REVISION RECORD SHEET

TITLE : PROCEDURE
REV.NO 00 FOR PROCESS CONTROL. DESC. OF AMENDMENT DATE OF AMENDMENT PROCEDURE RESTATED. 16.03.1997

PR.NO : QP-09-01 PAGE NO : 1 OF 5 ISSUE NO : 01 REV NO : 00 DATE : 16.03.1997 REASON FOR AMENDMENT UPDATION TO QS9000:1995 REQ.

DISTRIBUTED TO :
SL.NO DESIGNATION NAME & SIGNATURE OF THE RECEIVER

PREPARED BY:

APPROVED & REVIEWED AND RELEASE CONTROLLED BY: .

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Process Control.
Purpose Scope Procedure : : : To establish a procedure for process control All products manufactured at

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QP-09-01 2 OF 5 01 00 16.03.1997

01. Dy. Mgr Production shall prepare production schedule on form FM-09-01, every month as indicated by GM(O) & AGM (STB) or as based on the market schedule and needs. Marketing shall give monthly schedule of despatch schedule on the format no. FM-03-07. 02. The form shall have provision to indicate the start & completion date and use it to schedule orders as they are received. 03. Dy. Mgr. Production shall hold daily production tracking meetings to monitor the progress of the work throughout the processes and recommend needed adjustments. Shiftwise M/C planning shall be done daily on the Production Logbook. Daily production reports FM-09-05/L & FM-13-22/S, Production Logbooks FM-09-04/L & FM-09-10/S, M.I.S. FM-09-06/L & FM-09-13/S, Shearing status FM-09-13/L, Productivity Report FM-09-07/L, Cost report FM-09-15/L shall form the basis of tracking. 04. Shearing plan to operators shall be given by shift engineer / team leader on form FM-09-13/L. In case of Stabilizer Bar Shift Engr. instructs the operator to shear the required model & quantity every planned shift. 05. Painting Plan to painting operator/ inspector is given daily on form no. FM-09-08/L. 06. Current work position is used to track production on form no. FM-09--09/L as and when required. 07. W.I.P. status is taken once at the start of the month on Form No. FM-09-16/L & FM-09-15/S . 08. In case any production schedule is released for job work to YamunaNagar / Mohali Plants, same shall be given on form no. FM-09-17/L & 18/L respectively. In case of job work of Stabilizer Bar, Material Movement Card no. FM-09-11/S, shall go along with the material to the vendor and shall be received back along with the same lot. To track different lots sent to different vendors, entry is made in the register RG-09-52/S. Tracking of jobwork items shall be the responsibility of Resp. Production Incharges.In case of jobwork of Leaf Spring, follow up shall be done on Telephone or through Inter Office Communications. 09. To achieve optimum efficiency, all processes shall follow a process flow path and these shall be standardised and displayed in the shopfloor. 10. Process flow path illustrating various processes involved in the production of

QUALITY ASSURANCE PROCEDURE

PR.NO : QP-09-01 PAGE NO : 3 OF 5 ISSUE NO : 01

TITLE : Procedure for Process Control.

REV NO DATE

: 00 : 16.03.1997

leaf spring & stabiliser bar manufacturing shall be prepared and maintained by responsibility Dy. Mgr. Production. Process flow path shall indicate the sequence of the process - operation wise, its number, the location/source & methodology , responsibility and applicable documents i.e. WIs, Control Plans, etc. 11. Resp. Dy. Mgr. Production shall ensure that appropriate & pertinent drawings provided by Engg. Dept. for the respective processes are made available at their locations. Resp. Dy. Mgr. Production shall adhere to any National/International standards or codes as per contract terms and specifications through copies provided by Engg. Dept. 12. At the time of induction of new products into regular production, apart from documents mentioned above, Engg. Dept. shall provide all information regarding the process capability study (PpK), the status of the process during prototype/pilot production using suitable methods ( preferably referred in process drawing). 13. Resp. Dy. Mgr. Production shall induct route card for all products at shearing & after Heat Treatment stages on Form no. FM-08-20/L, 21/L, 22/L, 23/L, 24/L, 25/L, FM-09-11/S & 12/S , as applicable. The route card shall indicate the part no. with revision status, part description, customers name, order quantity, batch quantity, operation no., operation name, date, shift, operators name, quantity taken for production, quantity accepted, quantity rejected & operators/QA sign & remarks. This route card will follow through the entire process till Final inspection. 14. All process shall be carried out under controlled conditions through pertinent controlled work instructions referred in the respective process flow paths to ensuremonitoring of the process parameters, as referred in process drawing, work instruction and control plan.( These work instructions shall be approved by GM(O) & AGM(STB) ) The main frame of the work instruction shall depict the following : Unique Reference no. Title of the work instructions Operation no. & Desc. Applicable part no. & its desc. with current revision status Tools, jigs & fixtures to be used Material Handling method Gages & Instruments to be used Safety precautions to be followed (in specific, if restricted matls. are handled during the process. Set up Instructions

QUALITY ASSURANCE PROCEDURE

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QP-09-01 4 OF 5 01 00

TITLE : Procedure for Process Control.

On going process performance requirement Job instructions Inspection/Verification Stages Handling Non conforming products Working Environment Instructions.

DATE

: 16.03.1997

The work instructions shall indicate any special characteristics in the process sequence as decided by CFT during APQP. 15. If necessary, based on the needs, respective Dy. Mgr. Production shall prepare their respective production dept. instructions in Hindi and displayed at appropriate work stations. 16. Workmanship standard ,as appropriate,shall be judged by comparing with master sample and decision on acceptance of products shall be taken by the quality assurance dept. Master sample shall be prepared and approved by production and quality head. 17. Tools, jigs & fixtures, equipments ,except Modules of STB ,to be used in the processes shall be requested through FM-23-03 by the respective Stage Engr. Production.The issue control shall be by Dy. Mgr. Tooling as described in the procedure QP-23-01. Modules of Stabiliser Bars shall be within the control of Engg. Deptt. of STB 18. Respective Dy. Manager Production shall ensure that all gages, instruments used in the manufacturing processes are studied for R&R and calibrated for accuracy of measurement. They shall also ensure the visibility of the status stickers put on the gages. 19. Whenever there is a Job Set Up, the respective Shift Engr. Production team leader shall verify the inspection report of the last off part produced using that particular tool. In case there is a modification done on the tool the same shall be referred to Engg. dept. for any PPAP requirements as agreed with the customer.If there is no change w.r.t. last off part, the job set up shall be as per respective instructions. Once the job set up is completed, the same shall be endorsed in the first off inspection report. 20. When process parameters/product characteristics are controlled through statistical process control, the same shall be controlled, analysed and reviewed as described in the procedure QP-09-05 21. The respective Shift Engr. production shall ensure, the suitable working environment is provided at each process. This includes adequate lighting, free space for material movement, proper facilities for handling of materials, cleanliness at work places, availability of safety devices and proper verification. This measures shall reduce fatigue to workers and maintain healthy productive atmosphere. This shall also be referred in all the applicable work instructions used for manufacturing.

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Process Control.

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QP-09-01 5 OF 5 01 00 16.03.1997

22. The process characteristics on the process control documents identified as unstable and non capable ,appropriate corrective action and reaction plan shall be decided. The approval of customer shall be obtained, if necessary as per contract terms. Basically, 100 % inspection shall be introduced through these plans till the corrective action plan within specified time is tested and ensured for effect on results by Q. A. and production Incharge. 23. On completion of job, at every operation, for the defined batch, the operator shall fill in the columns of the route card for qnty acc., qnty rej., and initial the card. 24. Periodic preventive maintenance shall be planned to keep all equipment in good working condition as described in procedure QP-09-03. 25. Handling Non Conforming products shall be handled as described in the procedure QP-13-01. 26. Handling Hazardous products shall be handled as described in the procedure QP-0904.