURING_TAPE | — | 1.0 |

### Section 13: Service point (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 18 | 1) Coolant oil , clutch oil , steering oil access to be easly | CRITICAL | MANUAL | — | 1.0 |
| 19 | 2) Diesel flap , Urea Flap , stepny cut out not off set | CRITICAL | MANUAL | — | 1.0 |
| 20 | 3) Air tank , Stepny hole rod acess to tyre remove panel hole 70mm with grommet | CRITICAL | MANUAL | — | 1.0 |

### Section 14: Under body (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 21 | Outrigger bolt tight / Ubolt tight torque check per day 1 bus | CRITICAL | MANUAL | — | 1.0 |
| 22 | Harness not loose and pinch , not foul ETS tank | CRITICAL | MANUAL | — | 1.0 |
| 23 | Front / rear bumper bkt tight | CRITICAL | MANUAL | — | 1.0 |
| 24 | Chassis number visible | CRITICAL | VISUAL | — | 1.0 |

### Section 15: Hatrack  Fitment (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 25 | Leg & bkt. Not taper and damage | MAJOR | VISUAL | — | 1.0 |
| 26 | Check Powder coating, no scratch, damages  & no peel off | MAJOR | VISUAL | — | 1.0 |

### Section 16: Front / rear bumper (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 27 | bumper bkt tiight , welding not missing , level ok with side and front frp | CRITICAL | VISUAL | — | 1.0 |

### Section 17: Chequred Plate /vinyl (As per Need) (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 28 | 1) Chequred plate fitment No loose and no gap at joint | MAJOR | VISUAL | — | 1.0 |
| 29 | 3)  chaqured plate Al. strip Lock nut pitch 250 +/- 15mm maintain | MAJOR | MEASURING_TAPE | 250.0 ± 15.0 mm • [235.000 to 265.000 mm] | 1.0 |
| 30 | 2)  Screw 12x19 tight from cabin , seat mtg area LH/RH wider body | MAJOR | VISUAL | — | 1.0 |
| 31 | 4) Vinly no bubbles in pasting / no short length rear and cabin area | MAJOR | VISUAL | — | 1.0 |

### Section 18: Front / Rear glass fitment (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 32 | 1)Glass Seating properly showing no gap in outside & Inside the windshield corners | CRITICAL | VISUAL | — | 1.0 |
| 33 | 2) Glass rubber not cut and not be damage , insdie proper fitted | CRITICAL | VISUAL | — | 1.0 |

### Section 19: Rear dickey (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 34 | 1) Rear dickey locking ok , No foul with side and No hard unlock function , vinyl ok , no gaps in corner , light cover fitted | MAJOR | FUNCTIONAL | — | 1.0 |

### Section 20: Driver Door Assembly (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 35 | 1) Driver door locking ok and handle not damage | MAJOR | VISUAL | — | 1.0 |
| 36 | 2) Driver Door opening closing and lock working smoothly | MAJOR | FUNCTIONAL | — | 1.0 |
| 37 | 3) Inner trim and panel around the door Not loose and not damage and not faul with aperture | MAJOR | VISUAL | — | 1.0 |

### Section 21: JK Door Assembly (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 38 | 1)JK Door- opening/closing not hard and no foul top , lock work smooth , bottom catcher ok | MAJOR | FUNCTIONAL | — | 1.0 |
| 39 | 2) Door hinge and Handle should not be tapper fitted & bolt & screw not loose. | MAJOR | VISUAL | — | 1.0 |
| 40 | 3)J.K Door foot step vinyl/chequred plate seated properly, No gaps | MAJOR | VISUAL | — | 1.0 |

### Section 22: Emergency Door Assy. (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 41 | Eme. Door opening closing and lock working smoothly | CRITICAL | VISUAL | — | 1.0 |

### Section 23: Driver Cabin Area (4 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 42 | Driver seat movement ok / raxine not damage , seat belt  , first add box with + sticker  , Sunvisor , saloon mirror Fitment ok and  Fire extingusher not expire date, | MAJOR | VISUAL | — | 1.0 |
| 43 | Engine hood straight and  locking ok , no foul with partition ,Not hot air leak | MAJOR | VISUAL | — | 1.0 |
| 44 | ABS fitment ok no gaps , no loose , Driver and co driver side handle not loose fitted | MAJOR | VISUAL | — | 1.0 |
| 45 | Side RVM fitted LH/RH side | MAJOR | VISUAL | — | 1.0 |

### Section 24: Dash Board Assembly (5 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 46 | 1) Glove box flap - locking ok , Dash board not loose from LH/RH side and front side , | MAJOR | FUNCTIONAL | — | 1.0 |
| 47 | 2) Harness -  Clamp under the dashboard,all harnes tight with tie | MAJOR | VISUAL | — | 1.0 |
| 48 | 3) Check ABS , ECO switch ,Battery cut off swtich , head light switch, fitted | MAJOR | MANUAL | — | 1.0 |
| 49 | 4) Telematics , USB socket, Painic switch and  POM TOM pin cap fittment propelry | MAJOR | VISUAL | — | 1.0 |
| 50 | 5) Cluster meter not damage / CNG OR DIESLE  working check | CRITICAL | MANUAL | — | 1.0 |

### Section 25: Partition,  & Graib rail Pipe (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 51 | JK door & D.door partition / grab pipe Should Not be loose and tapper fitted , paint no scratch and no extra holes | MAJOR | VISUAL | — | 1.0 |

### Section 26: All flaps (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 52 | 1) Locking proper , No fouling | MAJOR | VISUAL | — | 1.0 |
| 53 | 2) Opening stopper provide in Battery and EATS servce flap | MAJOR | VISUAL | — | 1.0 |

### Section 27: Rear Grab Handle (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 54 | Rear Grab Handle should be straight and  not loose fitted . | MAJOR | VISUAL | — | 1.0 |

### Section 28: Electrical Connection-12 Volt / 24 Volt (7 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 55 | Exterior light - Head lamp working ok ,  not off set with rubber cap fitted , All side replactor , Side indicator , rear tail lamp light yellow , white and red working ok , height marker front / rear working ok | CRITICAL | FUNCTIONAL | — | 1.0 |
| 56 | RPAS sensor fitemt ok and functiona ok , rear number plate light not incleined and working ok | CRITICAL | FUNCTIONAL | — | 1.0 |
| 57 | Rear diecky light , rear registation number plate work ok | MAJOR | VISUAL | — | 1.0 |
| 58 | Stop switch working , fan working ok and fitment position ok | CRITICAL | MANUAL | — | 1.0 |
| 59 | check All roof light working ok and no loose | CRITICAL | VISUAL | — | 1.0 |
| 60 | buzzer fitted at driver cabin area to jk door open / e door open in school bus | CRITICAL | VISUAL | — | 1.0 |
| 61 | Roof light 20.90L - 5 nos , 20.75H- 4 nos , 20.70 E -4 nos ,20.50D -3 nos | MAJOR | VISUAL | — | 1.0 |

### Section 29: CNG Bus (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 62 | CNG cylender connection ok , Air tank mesh fitted , Hose pipe connection and service indicator fitted ok , Exhause cap fitted as cylender qty | CRITICAL | MANUAL | — | 1.0 |

### Section 30: RLC (1 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 63 | RLC Luggage / ladder  bolt not loose , no scratches, no paint peel off | MAJOR | VISUAL | — | 1.0 |

### Section 31: Pneumatic door (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 64 | Pneumatic door pipe connection in cylender bolt not loose .  Cylinder pressure flow nut should be tight | CRITICAL | VISUAL | — | 1.0 |
| 65 | Pneumatic door cylender mtg 4 screw locking nut | CRITICAL | VISUAL | — | 1.0 |

### Section 32: AC bus (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 66 | AC device  fitted / Raxene not loose / blower not loose | MAJOR | VISUAL | — | 1.0 |
| 67 | AC bus hatrack duct not loose and partition door locking ok | MAJOR | VISUAL | — | 1.0 |
| 68 | AC buses Partition E hood not foul | MAJOR | VISUAL | — | 1.0 |

---

## VECV Bus Structural Quality Checksheet (`QS_VECV`)
- **Format No:** `AA/QA/VECV/FM-014` | **Revision:** `06`
- **Description:** VECV Pithampur Structural In-Process Checksheet (Marker holes, emergency door 1570mm, foot step)

### Section 1: Outer (10 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 1 | Side marker hole 20.90L -04 NOS , 20.75H - 3NOS , 20.65E- 3 NOS | MAJOR | VISUAL | — | 1.0 |
| 2 | Emergency door 1570mm height | MAJOR | VISUAL | — | 1.0 |
| 3 | Sliding foot step manalee make -Stopper pin Functional verification | MAJOR | VISUAL | — | 1.0 |
| 4 | Grab rail support / Faps support | MAJOR | VISUAL | — | 1.0 |
| 5 | Wheel Hump as per Arai Flat type welded | MAJOR | VISUAL | — | 1.0 |
| 6 | Light support per blaock and last rear two support | MAJOR | VISUAL | — | 1.0 |
| 7 | 20.75H /20.90 K/ 20.90L  Water tank bkt height redcue - 370mm height from floor to bkt bottom Mount in chassis | MAJOR | VISUAL | — | 1.0 |
| 8 | 20.75G/20.65E/20.70E VECV bus cylindr 85 ltr / 6.5 ltr on rear dickey | MAJOR | VISUAL | — | 1.0 |
| 9 | Wiper linkge camoflex fitted | MAJOR | VISUAL | — | 1.0 |
| 10 | Roof middle panel sealant past in middle area | MAJOR | VISUAL | — | 1.0 |

### Section 2: INNER (3 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 11 | 1) Wiring harness for FDSS,VLTS , ALL ROOF LIGHT , FAN | MAJOR | VISUAL | — | 1.0 |
| 12 | 2) FAPS pipe / wiring  fitted | MAJOR | VISUAL | — | 1.0 |
| 13 | 3) FAPS support / grab rail supoort  welded and hanress ok passed | MAJOR | VISUAL | — | 1.0 |

### Section 3: Mount (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 14 | Water bottle as new supply camoflex make | MAJOR | VISUAL | — | 1.0 |
| 15 | Camoflex linkage not foul in function | MAJOR | VISUAL | — | 1.0 |

### Section 4: Paint (2 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 16 | Chassis covered | MAJOR | VISUAL | — | 1.0 |
| 17 | Foot step chaqured plate covered , wiper linakge covered | MAJOR | VISUAL | — | 1.0 |

### Section 5: Trim/FVI (28 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 18 | FDSS 6 ltr -09 nozzles and make safex , cylender assembly behind the co driver side , Activation to be ok | MAJOR | VISUAL | — | 1.0 |
| 19 | Sliding foot step manalee make -Stopper pin Functional verification | MAJOR | VISUAL | — | 1.0 |
| 20 | Head lamp area - one marker lamp and one without marker lamp , make Neo lite | MAJOR | VISUAL | — | 1.0 |
| 21 | Roof light - 20.90L -09 no, 20.75H- 8 nos    , 20.65 -6 nos with night lamp function verification | MAJOR | VISUAL | — | 1.0 |
| 22 | Roof Grab rail  assembly without Hand grip | MAJOR | VISUAL | — | 1.0 |
| 23 | Wiring Harness connection for FDSS ,VLTS , ROOF LIGHT, ,FAN fitted | MAJOR | VISUAL | — | 1.0 |
| 24 | All sticker Body - Emergency Exit white ,  Hemmar , Fire extunghisher , Break glass  ,  First aid kit need self illumination as per VECV | MAJOR | VISUAL | — | 1.0 |
| 25 | Side marker lamps - 20.90L - 04 NOS , 20.75H- 03 Nos , 20.65- 03 nos | MAJOR | VISUAL | — | 1.0 |
| 26 | Handle as per ARAI - JK door B pillar , Driver door B pillar | MAJOR | VISUAL | — | 1.0 |
| 27 | window guard rail -03 number | MAJOR | VISUAL | — | 1.0 |
| 28 | Galss breaking hemmar wire rop type-03 nos for all models | MAJOR | VISUAL | — | 1.0 |
| 29 | Wipr assembly cemoflex - linkage and blade butterfly type , motot pipe connection complete  and functional verify | MAJOR | VISUAL | — | 1.0 |
| 30 | Sticker chiild -200x200mm , fuse boxsitcker , EOS , Ad blue sticker pasted in cabin | MAJOR | VISUAL | — | 1.0 |
| 31 | Hemmar wire rop -03nos | MAJOR | VISUAL | — | 1.0 |
| 32 | Side brown sticker ( Patta ) Pasted LH/RH side | MAJOR | VISUAL | — | 1.0 |
| 33 | Wheel Hump as per Arai Flat box  type welded | MAJOR | VISUAL | — | 1.0 |
| 34 | JK door assembly Lock position as per ARAI  - 965mm lock knob | MAJOR | VISUAL | — | 1.0 |
| 35 | Seat Divesitech supply - Emergecny door area clearence min 300mm , co driver seat seat belt req, RH 1st , last seat seat belt required . | MAJOR | VISUAL | Min 300.0 mm • [300.000 to — mm] | 1.0 |
| 36 | LH/RH Mirror as per homologation requirement Manas supply and Proximity mirror fitted in RH side . Screwing proper tight | MAJOR | VISUAL | — | 1.0 |
| 37 | Branding - EICHER / HORSE Emblum In front facia , only  Eicher Emblum in rear facia | MAJOR | VISUAL | — | 1.0 |
| 38 | Passenger door , E door and Retractable foot step ( sliding foot step) open Hazard functionality  shall fucntion . | MAJOR | VISUAL | — | 1.0 |
| 39 | Rear bumper red replcator both side | MAJOR | VISUAL | — | 1.0 |
| 40 | Rear number plate   light box type | MAJOR | VISUAL | — | 1.0 |
| 41 | Proximity mirror RH side | MAJOR | VISUAL | — | 1.0 |
| 42 | Side marker 20.90L -4 nos ,20.75H-03 nos ,20.70E -3 nos | MAJOR | VISUAL | — | 1.0 |
| 43 | Driver seat as per chassis supply - vecv bus | MAJOR | VISUAL | — | 1.0 |
| 44 | Fire extinguisher 6+4 kg  , front 4 kg and rear 6 kg . Pipe proper tightening jyoti make | MAJOR | VISUAL | — | 1.0 |
| 45 | Brown patta both side | MAJOR | VISUAL | — | 1.0 |

### Section 6: PDI (6 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 46 | Diversitech seat make -  RH 1st -01 no , Rear 5 seater -02 no, co drvier seat -01 no seat  belt fitted | MAJOR | VISUAL | — | 1.0 |
| 47 | Seat assembly with Flange  bolt M8 GRADE 8.8 and Flange nut | MAJOR | VISUAL | — | 1.0 |
| 48 | Emergecny door area seat clearance 280mm required | MAJOR | VISUAL | — | 1.0 |
| 49 | Body vin plate seat capacity to be check as Layout (i.g -20.90l , 50+CD+D, 20.75H - 40+CD+D ,20.65 - 30+CD+D) | MAJOR | VISUAL | 20.65 ~ 30.0 mm • [20.650 to 30.000 mm] | 1.0 |
| 50 | GSL lever ( Gear shift liver ) /Steering pad/ Rubber boot / oil cap  assembled | MAJOR | VISUAL | — | 1.0 |
| 51 | Seat leg not overlap on floor stepny service hatches | MAJOR | VISUAL | — | 1.0 |

### Section 7: Complain points (12 items)
| # | Checkpoint Description | Class | Method | Standard Spec / Tolerance | Freq |
| :--- | :--- | :--- | :--- | :--- | :--- |
| 52 | Battery harness burned by touched with EATS Unit | MAJOR | VISUAL | — | 1.0 |
| 53 | Inner dome in air bubbles | MAJOR | VISUAL | — | 1.0 |
| 54 | FAPS Fire alram siren continuesely get on | MAJOR | VISUAL | — | 1.0 |
| 55 | GSL Cover missing found | MAJOR | VISUAL | — | 1.0 |
| 56 | Wiper not working-Camoflex | MAJOR | VISUAL | — | 1.0 |
| 57 | Wiper cleaning issues-Glass not clean properly-VECV Kollam) | MAJOR | VISUAL | — | 1.0 |
| 58 | FRP Bubbels on rear dome | MAJOR | VISUAL | — | 1.0 |
| 59 | 1.Dashboard Glow box black bolt loose | MAJOR | VISUAL | — | 1.0 |
| 60 | FAPS Tank belt broken-As per customer around 4 to 5 vehicles in same issue | MAJOR | VISUAL | — | 1.0 |
| 61 | Dashboard suface cracked | MAJOR | VISUAL | — | 1.0 |
| 62 | Battery changed as chassis | MAJOR | VISUAL | — | 1.0 |
| 63 | Nitrogen Cylinder empty found | MAJOR | VISUAL | — | 1.0 |

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