Guidelines for Zero Defect Model Line

4M Area of Improvement Process/

distributio Guidelines ZD Model Line(s) Observations
n improvement Objective System
No structure approach defned for
Study of process design/ Defect matrix / PFMEA study (all critical points of drawing should identification of failure modes, PFMEA
P
be controlled in the process) available for previously developed similar
part

10 machines applicable for Y1K and

P Biometric system / Pokayoke for avoiding unauthorized change in process parameters. biometric authorization not available for 2
machines

Poke Yoka checking sheet not available for

S Poka Yoke audit and Poka Yoke working monitoring.
Y1K assy area

MIS-P available; no other method available

P CTQ process / dimension identification/ operation standard availability
to capture the CTQ's

To Avoid process
Process
Strengthening
bypass/ miss and
wrong process. Process Audit/ review of action on past defect in similar parts or during various All inputs not captured only development
S
development stages issues captured

Draft PCS and MIS-P available. To be

Verify draft PCS/ MIS-P availability including child parts from Tier 2 (should be available
S approved by MSIL. Incoming inspection std.
by MPT trial)
will be prepared for seal of cowl top
P Closure of all PPVT/LVPT/ Process Audits gaps Process audit done, PPVT yet to be done
Rework procedure available but defects
S Procedure for Rework of parts (how and what to be repaired)
reworkable or not reworkable not identified

Mating part available for console (garnish

available), Checking fixture made as per
P Mating part understanding and its control in Jigs/ Checking fixture/ EOL
mating parts requirement and drawing
available
Method
System available, quality and productivity
To define a S System of operator observance to be formed (checksheet, defining responsibility, training)
qualifying criteria not defined
Process method to ensure
Adherence all decided
Improvement process are being S System for check on check, layered audit to be build (checksheet, training) DWM system available and adhered
followed Installation of CCTV camera to monitor line process adherence/ change management
S Available
(this data can be used for training & educating the line persons)
P Implementation of cyclic / sequential checksheet. To be prepared

P CTQ dimension / parameter & GCA parameters of parts checking in Final Inspection/ PDI To be prepared

Final S Final Inspection/ PDI system assessment/ Input-output inspection To be prepared

To ensure no
Inspection
Strengthening outflow of defects S
Recording of all defects observed in final inspection station with information to line Quality
Rejection recording sheets availables
incharge
Validation of EOL for adequacy based on past defect/ potential defect/ mating part/ vehicle
P Checking fixture not avaialble
fitment area/ vehicle level check
S IFM check system (both A & B shift) Controled system to be reviewed

Implementation of all Critical Quality systems on ZD line with training to all concerned
Defects related training done but ZD line training
S (Study VSA report to identify critical gap area, improve system accordingly and ensure adherance
& VSA system review is pending.
of the same: VSA approach)

S Daily monitoring/analysis/ action of line issues (Quality & production) System available
Ensure
implementation of S Weekly/daily top defect analysis and countermeasure. System available
System
all systems
Improvement Implmentation of 4M change management/ Abnormality handling system (Check
required for
S availability, adequacy & adhereance of existing system on line with awarness to line System available to be reviewed
Quality assurance
supervisiors/ incharges)

S CFT formation for reduction of internal rejection/defects during trial & machine breakdowns System available

S Weekly sustenance check of line DWM

P Map availability of manpower for all process as per Skill level required Requirement to be identified
To ensure
Plan for availability of adequate number of line leaders/ supervisors on line (Supervisor
Organization adequate no of S Existing Supervisors will be use
span of control)
structure Operators and
supervisor S Daily work management of the supervisors - clarity in roles and responsibilities. DWM available to be reviewed
S In case of new Line, what is the manpower recruitment plan Existing manpower will be use
Available, DOJO effectiveness eveluation to
Availability of Dojo Training center with all manpower of ZD line (Operator, Inspector &
P be done and actions to be planed against
Supervisor) training through Dojo
the observations
To ensure
Manpower Training of manpower (operator/supervisors) of ZD line at MSTA or MSIL for shop floor
availability of S ,---
Training process, process control etc.
Man trained manpower.
S Multi skilling plan of all operators and display in skill matrix Skill matrix available
P Fixing of manpower on stations with its daily monitoring. Under superviser control
To ensure trained
Manpower Daily attendance/monitoring of operators to ensure no new operator is deployed (new
manpower is working S Under superviser control
Continuity on the line operator if deployed should be Dojo trained with special monitoring by line supervisor)

Talk to operators/ Inspectors & Supervisors to understand problems being faced during
P
working & Generate ideas of improvement and implement the same
To involve all
Manpower Involvement of Tier 2 organization in Zero Defect process (verify use of Only Green Tier 2 being
Involvement
people working on S Only green tire-2 used
used & monitor improvement activity of yellow Tier 2 to make to Green before SOP)
the line
Kaizen scheme, Attandance scheme, Best
S Motivational schemes to be stared and link the same to the line Quality performance
operator award available.
P Traceability of parts, verify Batchcode for traceability is visible in vehicle condition Operator code, shift, date, Calander makring

P Review of material flow process - ensure single piece flow To be reviewed

Review and verify no mix up of OK NG parts. Explore all possibility of Mix-up of Rework
Saperate room for trial parts and scrap note
S parts/ ECN/ Trial parts on Shop (Must ensure clear identification of these parts)
generating for scraping the parts
Verify no mix up of semi-processed/ unprocessed / in-put part with finished/output part.

To ensure no S Instructions for handling method of sensitive child parts. Available

Material
defect due to part
Handling No trolly to be used for WIP handling for
mix up
Box floor
P Bin trolley adequacy in numbers for WIP and FG.
No. of bins and trolly requirements to be
Material identify
Check design of bin/ trolley so that no damage while keep/ taking out/storage of parts (no To be reviewed and approval to be taken
P
overflow/overcrowding in bins storage) from MSIL
P Check for storage space availability for keeping bins/trollies, FG inventory, raw material To be done for WIP storage and FG storage

S Maintenance system for bin and trolley. Available, To be reviewed

P One round of revalidation of all child parts of ZD line. To be done
Incoming part P Receipt inspection of all child parts used on line. Stricter inspection criteria to be defined
Revalidation/ To ensure Quality
Tier 2
S Tier 2 vendor Upgradation activity by Tier 1. Vender visit to be done at Ingress Mayur
parts from Tier 2
improvement P PFMEA of critical process at Tier 2
P Receipt standard verification with drawing & CTQ dimensions/ parameters CTQ identify to be done
P Evaluation of tools, jigs and machines being used on line. Assesment as per PFMEA check sheet
Tool and To ensure correct S Implementation of PM guidelines (mould maintenance, die maintenance) Mold maintenance manual impliment
Machine Equipment Quality of tools
check and equipment S Tool life monitoring system History card (IT system)
P Capability study & Calibration of Machines/ tools/ equipment/ instruments like EOL As per Calibration plan, system implement.