MSES Manual PDF

L I E R E VA LUAT
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Rise Culture - The House of Mahindra
ACCEPTING ALTERNATIVE DRIVING POSITIVE

NO LIMITS THINKING CHANGE
Rise by daring to disturb Rise with your Rise by shaping

the universe ingenuity destinies
CORE VALUES
• PROFESSIONALISM • GOOD CORPORATE CITIZENSHIP • CUSTOMER FIRST • QUALITY FOCUS • DIGNITY OF THE INDIVIDUAL
First Edition, May 2012

The information contained herein is an exclusive property of Mahindra & Mahindra Ltd. and shall not be distributed, reproduced, or disclosed in whole or in part without prior written permission of
Mahindra & Mahindra Ltd., failing which legal action can be initiated as per Jurisdiction of Mumbai. The content of this information is subjected to change without notice.
Mahindra & Mahindra
Group has a vision to be recognized globally for Quality, Durability & Reliability of our products. Quality focus is an integral part of our
Core Purpose and Core Values.
In Promise 2013, we laid out an aggressive road map for growth and organizational transformation. The product portfolio has been strategized
and designed in a way to develop and introduce new products as well as variants in coming three years, under various platforms.
Quality, profitability and growth plans set out in our Aspiration 2016 and Long term plans must be implemented and applied companywide,
through precise action plans. But we will not meet these targets, without your active participation and support.
The best organizations of the world focus on Supplier Development and Supplier Strategy, as the key driver for quantum growth and profitability.
Keeping this in mind, we have introduced Mahindra Supplier Evaluation Standard (MSES) as an additional milestone in our supplier selection
and development process. The purpose of this manual is to elaborate the Process and Systems requirements that need to be adopted by the supplier,
to achieve Global Quality Levels.
I look forward to your continued support and whole hearted participation to ensure the effective implementation of the MSES.
Rajan Wadhera
Chief Executive
(Technology Product Development & Sourcing
Member of Group Executive Board)
We live and work in a hyper competitive world. Competing and winning in today’s global marketplace requires that our products and services
must be of high quality, developed with short lead times, delivered in right quantities and on time and at competitive cost.
This requires very robust processes and a strong commitment, led from the top, to quality delivery and continuous improvement.
We at M&M, have a firm belief that to achieve this goal, we must work closely with our suppliers as partners. We must have a process in place
that selects, supports and ensures our suppliers meet high quality requirements.
This has made it necessary for us to define the Quality expectation of Mahindra to our supplier partners, which have been formulated in the form
of Mahindra Supplier Evaluation Standard and Rank up manual.
The objective of this manual is to define the basic quality systems and process requirements that we expect our suppliers to follow to ensure that
our mutual responsibilites for product and service quality are understood and implemented.
We look forward to your complete understanding and support and believe that by working together we can develop a robust supply chain to achieve
world class quality and satisfy our customers needs.
Hemant Sikka
Head Sourcing (AFS)
Mahindra & Mahindra
Index
1. Introduction........................................................................................................................ 02
a. Definition...................................................................................................................... 03
b. Objective....................................................................................................................... 03
c. Applicability................................................................................................................... 03
2. Approach............................................................................................................................. 04
3. Evaluation Structure............................................................................................................ 05
a. Rating System................................................................................................................ 05
b. Final Rank and Total Score............................................................................................. 06
4. Chapter 1 Quality Policy & Quality Assurance System.......................................................... 07
5. Chapter 2 Analysis of the Quality Concerns for the Current Products.................................. 14
6. Chapter 3 Quality Assurance at the Process Development Stage......................................... 41
7. Chapter 4 Quality Assurance at the Pre-Production Stage................................................... 53
8. Chapter 5 Quality Assurance at the Production Stage......................................................... 61
9. Chapter 6 Control of Sub Suppliers..................................................................................... 148

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Introduction
The Automotive Industry in India is one of the largest in the world and one As a part of this strategy we have already introduced Global Benchmark
of the fastest growing globally. India’s vehicle manufacturing industry is the practice of Mass Manufacturing Approval during Start Of Production. This
sixth largest in the world. has yielded highly successful Ramp Up in many of our key projects.
This has given rise to the challenges of creating World Class manufacturing To further support our Endeavour to be Best in class for Quality Practices
systems and World Class Supplier Base. there is a need to Next Mark the way we work.
At Mahindra to meet these Challenges of the Industry we have adopted the In line with this we have introduced a Preventive approach which is Mahindra
Philosophy of Rise which is Strong Foundation of Following Three Pillars. Supplier Evaluation Standard termed MSES that outlines the detailed
These are strongly supported with quality as the main ingredient. requirements of Mahindra & Mahindra to establish a robust methodology in
Quality Assurance Management.
• Accepting No Limits
MSES is a structured Quality tool, that helps in establishing a robust quality
• Alternative Thinking system which will guarantee Quality Systems, Development Planning, Concern
Management, Daily Work Management and Sub Supplier Management.
• Driving Positive Change.
This ensures readiness of supplier in terms of quality & delivery requirements

We have established our own Quality way which is the MQW (Mahindra
of the customer during supplier selection, in case of new business and for
Quality Way)
Ranking Up quality level of existing supplier.
With this increasing demand it is imperative that we are able to achieve
The supplier is expected to Rank Up their existing Quality Systems in line with
World Class Quality levels in all areas of our operations including our supplier
this methodology.
development and management
This Manual is only for Reference.

We also strongly believe that the contribution of suppliers is key to the
growth of our business as we follow the philosophy of suppliers as partners
who need to have World Class quality Practices to meet this challenge.
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A. Definition MSES Flowchart
Mahindra Supplier Evaluation Standard is a Structured approach for evaluating
Quality Management of new supplier and for Ranking up of existing supplier
to required Mahindra & Mahindra Quality Level.
This is a guideline based approach where each and every requirement is

evaluated from World Top Level to Not Satisfactory Level.
B. Objective
The main objective of MSES activity is to clarify
1. The quality level of supplier (s) and ask to improve this level and
2. Identify supplier (s) with whom Mahindra & Mahindra should have
Commercial Relationship.
C. Applicability
MSES activity is to be carried out under following cases:
• New supplier selection.
• New plant location.
• Existing Supplier Quality level Rank-up.
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Approach
MSES activity is performed during the phase 1 of APQP i.e. before sourcing confirmation and during rank-up for existing supplier.
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Evaluation Structure
MSES Evaluation is based on 6 chapters which covers different aspects of (2) Certain check points are considered to be Critical points which have Demerit
production systems which directly or indirectly affects product quality. rating. These 17 Critical Points have been decided by considering their direct
effect on performance & quality of the product and are as below.
Different chapters of MSES Evaluation are:
1 Warranty Information Analysis 10 NC Management
Chapter 1. Quality Policy and Quality Assurance System
2 Cause Analysis 11 Rework Management
Chapter 2. Analysis of the Quality Concerns for Current Products 3 Recurrence Prevention 12 Mix Up Management
Chapter 3. Quality Assurance at the Process Development Stage 4 Process FMEA 13 Abnormal Situation Management
5 Control Plan 14 Safety Characteristic Management
Chapter 4. Quality Assurance at Pre-Production Stage
6 Process Change Control 15 Internal PPM reduction activity
Chapter 5. Quality Assurance at Production Stage 7 Design Change Control 16 Continual Improvement
Chapter 6. Control of Sub-Suppliers 8
Control of Equipment
17 Sub Supplier Change Management
Condition
9 Operator Training
A. Rating System
The Rating system for MSES is broadly classified into three Categories • Scoring of Critical items for demerit is as follows :
(1) Merit Ratings 5, 4, 3, 2, 0 are given to each checkpoint Chapterwise which have - Each item with low score (2 pts/5) => -5 points for process indicator total score
different Weightages. - Each item with very low score (0 or 1 pt/5) => -10 points for process indicator
total score
5 World top level 3 In addition to this each Chapter has different weightages in Evaluation as shown
below:
4 Some competitiveness
3 Implement somehow Chapter Evaluation Criteria Weightage %

1 Quality policy and quality assurance system 5
2 Many insufficient items
2 Analysis of the quality concerns for current products 30
0 Almost not able 3 Quality assurance at the process development stage
25
4 Quality assurance at pre-production stage
5 Quality assurance at production stage 30
6 Control of sub-suppliers 10
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B. Final Rank and Total Score:

The total score is calculated as follows:
Total Score of Process Indicators = Total Score – Demerit Score
The Final Rank is given based on the Total Score of Process Indicators as shown in table below:
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Chapter 1
Quality Policy & Quality Assurance System

Objective: To ensure existence of Standard Working Processes and Methodologies for Sustenance of Day to Day activities.
1.1 QA System
PURPOSE
• To assure existence of Basic Quality System like ISO/TS.
• To assure methodology of Internal audit system is followed for Sustenance.
• To demonstrate ability in Maintaining Quality Systems.
REQUIREMENTS REFERENCES
• Availability of ISO/TS certification for the existing • Internal audit procedure.
plant. • Master list of business process (Apex manual).
• Availability of standard procedure for the Internal • Audit Plan.
system, process, & product Audit. • Audit check sheet (Ex. 1).
• Defined Plan & Frequency of internal system, • Audit report.
process, & product audit. • NC Analysis Report (Ex 2).
• Availability of specific Audit checklist for system, • NC summary.
process, & product.
• List of internal auditors.
• Audits should be conducted by Qualified & skilled auditors.
• Availability of reporting mechanism for Non Conformity.
• Methodology defined for deciding gravity of NC
(Major or Minor).
• Use of standard QC tools such as Why Why analysis
deployed to arrive at root cause.
• Availability of Non Conformity monitoring system
with open/close status.
• Conduct follow-up audit methodology to close the
NC.
• Quality award from Car Maker.
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Example 1 - Audit Check sheet

Doc No.
Process & Product Audit Check Sheet Rev No.
Date
Process Name : Date :
Part No : Shift :
Part Description : Area : Incharge :
Customer : Machine No./ Name :
Operator :
ACCEPTANCE CRITERIA :
CATEGORY : RATING CRITERIA :
Strong Area Must score 50% in all sections M - Must If zero in M,score will be -5
VI - Very Important If zero in VI,score will be -2
Weak Area Not meeting above requirement I - Important If zero in I,score will be -1
I – SYSTEM CHECKS
Sl Weightage Points Score
Check Item Category Result Remarks
No (a) (b) (a x b)
1 ) Incoming Packing Condition (If Applicable)
1.1 Any damage in package? I 0.5
1.2 Any mix up? I 0.5
1.3 Any dust or dirt? I 0.5
1.4 Are all products/ packages identified? I 0.5
1.5 Strapping (Three strap radially and one on the circumference). I 0.5
1.6 Wrapping (To be completely covered with gunny bags) I 0.5
2 ) Raw Material/Storage (If Applicable)
2.1 Is the Raw material properly identified. I 0.5
2.2 Is the area marked for keeping raw material. I 0.5
2.3 Is there any wrong identification? I 0.5
2.4 Is checklist for material receipt available & being followed? I 0.5
2.5 Is the prctice being followed as per control plan/ receiving inspection M 1
standard ?
Refer Annexure for Ex 1
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Example 2 - N C Analysis Report A
Contd...
Doc No:
Rev No: 00
NON CONFORMITY REPORT Rev date:
AUDIT SCHEDULE NO: REPORT NO: DATE:
AUDIT SDEPT/ AREA/ PROCESS: TIME : From ………………. PROPOSED PREVENTIVE ACTION Target Date Responsibilit
y
AUDITEE(s): AUDITOR(s):
Sl. No of Audit findings for which NC was sighted: Sign of AUDITEE
Attribution to ISO-TS 16949 / ISO 140001 / OHSAS 18001: Sign of AUDITOR
NON CONFORMANCE / NEGATIVE OBSERVATION

Auditee Sign
DATE FOLLOW UP AUDIT / VERIFICATION FOR IMPLEMENTATION (Write Observation) Auditor Sign
DISPOSITION ACTION
(use space overleaf if required)
VERIFICATION OF EFFECTIVENESS OF IMPLEMENTATION (Write Evidence )

ROOT CAUSE - (USE WHY - WHY ANALYSIS)
Date Auditor Sign
NCR Status VERIFIED BY MANAGEMENT REPRESENTATIVE

PROPOSED CORRECTIVE ACTION Target Date Responsibilit
y
Date Sign. MR
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1.2 Quality Objectives
PURPOSE
• To assure mechanism of Quality Policy and Quality Objectives are defined in line with Company Indicators.
• To assure activity for deployment of these Objectives to Process, Product and Individual level is done.
• Availability of Specific Quality Policy signed by Top Management. • Quality Policy.
• Each element converted into Measurable & Quantifiable Objectives with clear • Quality Objective / Business Plan / Balance Score Card / Simple Objective List.
linkages to Quality Policy. • Customer Target Information.
• Deployment of Quality targets based on past performance of the company and • Target breakdown into product & process level (Ex 3).
plants. • Data for target v/s actual.
• Company Objectives higher than all customer targets (LOI /CSR /CIR /SOR).
• Deployment of Objectives to process as well as product level on the shop floor.
• Relevant employees have been trained & understand the deployment of Objectives.
• Regular monitoring of target v/s actual.
• Should have Achieved objectives consistently for 3 years.
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Example 3 - Target Breakdown into Product & Process Level
OBJECTIVE FOR THE YEAR OF 2010-2011
OBJECTIVE FOR
S.NO PARAMETER AUG '10 SEPT'10 OCT'10 NOV '10 DEC'10 RESPONSIBILITY JAN'11 FEB '11 MAR'11 APR'11 MAY'11 JUN'11 JUL'11 AUG'11 SEP'11 OCT'11 NOV'11 DEC'11 AGGREGATE
THE YEAR 2011
1 INTERNAL QUALITY PPM 100 120 80 90 60 50 0 50
2 DELIVERY PPM 0 0 0 0 0 0 0 0
3 WARRANTY PPM 0 0 0 0 0 60 0
4 CONVERSION COST (Rs) 157.8 89.77 81.91 93.03 74.89 75 64.85 76.9425
5 YIELD % 83.07% 86.61% 85.58% 85.38% 86.87% 88.00% 86.08% 0.8658175

INTERNAL REJECTION
LINE 1 3.39% 2.70% 0.86% 0.77% 1.14% 1.32% 0.71% 0.00985
LINE 2 4.64% 0.74% 0.78% 0.54% 0.16% 0.52% 0.61% 0.004575

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ASSEMBLY 1.04% 0.40% 0.29% 0.05% 0.26% 0.33% 0.24% 0.0022
PAINTING 0.00% 0.00% 0.01% 0.00% 0.02% 0.00% 0.05% 0.000175
LINE 1 10.26% 6.47% 4.83% 4.79% 10.65% 4.46% 1.80% 0.05425

INTERNAL REWORK
LINE 2 22.15% 2.48% 7.00% 4.61% 1.84% 5.92% 3.31% 0.0392

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ASSEMBLY 5.11% 2.60% 1.20% 3.83% 2.70% 2.02% 1.11% 0.02415
PAINTING 6.54% 3.10% 3.56% 6.50% 4.27% 3.58% 4.98% 0.048325
8 ACCIDENTS 0 0 1 1 0 0 0 0.25
9 MACHINE BREAKDOWN 10.56% 5.25% 2.83% 3.58% 4.25% 4.00% 3.00% 0.037075
10 PARTS / MANDAY 4.2 6.6 6.5 6.9 5.8 12 10 8.675
11 TRAINING HOURS 68 272 160 0 496 800 224 380
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1.3 QA System & Organization
PURPOSE
• To assure existence of QA organisation within the company, with clear Roles and Responsibilities defined for Quality Management.
• To assure mechanism of conducting Regular Quality Meeting.
• Availability of QA Organization including • QA organization chart (Ex 4).
functions such as development, in-process, • Roles & Responsibility document for QA.
final inspection, customer, incoming, change • KRA/MOP Sheet.
management, continuous improvement, and • Quality Meeting Guideline.
safety characteristic.
• Quality Meeting Agenda, Minutes.
• Defined Roles and Responsibilities of each
• CSI format.
employee.
• Guideline to conduct Quality meeting
(Agenda, Frequency & Minutes).
• Attendance of Top management in Quality
meeting once per month.
• Recommendations from top management in case of delay or no achievement of
target.
• Take CSI from all plants of customer (SCM, MM, & SQA) and improve upon the
gaps.
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Example 4 - QA Organisation Chart
ORGANISATION LAYOUT CHART FOR QUALITY ASSURANCE DEPARTMENT
Overall responsible for QA

HEAD Q A & QS
1. IMS Docs.
1. Process Audit 1. Process Audit
2. System Audit
2. Product Audit 2. Product Audit 1. Product
3.Management
3. Supplier PPAP 3. Supplier PPAP Engineer - Review Engineer Audit, Dock
Engineer - A 4. Dock Audit Engineer -B 4. Dock Audit audit, layut
5. Layout inspn 5. Layout inspn Systems 4. Training
5. FMEA
……….. Inspection
6. Cust. Compl. 6. Cust. Compl. 2. Q I S
6. Safety Audit
7. Rej handling 7. Rej handling 3. PokeYoke
7. Liasoning
8. Problem solving 8. Problem solving
8. SPC
9. Safety 9. Safety
9. PPAP Approval
Charecteristics Charecteristics
10. Change Control
10. Quality Meeting 10. Quality Meeting
J E Lab
J E STD. ROOM 1. CMM
1. P D I
Lab Inspection of
1. Sample
2. Paint Shop Testing Assistant collection & :-
1. Calibration i. Product
3. Final Inspection Preparation. of all IMT ii. IMTE`s
4. New Prod Quality 2. Master & 2. External Operator
representativ Calibration
e Sample 3. Standards R M Inspection
preparation updation & MSA
1. CFT, RFT,
Weld Tetsings,
Helper
BW testings, Salt Helper
Spray, Wheel
Unbalance
1. Collection 1. Raw Material
of IMTEs Receiving
2. Servicing Inspection
of IMTEs
Inspectors
Inspectors 9
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Chapter 2
Analysis of the Quality Concerns for the Current Products

Objective: To ensure the Methodology of Defining and Monitoring the Progress of the actions to achieve the defined Targets
and Identifying the Real Root Causes by using Problem Solving Technique to avoid Recurrence of the problems.
2.1 Target Control
PURPOSE
• To assure that the targets are defined at the start of the year based on past performance.
• To assure that the targets are achieved by defining the action plan on prioritized problems and by monitoring the progress through structured
Quality concern reviews for warranty, Delivery and Internal defects.
• Availability of Warranty, Customer & In-house concern logbook / register / tracking • Warranty Register, Customer PPM & In house PPM Register / Log book (Ex 5).
sheet. • Monthly monitoring trends, Pareto charts (Ex 6).
• Availability of Monthly Monitoring trends for Warranty, Customer & In-house defects. • Annual reduction Plan – 4M Level Macro Action plan and Monitoring(Ex 7).
• Use of Pareto charts (By customer, by plant, by part, by defects etc ) to identify • Quality Review Meeting Plan Vs Actual Status.
Major contributors in case of Warranty , Delivery and In house defects. • Progress Control Sheet (Tracking Sheet) for Warranty, Delivery & Internal defects
• Mechanism for sharing these defects throughout the organization. (Ex 8).
e.g. display of graphs at central location for tracking customerwise, monthwise,
partwise, defects / PPM.
• Defined the targets for Warranty, Customer PPM & In house PPM based on Past
1 year data.
• Defined 4M level Macro Action plan linked with organization Objective and
customer quality targets at the beginning of the Year based on this last year Quality
Performance data.
• Mechanism for monitoring the Progress of defined actions through Quality Review
Meeting.
• Defined Frequency of Quality Review Meeting (General – Monthly) and Plan as per
that frequency.
• Availability of All actions as a part of Progress Monitoring Sheet.
• Mechanism of Reviews for all earlier pending actions during Quality & Management
review MOM.
• Defined and Implemented recovery / revised action plan in case of any delay or non
achievement of target.
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Example 5 - Warranty Register
WARRANTY/FIELD COMPLAINT REGISTER
Date of Chasis Month of Defect Claim Phenomena Before After

Car Part Part Prod Usage Claim # NTF/ New/Repeat/Rare
S No. Customer warr. Dealer City Zone Mfg. prodn./ unit Kms Des. by Accepted / found after Qty break break
Model No. Name Line Months Dt DNR Concern
Recd. month no. customer Rejected analysis point point
Date: Reviewed By: Approved By:
V1 Refer BMS for current revision level Page 1 of 1
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Example 6 - Monthly Monitoring Trend, Pareto Chart

MONTHLY MONITORING TRENDS
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Example 7 - 4M Reduction Plan Global Targets - Rejection
Doc No :
REJECTION TARGET - ASSEMBLY Rev No :
Date :
TARGET - ASSEMBLY (REJECTION) BREAK DOWN OF TARGET

ASSEMBLY 2008 2009 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC REMARKS
Flange
1 bWeld unde weld shift porosity 2008 0.48 Porosity 0.08 0.05 0.003
0 0 0.14 0.003 Jan 09 0.24 Weld shift 0.08 0.04 0.14
0.9 Feb 09 Weld undercut 0.06 0.04 0
Mar 09 Flange bend 0.03 0.02 0
0.8 Apr 09 Pin hole 0.02 0.01 0
May 09 Runout problem 0.02 0.02 0
0.7 Jun 09 Flange width variation 0.02 0.02 0
OWN TARGET
Jul 09 Batch code damage 0.01 0.005 0.05
0.6 Aug 09 Weld short length 0.01 0.005 0
Sep 09 Grinding mark 0.01 0.005 0.008
% Rejection
0.5 0.475 Oct 09 Material pitting 0.01 0 0

Nov 09 Weld miss 0.01 0 0
0.4 Dec 09 Others 0.115 0.115 0.039
0.33%
2010
0.3 2011 Over all 0.475 0.33 0.24
0.24 Monitoring (month)
0.27% Target Responsibil
Effectiveness
PROBLEM ACTION Actual ity 1 2 3 4 5 6 7 8 9 10 11 12
0.2
0.21% 1, Nozzle cleaning frequency to be defined in OS to 0.1
Porosity
ensure gas flow. 0.1 Feb
0.1 0.1
0.06
Mar
2, Poka yoke for less gas flow to be introduced. 0.1
0.05
Apr
0.04
Porosity 0.1 May
0
0.03
0.1
0.02
Jun
2008
2010
2011
Jan 09
Feb 09
Mar 09
Apr 09
May 09
Jun 09
Aug 09
Sep 09
Oct 09
Nov 09
Dec 09
Jul 09
0.01
0.1 0
0.003 Jul
0.1 Aug
Jan 09 Feb 09 Mar 09 Apr 09 May Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09
09
0.1 Sep
1. To replace sliding rail of AW - II with round bars 0.1 0
Weld shift
REJECTION ASSEMBLY - YTD 2. To device fastening arrangement according to 0.1 0
round bar 0.1
0.16
0
0.14
0 0.14
120 120
0.12
Weld shift 0.1

0
107 0.08
100 REJECTION = 0.47% 0.06

0.04 0
0
0.02
100 100 0
0
09
75 0
80 80
1, Setting parameters to be monitored & frozen 0 0
2. To have a master setting disc to set ESO at the 0 0Weld undercut
60 60 time of setting 0.045
0 0
0.04
0
40 0.035
Weld undercut 0
0.03
40 35 32 34 40 0.025
0.02
28 0.015
0.01
0
21 0.005
0 0
20 16 15 20
0 0
12 12 12 10 10 9 0 0
8 8 7 7 6 6 6 09
0 0
0 0 1, Final wheel inspection table located after the 0 0
Batch code…
Flange bend
conveyor is shifted before conveyor i.e. immediately 0 0
Porosity
Weld miss
Grinding mark
weld shift
Flange bend
Pin hole
Power cut
Dent
Weld short length
Trim line
Scuffing mark
Over bead
weld undercut
Thin down
Others
Weld problem
Material pitting
Hub Crack
Trial (MIG weld)

Dimension problem
Runout problem
rej. Due rework
Disc problem
after unloading. 0.025

0 0
2, An extra packing machine is installed to avoid 0.02 0
Flange bend wheels waiting for packing 0.015
0
0.01
0.005 0
0 0 0
0
Jan 09 Feb 09 Mar 09 Apr 09 May Jun 09 Jul 09 Aug 09Sep 09 Oct 09 Nov 09Dec 09
09
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Example 8 - Progress Control Sheet for Warranty. Delivery & Internal Defects
Doc No.
Rev No.
QUALITY CONCERNS PROGRESS CONTROL SHEET DATE
Emergency Root cause Horizontal
Problem Interim action Corrective action Preventive action Change Documents Updation (Please put date when activity completed)
S.No QPCR / Raised Responsibi Target Quality Response analysis deployment Closed
Concern Description New or control
. 8D No. on lity Date Alert Control Set up Start up Alarm Technic on
Repeat Plan Actual Plan Actual Plan Actual Plan Actual Plan Actual Plan Actual no. PFC FMEA WI OS SIR PTD
plan verificati checklis level al know
1 QD/11/01 Flange width variation 03.01.11 11.01.11 New P 03.01.11 03.01.11 03.01.11 03.01.11 10.01.11 06.01.11 17.01.11 11.01.11 17.01.11 11.01.11 17.04.11 P P 03.01.11
2 QD/11/02 Vent hole pierced at wrong location 05.01.11 10.01.11 New - NA NA NA NA 12.01.11 06.01.11 19.01.11 06.01.11 NA NA NA NA P 05.01.11
3 QD/11/03 Weld crack 05.01.11 New - NA NA NA NA Under progress P 05.01.11
4 QD/11/04 Band overlap 05.01.11 24.01.11 New - NA NA NA NA 12.01.11 07.01.11 19.01.11 24.01.11 19.01.11 24.01.11 19.04.11 P P 05.01.11
5 QD/11/05 Flange bend 05.01.11 19.01.11 New P NA NA NA NA 12.01.11 08.01.11 19.01.11 17.01.11 NA NA NA NA P 05.01.11
6 QD/11/06 Band bulged 05.01.11 12.01.11 New - NA NA NA NA 12.01.11 08.01.11 19.01.11 10.01.11 19.01.11 10.01.11 19.04.11 P P 05.01.11
7 QD/11/07 Weld shift 05.01.11 15.01.11 New - NA NA NA NA 12.01.11 05.01.11 19.01.11 17.01.11 19.01.11 17.01.11 19.04.11 P 05.01.11 30.01.11
8 QD/11/08 Air pocket 05.01.11 31.01.11 New P NA NA NA NA 12.01.11 12.01.11 19.01.11 23.01.11 NA NA NA NA 001 P P 05.01.11 30.01.11
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2.2 Information Analysis
PURPOSE
• To assure the System of Proactive collection and recording of Warranty Information with defined details.
• To establish the mechanism of Monitoring the Alarm indicators and take actions in case of Alarm level is reached.
• To assure the Information Analysis on defined elements ( like Production month , Kms etc ) and also in case of rare claims detailed analysis is available.
• Defined Frequency and Responsibility to collect • Warranty Information Analysis procedure with defined Responsibility and Frequency
Warranty Information (Proactively). to collect the information (Ex 9A, Ex 9B).
• Defined mechanism to collect Warranty raw data • Warranty Information Register (Refer Ex 5).
with required details (Mfg. date, Sale date , vehicle • Warranty Information Analysis monthly (Ex 10).
no, area, dealer, region, KM, Mfg. traceability, chassis, • Detailed cause analysis for rare claims.
model, problem description, whether parts replaced, • Monitoring of Alarm controls which is predefined for elements (like Kms, Dealer,
etc.). region, Model etc.) with recovery action plan.
• Mechanism of defining alarm controls and taking
• Progress Control Sheet for rare claims to track the progress on actions.
actions in case of alarm is reached.
• Defined specific alarm control for Safety parts.
• Availability of a standard procedure for information
analysis which describes analysis steps and parameters
like Production Month, reported month, dealer, Kms etc.
• Use of Information Analysis is done for each defined item.
• Mechanism of tracking the Progress of actions for rare claims through a Progress
Control Sheet (Tracking sheet).
• Availability of Cause Analysis for Occurrence and non-detection for all the defects.
19
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Example 9A - Warranty Information Analysis Procedure

Procedure No
PROCEDURE FOR WARRANTY HANDLING Page No
Page issue No
Issue date
TITLE :- WARRANTY HANDLING
Signature
Input What Where Output When Who How
START
Attend the Warranty

meeting at customer
end.
Receipt of the warranty complaint from the customer through As per customer's
--- Warranty formats QA email / phonecall
Telephone call / Warranty analysis meeting (1)TKML :- Once/month. requirement/monthly
Other customer email
monthly to get data or nil
rejection from customer.
Conduct the data analysis and the preliminary joint analysis (

Visual inspection & feel) with the customer at warranty cell and
decide
a) Accept claim - Confirmed by visual inspection
b) Accept claim - needs further investigation at plant
Joint analysis report &
c) Reject claim As per customer's
Customer given samples Warranty cell Parts accepted / QA/ Marketing Joint analysis format.
requirement/monthly
d) New claim rejected
e) Rare claim
Claim accept -a) The part in which defect is confirmed is sent to

scrap yard
Joint analysis report b) Carryout Testing like Axial play & torque ,Push out & pullout Plant Warranty log After initial analysis QA Warranty log
,Dimesional in plant standard room for the parts in which defect
is not evident.
Refer Annexure for Ex 9A
Joint analysis report with
Customer given samples Claim Reject : Reject claim and handover parts to customer Warranty cell NTF records After Initial analysis QA
customer.
20
Claim for Old cases (Whose actions are completed).Verify the
Observations after
Customer given samples failure mode by visual / dimensional / metallurgical inspection Plant After initial analysis QA Analysis report
Example 9B - Warranty Assessment Flow Chart
WARRANTY ASSESSMENT PROCEDURE
Title: Warranty Assessment (Information collection, trend analysis & feedback to
customer) Doc No. :
PURPOSE: To establish a documented procedure to ensure that the Product that does not conform to specified requirements are prevented from Org Date :
unintended use/Before Warranty period From end user . Rev/date :
SCOPE: Applicable for all Warranty. Page No: 1 Of 3
Responsibility : Customer Representative/Marketing/PD

Input Process Output
Receive warranty information ( QA/Engg/NPD Compiled data
market Claim)from customer Receive the data( market Claim) for compilation Data for trend analysis captured in Format
through our representative by No.AAP/WGF/00/00 . & AAP/WF/01/00
website, mail, fax, phone or QA/PD/Aditya Reps..
letter (or) returned part. If no warranty information is received from customer Immediately after occurred
end, Aditya respresentative at Customer End will visit
the Customer place & collect the Information on Forward this to QA / Production / Engg. /
monthly basis or as per the customer practice. Maintenance / Purchase.
- Conform the Warranty Information through Email &
update the the Warranty data for the month.
Onces in a month
Yes
QA /Project Manager /Engg..
Update the data production monthly wise in the format Two working day
(AAP/WF/01/00 ) .
Pareto analysis graphs updated
Data to be captured - Modelwise trend
- Vehicle model Compiled date and Project Manager /Engg.. - Kilometerwise trend
- Vehicel chassis(Sl.no) make Trend/ parato - Dealerwise trend
- Vehicle manufacturing / sale date analysis - Phenomenon trend
- Vehicle defect report date(Claim Date) - Defect Wise trend
- Defect / Problem reported Yes - Aditya Production batch wise
- Dealer details (name, location) Fix Targets for the current year with Start of year. - Location/ Zone wise trend( N,E,W,S)
- Production code of Aditya Reduction percentage and Decide the - Defect compared to sale date trend
-Aditya label / pad print details( If Applicable) Focuse areas for Problem Solving Viz, - Warranty cost trend
- Kilometers covered Production Month wise Defects, Claim - claim monthwise
- Location/ Zone wise trend( N,E,W,S) Month Wise Defects, customer Zone Wise
- Cost of warranty Defects, Product Wise Defects etc. onces in year & ever month
- Customer PPM
A Forward to QA, Operation, Production, ME &

Alarm Conditions are Purchase & give the feed back as per
procedure 14 P 01 00 C
- New Defect
- Defect after the action Taken Yes
21
- Zone Wise Defect in %
- Delear Wise Defect in % Project Manager /Engg..
QA /Project Manager /Engg..
Update the data production monthly wise in the format Two working day
R EVALUAT (AAP/WF/01/00 ) .
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UP Data to be captured - Modelwise trend
NS
AS
- Vehicle model Compiled date and Project Manager /Engg.. - Kilometerwise trend
TAN
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- Vehicel chassis(Sl.no) make Trend/ parato - Dealerwise trend
DARD
- Vehicle manufacturing / sale date analysis - Phenomenon trend
- Vehicle defect report date(Claim Date) - Defect Wise trend
- Defect / Problem reported Yes - Aditya Production batch wise
- Dealer details (name, location) Fix Targets for the current year with Start of year. - Location/ Zone wise trend( N,E,W,S)
- Production code of Aditya Reduction percentage and Decide the - Defect compared to sale date trend
-Aditya label / pad print details( If Applicable) Focuse areas for Problem Solving Viz, - Warranty cost trend
- Kilometers covered Production Month wise Defects, Claim - claim monthwise
- Location/ Zone wise trend( N,E,W,S) Month Wise Defects, customer Zone Wise
Contd...
- Cost of warranty Defects, Product WiseA Defects etc. onces in year & ever month
- Customer PPM
Forward to QA, Operation, Production, ME &

Alarm Conditions are Purchase & give the feed back as per
procedure 14 P 01 00 C
- New Defect
- Defect after the action Taken Yes
- Zone Wise Defect in %
- Delear Wise Defect in % Project Manager /Engg..
- 0- 1000 Km range Check for the Alarm Conditions / update the trend Every month
graph.
Below the Alarm control Action to be NO Beyond

taken based on the CFT review ( Focused & Alarm
Priority area action will be taken for CAPA . Conditions
Yes
. Project Manager /Engg..

Analysis wide Customer input and Warranty analysis
Procedure (14 P 01 00 C)
Prepared by : Approved by :
Ammendment details:
ISSUE NO & DT REV NO & DT PG PT
Sl
No. B/F A/F B/F A/F NO NO Details of change Reason for change Changed By
------ 00/06.06.09 nil 00/06.06.09 ---- ----- New Release New Release
1
2
22
Example 10 - Warranty Information Analysis Monthy
Warranty Trend Analysis of March'11
Trend graphs : MODLE FORMAT Doc No. : Org Date :
Page No: 1 Off 3 Rev/date :
Defect to Production batch - trend

produced
Prodn month Claims Defect PPM
quantity
Mar'10 9 Defect wise trend 25 22
Defect Qty
20
Model trend Conclusion: From the Graph FRM has highest Center locking defective 5
12
FRE ECU 0 11 Warranty Claim & is considered for Analysis Not Open From Inside 5 15
FRM 6 Note: Warranty Target cannot be fixed because: not working 22
Back Manual 1 1. Based on production batch: There are 25 models outside not releasing 4 10
10 5 5
170N back 0 & production Qty will vary for every model in every 4
5
FLE 2 month. Data/ claims available from Sep'09 whereas
RLE 0 production batch varies from Year 2008-10. 0
Back ele w/o irc 3 8 2. Based on Warranty PPM Target fixed: Target fixed
Back ele 3 in PPM but the data available in Qty & PPM cannot Conclusion: Prioritise the Defects for which
RLE 2 be calculated. TOTAL 36 Actions to be taken by plotting the Pareto Graph.
6
6 Take Corrective & Preventive Action for Horizantol
RLM 1
deployment of all the Defects.
RRM 1
FRE nippon 11 Note:
1. For each & every defect/ phenomena we are
FRE 1500N 0 4 Phenomenon trend
plotting the Pareto & taking Corrective actions for
20N back 0 3 3 3 3 Actuator signal not passing 2
all the problems.
10N back 0 Actuator noise 4 25
2 2 22 2. If the warranty is claimed after CAPA
RRE 3 2 ouside release free play 3
Implementation date then it is considered as Alarm
FLM 3 1 1 1 Found ok 22 20
condition & necessary action will be taken.
950N back 0 Latch damage can,t able to analyse 5
210N back 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 15
141N back 0
200N back 0 TOTAL 36 10
FRE 0
FRE 950N 0 5
5 4
3
RRE 0 2
RLM 0
0
FRM 0
1 2 3 4 5 6 7
TOTAL 36
Kilometerwise trend
14
25 K to 50 K 7 Zone wise trend
25
10 K to 25 K 12 12 North 20 20
Conclusion: 50% of rejections have failed in b/w 20
5 K to 10 K 4 25K-50K Kms Range. West 6
Alarm Condition
10 15 Conclusion: Considering the Top 3 Dealer's from a

NO TAG 2 27% of rejections have failed in b/w 25k to 50k Kms South 4
10 6 particular Zone contributing Warranty claims more
0 to 1K 7 8 East 2 4 4
5 2 than 10% of the total is considered as Alarm Cond
1 K to 5 K 4 Note: Central 4
6 0 & necessary action will be taken.
50 K to 75 K 0 1. Warranty Claims less than 1000Kms is considered north east
as Alarm Condition & actions will be taken for the North West South East Central north
75K to 100 K 0 4
east
same.
2 2. Warranty target could be fixed based on
0
percentage but it is not the appropriate method.
1 2 3 4 5 6 7 8 9 10 11 12 13 Warranty Cost MIS Trend 12
16000
FRM 1520.04 0 to 3 7
10
Total 36 Back Manual 242.27 14000 4 to 6 10
10
FLE 709.41 7 to 9 2
Back ele w/o irc 1828.08 12000 10 to 12 4
Pareto for Supplier Rejections 8
Monthly Defect wise Pareto Graph Back ele 1977.81 13 to 15 4 7
10000
Defects Qty % Cum. % RLE 1268.88 16 to 18 1
6
Not Working 19 52.8 52.8 RLM 271.95 19 to 21 1 5
20 19 120.0 8000
Not Open From Inside 4 11.1 63.9 RRM 271.95 22 to 24 2 4 4
18 4
nor open from outside 8 22.2 86.1 FRE nippon 13879.58 6000 After 2Yrs 5
100.0
not lock by remote 5 13.9 100.0 16 RRE 1903.32 Total 36 2 2
4000 2
0.0 100.0 1 1
14 FLM 760.02
0.0 100.0 80.0 2000 0
0.0 100.0 12
0 to 4 to 7 to 10 13 16 19 22 After
0
0
0
0
0
0
0
0
0
0
0
0.0 100.0 10 60.0 3 6 9 to to to to to 2Yrs
8 12 15 18 21 24
0.0 100.0 8
Total 24633
Cumulative %
40.0
Qty
6 5
4
4
20.0 Conclusion: 11% of rejections has been claimed by the Dealer dehradum premier Visit Dealer Appropriately. If any Dealer causing Warranty Claim more than
2 10% is considered as Alarm Condition.
0 0.0
Total 36
A
Dealerwise trend
Cai Industries 1
4.5
Dehradun Premier 1
DPC Motors 1 4
4
Garapati Autoventures 1
Global Gallarie
India Garage
4
1
3.5
3 3
23
JS Fourwheel 1 3
Koncept Automobiles 1
KS motors 3 2.5
MPL Automobiles 1 2 2 2 2
Pareto for Supplier Rejections 8
Monthly Defect wise Pareto Graph Back ele 1977.81 13 to 15 4 7
10000
Defects Qty % Cum. % RLE 1268.88 16 to 18 1
6
Not Working 19 52.8 52.8 RLM 271.95 19 to 21 1 5
20 19 120.0 8000
EVAOpen
R Not LU From
PLIE nor openAfrom
Inside 4 11.1 63.9 RRM 271.95 22 to 24 2 4 4
TIO outside 18 4
UP
8 22.2 86.1 FRE nippon 13879.58 6000 After 2Yrs 5
100.0
not lock by remote 5 13.9 100.0 16 RRE 1903.32 Total 36 2 2
2
NS
AS
4000 1 1
0.0 100.0 FLM 760.02
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0.0 100.0 80.0 2000 0
MSES
0.0 100.0 12
DARD
0 to 4 to 7 to 10 13 16 19 22 After
0
0
0
0
0
0
0
0
0
0
0
0.0 100.0 10 60.0 3 6 9 to to to to to 2Yrs
8 12 15 18 21 24
0.0 100.0 8
Total 24633
Cumulative %
40.0
Qty
6 5
4
4
20.0 Conclusion: 11% of rejections has been claimed by the Dealer dehradum premier Visit Dealer Appropriately. If any Dealer causing Warranty Claim more than
2 10% is considered as Alarm Condition.
0 0.0
Contd... A
Total 36
Dealerwise trend
Cai Industries 1
4.5
Dehradun Premier 1
DPC Motors 1 4
4
Garapati Autoventures 1
Global Gallarie 4 3.5
India Garage 1
3 3
JS Fourwheel 1 3
Koncept Automobiles 1
KS motors 3 2.5
MPL Automobiles 1 2 2 2 2
Narain Automobiles 2 2
Nataraj Mobiles 1 0.111111111
NO tag 2 1.5
Patwa Automobiles 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
Pratik Automobiles 2
Provincial Automobiles 1
0.5
Royal Automobiles 1
Sablok cars 1 0
Silver Jublee 1
Sri durga 1
Sterling Motor 3
Tirupati Automobiles 1
Trendy Wheels 1
Tvs Sundram 1
United Automobiles 1
Total 36
Problem Description MANUFACTURED MONTH
Mar-08 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Year'07/Blanks/Year'00/Year'04 Total
Found ok 1 1 1 1 1 1 2 14 22
Actuator Failure 1 1 1 3
Actuator soldering missing 1 1 2
Actuator working noise 0
Clow singal unlock From both side 2 3
Inside release lever stuck 1 1
Outside not open 1 1
Not opening by key 2 2
Blanks 1 1
Lock lever broken 0 0
TOTAL 0 1 0 0 0 0 0 0 0 1 0 0 1 2 1 1 0 2 0 2 1 4 0 18 34
40
35 Lock lever broken
30 Blanks
Not opening by key
25
Outside not open
20 Inside release lever stuck
15 Clow singal unlock From both side

Actuator working noise
10
Actuator soldering missing
5 Actuator Failure
0 Found ok
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Ammendment details:
ISSUE NO & DT DT PG PT
Sl No. Details of change Reason for change Changed By
B/F A/F B/F A/F NO NO
24
2.3 Cause Analysis of Returned Parts (Sequence should be Warranty, Delivery and In-House Defects)
PURPOSE
• To assure the System of Proactive collection and analyzing of Warranty & Delivery returned parts.
• To ensure the use of Detailed Cause Analysis / problem solving technique to identify the real Root Cause for Customer & In House complaints.
• To assure the Analysis of NTF concerns.
• Defined frequency to collect Warranty • Cause Analysis procedure (Ex 11A).
& Customer returned parts. • Cause Analysis Flowchart (Ex 11B).
• Mechanism to make analysis with • Detail Root Cause Analysis report (eg. 8D) for Warranty, Customer & Internal
defined frequency for Warranty concerns (Ex 12).
& Delivery (Warranty - monthly / • Phenomenon wise analysis Flow Chart (Ex 13).
customer PPM - monthly). • Approved recommendation sheet (by Customer SCM / STA & buyer) with Dos &
• Defined Standard procedure for Root Don’ts (Ex 14).
Cause Analysis. (Non detection & • Customer Line Verification Plan (Ex 15).
occurrence, cause validations)
• Customer line verification Check Sheet and Agenda for visit (Ex 16).
• Use of such defined guideline for
• NTF & DNR Target , Monitoring sheet with action plan to reduce the same (Ex 17).
analysis of warranty PPM (all defects),
Customer PPM (all defects & Internal • Master Ishikawa for Part level Repetitive concerns (Ex 18).
Concerns major contributors.
• Availability of Targets Set for NTF or DNR reduction and Monthly Monitoring with
action plan in case of non achievement.
• Availability of part wise or commodity wise Dos & Don’ts signed off with customer.
• Defined agenda for Line Visit.
• Availability of Customer line verification plan and actual status.
• Defined and applied analysis method by Phenomenon (for assembly / system
related defects) / Master Ishikawa for Part level, and its application.
25
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Example 11A - Cause Anaysis Procedure

CAUSE ANAYSIS PROCEDURE SOP
PROCESS APPROACH FOR ANALYSIS OF PROD/PROCESS PROBLEMS & INITIATION OF CORRECTIVE & PREVENTIVE ACTIONS Date
Page
TS CLAUSE NO. 8.4, 8.5.2, 8.5.2.1, 8.5.2.2 , 8.5.2.3, 8.5.2.4 & 8.5.3 ISO 14001 CLAUSE NO. 4.5.3
Rev No.
Rev. No 04
1 PURPOSE
To establish and maintain a system for taking corrective and preventive actions.
actions
2 SCOPE
Applicable to Customer return , warranty return , as well as inhouse rejections ( Monthly Basis) .
3 PROCESS OWNER
3.1 Head quality assurance is overall responsible for implementation of this process approach.
32
3.2 R
Respective
i sectioni incharges
i h are responsible
ibl ffor iimplementing
l i off the
h immediate
i di andd permanent countermeasures decided
d id d by
b CFT/ team.
3.3 Respective section incharges are responsible for analyzing the potential non-conformances with concerned CFT and submit the countermeasure report to head quality assurance.
3.4 Other specific responsibilities are as given in the procedure by means of flow chart.
4 Quality Records
Doc.No. Description Retention Period Responsibility Location Method Of Disposal
F07-8204 Defect information cum countermeasure report Current financial year+1 year back Relavent sec.head Defined place Sale to scrapper
F02-7103 Action plan Current financial year+1 year back Relavent sec.head Defined place Sale to scrapper
5 DEFINITION
QC Quality control CL Customer Line
Activity responsible department WR Warranty Return.
CFT Cross functional team IN HO
IN-HO In House
In-House.
QA Quality assurance
FMEA Failure mode effect analysis
OCI Operation
p control instruction
CP Control plan
6 Effectiveness & Efficiency Indicators /Performance Indicators

Performance
P f iindicators
di t Relavent
R l To Q/E
tT Detail
D t il off P
Performance
f IIndicators
di t Responsibility
R ibilit Frequency
F Reference
R f Documents
D u t
No.of fool proofing done in the process Respective Monthly Summary of poka-yoke
Effectiveness Q
No.of preventive actions taken incharge Monthly
y DICR reports
Q-Quality Management System Requirement , E-EMS Requirement

7 REFERENCES
----------
------------ Refer Annexure for Ex 11A
8 AMENDMENT RECORD
26 Amendment Date Amd No Amd Details Reason For Amd Amd By Approved By
04.01.10 03 Nill Periodical Review Bhupendar MR

Example 11B - Cause Analysis Flow Chart
INTEGRATED MANAGEMENT SYSTEM SOP
8.4, 8.5.2, 8.5.2.1, 8.5.2.2 , Page
TS CLAUSE NO. ISO 14001 CLAUSE NO. 4.5.3
8.5.2.3, 8.5.2.4 & 8.5.3
Rev. No.
Activity/ WHAT Output/Format
Sl. Responsibility CONTROL
INPUT QA Pur Engg Prod PPC Sales CFT All HOW WHERE WHEN WHY & Reference
no (WHO) /CRITERIA
1 2 3 4 5 7 19 20 Instruction
19
customer line complaints/ in- Analyse the complaint As & when complaint
Customer end & In
house mothly top 2 issues considering environmental Using QC tools through received from customer & To resolve the
1 CFT . house at relavent F07-8204 ----------
based on pareto / Warranty aspects if applicable. DICAR For inhouse , take a major issue
stages.
Complaints. rejections monthly once.
19 1.Implement the 100 %

Identify and implement the
inspection/ Prepare one point
interim countermeasure for
lesson / Work instructions
output flow & occurrence. Within 12 hrs of defect To resolve the
2 CFT Defect details. for prevent the output flow At relavent stage F07-8204 ----------
noticed issue
2.Implement Error Proofing
(or) kaizen for prevent the
occurrence.
19
If NO
Is Interim Effectiveness varification No repeatation
Interim Corrective action corrective action Simulation test / To confirm the
3 CFT At relavent stage continue one shift of F07-8204 of non
details effective ? effectiveness varification countermeasure
after action taken conformance
If Yes
19
Do the brain storming for why C
defect occured ? & Why defect As & when complaint To identify the
4 CFT. Non-Conformity detials Identify the Probable causes At relavent stage …………. ……………..
not detected ? received probable causes.
19
Draw the Cause and effect
Immidiate and after the
diagram for why defect occured To identify the
5 CFT Probable causes of the defect 4M Method At relavent stage identification of probable F07-8204
? & Why defect not detected ? potential causes.
causes.
19
Carried out the validation for To validate the
Verify the status , by Immidiate and after the
Potential causes for each cause of occurrence ,non Each and every potential cuase
6 CFT detection and findout the status specification of the potential identification of potential F07-8204
subclauses potential cause and find out the
causes VS observations. causes.
root cause.
19
If status non
significant, If status significant ,Conduct
validate the WHY WHY analysis for the
next causes
potential causes for why defect Immidiate and after the
Potential cause specification"s Observation To find out the
7 CFT occurred ? And why defect not 5 Why-Why. validation of potential F07-8204
observation status detected? potential causes root cause.
causes.
Prepared By Checked By Approved By Format Rev.

A
27
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INTEGRATED MANAGEMENT SYSTEM SOP

Contd... 8.4, 8.5.2, 8.5.2.1, 8.5.2.2 , A Page
TS CLAUSE NO. ISO 14001 CLAUSE NO. 4.5.3
8.5.2.3, 8.5.2.4 & 8.5.3
Rev. No.
Activity/ WHAT Output/Format
Sl. Responsibility CONTROL
INPUT QA Pur Engg Prod PPC Sales CFT All HOW WHERE WHEN WHY & Reference
no (WHO) /CRITERIA
1 2 3 4 5 7 19 20 Instruction
A
19
CFT / Appropriate action to To avoid re-
Identify and implement the
8 sec.incharge - Root cause of defects eliminate the reoccurence of At relavent stage With in 14 working days occurance of F07-8204 ---------
permanent corrective
relavent area action for occurrence and non conformance defect
non detection.
19
Communicate the results Through mail
CFT / Immidiate after Proper
to customer if it is a correspondence / Visit the
9 sec.incharge - F01-8501 Customer end. established the corrective communication F07-8204
customer complaint (or) customer , if customer is in
relavent area Warranty Complaint. action. given to customer.
local place.
19
If No Effectiveness varification No repeatation

Sec.incharge- Is corrective Simulation test / To confirm the
10 Corrective action details action effective ? C At relavent stage continue three month of F07-8204 of non
Q.A./CFT effectiveness varification countermeasure
action taken conformance
YES
B
19
Identify the similar application in Identify in all area by To avoid re-
Sec.incharge- Simillar process the product/ process/systems & After 3 months of
11 make action plan . considering environmental Similar area occurance of same F02-7103 ---------
Q.A./CFT ,product,defect,systems. effectiveness verification
aspects defect
19 For timely
12 CFT Action plan Review the status of actions Plan vs actual status At relavent stage Decided time frequency execution of F02-7103 -------
activities
19
NO
Implement as
13 CFT Activity status per plan Plan vs actual status At relavent stage Decided time frequency ---Do--- --------- --------
19 YES
Review and update process FMEA,
control plan, Work instructions , PFMEA , CP
process sheets ,PFD,Inspection
Incorporate all actions in As per decided time To update the ,Work
14 CFT Countermeasure details B reports,maintenance check sheets, Related documents ---------
tool drawing, fixture drawing as documents frame-F01-8501 documents instructions ,
applicable. process sheet
END
28
Example 12 - Detail Root Cause Analysis Report (8D Report)
DICR NO. : Phenomenon Part No. & Name
DEFECT INFORMATION CUM COUNTERMEASURE REPORT (8D Report) Supplier/Sub-Supplier Name: Defect Model & Customer
Occurance Date Defectective Qty.
Phenomenon Occur 1st time Phenomenon Occur 2nd time Phenomenon Repeat Informed By Occurance Place Batch Code
STEP-1 ( PROBLEM DESCRIPTION ) STEP-2 PROCESS FLOW DIAGRAM : STEP-3 IMMEDIATE ACTION Prepared By Reviewed By Approved By
Id mark
Parts checked Batch
Date OK NG on OK Remark
NG PART PHOTO OK PART PHOTO (Location) Code
part
Customer End (Name & Signature) (Name & Signature) (Name & Signature)
Detail : On line at Sona CFT Members Name & Department :
Store (SONA) 1.
Godown(Vendor) 2.
Factory(Vendor) 3.
4.
STEP-4 ( CAUSE ANALYSIS PROCESS/ OCCURANCE ) STEP-5 ( Cause Validation Of Occurance) Why-Why Analysis
Cause Sub Cause Specification Observation Status (Yes/No) Why Why Why Why Why
MACHINE MATERIAL MAN
Man
Machine
Material
Method
Measure-
MEASUREMENT ment
METHOD
STEP-6 ( CAUSE ANALYSIS(INSPECTION OVER LOOK /DEFECT OUTFLOW ) ) STEP-7 ( Cause Validation Of Ouflow) Why-Why Analysis
Man
Machine
Material
Method
Measure-
ment
METHOD MEASUREMENT
Step-8 Countermeasure taken (Against Occurance) Step-9 Countermeasure taken (Against Outflow) STEP-10 Standardisation STEP-11 Horizontal Deployment
A
Applicable ( Machine
S.No. Temporary Action Resp. T.Date Status S.No. Temporary Action Resp. T.Date Status S.No. Document Resp. T.Date Status Part No. & Name Resp. T.Date Status
Yes/No) /Area
1 Process Flow Diagram
2 PFMEA
3 Control Plan
4 Quality Check Sheet
S.No. Permanent Action Resp. T.Date Status S.No. Permanent Action Resp. T.Date Status 5 Machine check sheet
STEP-12 Check Effectiveness
6 One point lesson M1 M2 M3 M4 M6 M9 M12
29
7 RQA Inspection std.
8 Final Inspection Standard

Method
Measure-
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Man
Machine
Material
Method
Contd... Measure- A
ment
METHOD MEASUREMENT
Step-8 Countermeasure taken (Against Occurance) Step-9 Countermeasure taken (Against Outflow) STEP-10 Standardisation STEP-11 Horizontal Deployment
Applicable ( Machine
S.No. Temporary Action Resp. T.Date Status S.No. Temporary Action Resp. T.Date Status S.No. Document Resp. T.Date Status Part No. & Name Resp. T.Date Status
Yes/No) /Area
1 Process Flow Diagram
2 PFMEA
3 Control Plan
4 Quality Check Sheet
S.No. Permanent Action Resp. T.Date Status S.No. Permanent Action Resp. T.Date Status 5 Machine check sheet
STEP-12 Check Effectiveness
6 One point lesson M1 M2 M3 M4 M6 M9 M12
7 RQA Inspection std.
8 Final Inspection Standard

STEP-13 Pl. Circle Appropriate Root Cause
9 Work Instrucions
10 SOP-QMS .
11 Product Drawings
12 Cutting Tool Dwgs
13 Non-Cutting Tool Dwgs MAN MATERIAL MACHINE METHOD MEASUREMENT
14 Gauges Dwgs
15 Past Trouble data Updation
Rev No : 01
30
Example 13 - Phenomenon Wise Analysis Flow Chart
PHENOMENON WISE ANALYSIS
Department Name :- MOULDING
Reported Problem :- Broken Phenomenon :- CRACK
Analysis flow of CRACK

Problem Found at
Customer End
Problem :- Broken
Defective Components
received from customer
All Usual Parameters.

1) Check for the location of defect on
Compare defective Sample component.
against defect library 2) Check for performance..
Visual inspection of the If Flat Mark not observed, Inform to

1) Check for the compound. components / Part Customer & arrange a joint meeting to
2) Check for the process parameter
(Temp, Cure time)
resolve the problem with evidence
3) Check for operating process of operator.
4) Check for the tool. CRACK observed
Check for : Process setting parameters
1.Check for processing parameter
2.Temperature 3. Cycle time.
Check for : Check for :

1. Different chemical lab approval Collect the data for analysis
Check for :1.Curing Time, 2.Loading 1.Burr
2.Check for physical properties. at various stages.
weight, 3.pressure, 4. Temperature, 5. 2.Shrap edges
Operating method 3. Damage mark
Verify the Compound used. Verify the compound Verify the Moulding Process & Verify the tool used.
Manufacturing process Operating method
Yes Yes Yes Yes

If it is ok….? If it is ok….? If it is ok….?
If it is ok….?
NO NO NO NO
Give refresh training Call CFT & Technical

Modify the compound & Set the same parameters /Retraining to operators & Rectify the tool & Take necessary
Revalidate , verify & Revalidate action and revalidate the tool Person for further
revalidate analysis
Prepared By Approved By
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Example 14 - Approved Recommendation Sheet with DO’s & DONT’s

Recommendation Sheet for Lock Set
Sr. no. DO'S DON’T
Always ensure the Crorugated cap on the Plastic Socket Do not take without cap part for assembly
hmaoSaa Qyaana do kI plaasTIk saa^koT pr kaorugaoToD k^p lagaa huAa hO. kop ko ibanaa paT- AsaoMbaila ko ilayoa na lao.
This will Damage /bend the terminals of the plastic socket causing electrical assembly failure.
RISK
yah plaasTIk saa^koT ko Trimanala kao baoMD yaa D^maoja krgaa ijasasao [laokT/Ikla AsaoMblaI nahI haogaI .
Do not clamp the assembly if the lock set is not located in the stearing
Ensure perfect guide when lock set is placed in the fixture.
column
laa^k saoT kao iFkscar mao rKnao sao phlao ]saka gaa[D saih hO yaa naih yao
yaid laa^k saoT sToirnga ka^lama mao laaokoT naih hao rha tao Asaomabaila na kro.
jaaca lao.
2 Location for
Stearing lock Locking Screws
assly
This will creat high interference between Latch lock & stearing column due to which stearing lock will not operate.
RISK
[sao la^ca laa^k Aoaor sToirnga ka^lama ko ibaca kaif jyaada [MTrfosa banaogaa ijasasao sToArIMga laa^k Aa^proT nahI haogaa .
Do not place the parts at any other position ( the terminals may touch
During Handling always keep the lock set in this position
the floor)
laa^k saoT kao [stmaala krto samaya inacao idKayao tirkosao hI rKo. paT- kao ikisaBaI AaoOr paoJaISana maoo na rKo Trimanala jaimana kao laga sakta hoO.
3
This will Damage /bend the terminals of the plastic socket causing electrical assembly failure.
RISK
yah plaasTIk saa^koT ko Trimanala kao baoMD yaa D^maoja krgaa ijasasao [laokT/Ikla AsaoMblaI nahI haogaI .
Approval
M&M - Stores ( Name,Sign & Date ) M&M -TCF ( Name,Sign & Date )
32
Example 15 - Car Maker Line Verification Plan
Doc. No:
CAR MAKER LINE CONFIRMATION VISIT PLAN & AGENDA Rev. No:
Rev. Date:
CUSTOMER VISIT PLAN FOR YEAR 2010-11
Customer Place Frequency April May June July August September October November December January February March
ABC Pune M
XYZ Pune M
DEF Pune M
EFG Pune M
HIJ Baramati M
ABAB Kandiwali AM
GAP Nasik Q
MNO Nasik Q
PQR Zahirabad Q
TUV Pithampur Q
SRK Aurangabad Q
NOTE: M= Monthly, Q=Quarterly
Indicates visited.
Indicates not visited.
Agenda for discussion during visit to customer :

1) Discussion on earlier open points with customer if any.
2) Interaction with receiving inspection , line people of customer.
3) Understand the Quality concern if any and initiate action for resolution of the same.
4)Verification of Do's & Don'ts in customer premises from receipt of material up to assembly.
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Example 16 - Customer Line Verification Checksheet & Agenda

Doc No : F/QA/268
CUSTOMER VISIT CHECKLIST Rev No: 00
Rev Date:
S. Quality Communication Log TARGET

CHECKPOINT OBSERVATION CORRECTIVE ACTION RESPONSIBILITY
NO No DATE
1 WARRANTY ISSUE
2 LINE REJECTION
3 PACKAGING ISSUES
4 USAGE OF PARTS
5 EFFECTIVENSS OF IMPLEMENTED ACTIONS
6 CUSTOMER AUDIT STATUS
7 SUGGESTION FOR IMPROVEMENT
8 . CHECK POINTS
a Are the Boxes properly unloading at Store
b Are the boxes properly stacked at store with pallets
c Are the boxes properly transferred from store to line
d Is the Conditions of line container proper
d Are parts stored with facing upwards
Operarator handling the part properly without any

e
damages before assembly
Is the Low point being matched with high point on
f
tyre while assembling
Is the torquing sequence being followed by line
g
operator while fitting part
h Is torque set as per specification
i Part assemled as per defined instructions
34
Example 17 - NTF & DNR Monitoring Sheet with Action Plan
NTF Warranty Trend - Monthwise Qty
NTF QTY. Vs MONTHWISE FROM AUG'10 TO JULY'11

40
35
34
NTF TARGET 4 NOS PER MONTH
30
25
22
Qty
20
QTY
Target
15
10
7
5 4
7
5
2
0 0 0 0 0
0
A 10
Aug-10 S 10
Sep-10 O 10
Oct-10 N 10
Nov-10 D 10
Dec-10 J 11
Jan-11 F b 11
Feb-11 M 11
Mar-11 A 11
Apr-11 M 11
May-11 J 11
Jun-11 J l 11
Jul-11
ACTION PLAN
S.No. Action Owner Target Status
For tempered cases discuss with Customer warranty & team that
1 ABC 15-Aug-10 Inprocess
training to be given to dealer how to dismentale the part from vehicle
For found ok pieces check on vehicle with Customer warranty team &
2 XYZ 16-Dec-10 Started and rejecting claim at Customer
Team for confirming no defect
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Example 18 - Master Ishikawa for Part Level Repetitive Concerns

Doc No:
MASTER ISHIKAWA Rev.No :
Rev. Date:
CAUSE & EFFECT DIAGRAM / ISHIKAWA for OIL MARK
PROCEDURE NOT UPDATED
MACHINE MOULD HEAT UP MAN PROCEDURE NOT AVAILABLE AT WORK STATION
HIGH OIL TEMPERATURE CYCLE DELAY
INSERT HIGH SIDE MTC SET NO REFRESH TRAINING UNTRAINED PERSON
NOT CLEANED PROPERLY LONG LEAVE WORK INSTRUCTION NOT AVAILABLE
POOR QUALITY OILY SURFACE ON THE MOULD NOT FOLLOWED WRONG MATERIAL FEED
PUNCTURED HOSE SILICON SPRAY USED PROCEDURE VIOLATION UNTRAINED PERSON
WARN OUT NEGLIGENCE UNTRAINED EMPLOYEE
EXCESS OIL SCATTERED AROUND THE M/C LACK OF AWARENESS NEW MAN HANDLING
GREASING ON EJECTOR ASSY INSTRUCTION NOT FOLLOWED SHORTAGE OF MANPOWER
GREASE COMING OUT UNTRAINED RELEAVER ATTEND AFTER LONG LEAVE
LOOSE FITTING EJECTOR PIN LACK OF HELPER LACK OF AWARENESS
MOULD HOSE PROBLEM SKIP OUT OPERATION NEW MAN INVOLVED
SEAL BROKEN NOT FEELING WEEL
LACK OF AWARENESS OIL MARK
HAND GLOVES NOT BEEN USED
NOT AVAILABLE
HIGH PRESSURE SETTING WRONG GRADE

UNCLEANED BINS USED
PROCEDURE NOT UPDATED

FALLEN PART FIRST TIME OBSERVED
SETU UP PARTS MIX-UP
WRONG PROCEDURE ADOPTED
SAME PART OF OTHER MODEL
METHOD MATERIAL
Date : Reviewed By: Approved By :
36
2.4 Prevention of Recurrence
PURPOSE
• To assure the mechanism to identify the Occurrence and Non Detection level Causes during Analysis.
• To assure the system to avoid the repetition of concerns by monitoring effectiveness and systemic actions through relevant document Updations.
• To assure the mechanism of Utilization of Past Concerns for New product development.
• Mechanism of identifying the Root Causes for Occurrence & Non Detection. • Horizontal Deployment in CAR.
• Defined Criteria to monitor effectiveness (where to check, what to check, how long • Monitoring system for warranty, Customer & Internal concerns.
to check and condition to restore). • Updated documents based on Corrective & Preventive actions.
• Availability of effectiveness monitoring evidence for Corrective & Preventive actions. • Updated PTDB (Ex 19).
• Defined and applied actions for Horizontal Deployment to similar parts, processes • Lessons Learned (Things gone Right & Wrong).
or plants. • Technical Know-How Document (Ex 20).
• Mechanism to update relevant documents (Eg. CP , PFMEA, PFC, PTDB etc) based
on the actions taken on the quality concerns during analysis.
• Defined responsibility for PTDB updation.
• Technical Know How based on the design (Process + Product) level actions on the
defects.
• Availability of Check list for New Product development to ensure the usage of all
such past Lessons Learned.
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Example 19 - Past Trouble Database

PAST TROUBLE DATABASE
APPLICABILITY REVIEW FOR NEW PROJECT
ABC PROJECT XYZ PROJECT
Work Instruction
Control Plan
Category ( Warrnty Corrective
Root Cause Of
PFMEA
/Customer Model Part Custome Root Cause Of Corrective Action Action Lessons Technical Implementati Implementation
4M
S.No Updated On Part No Nature of defect Qty DICR No. / QPCR Non Name of the Name of the
complaint / In- Name Name r Occurrence of Occurrence of Non Learnt Know-How on status - Remarks status -Put Yes / Remarks
Detection new project new project
House Rejections ) Detection Put Yes / No No
It is addressed
It is addressed in
1 10.1.2011 In-house 7 DICR NO:-1 YES NA NA YES Yes Yes in the FMEA &
the FMEA & line
line
It is addressed
It is addressed in
2 10.1.2011 In-house 12 DICR NO:02 YES NA YES NA Yes Yes in the FMEA &
the FMEA & line
line
It is addressed
It is addressed in
3 08.02.2011 Customer complaint 1 1 YES YES NA YES Yes Yes in the FMEA &
the FMEA & line
line
It is addressed
It is addressed in
4 12.2.2011 In-house 17 DICR NO:03 YES NA NA YES Yes Yes in the FMEA &
the FMEA & line
line
It is addressed
It is addressed in
5 12.2.2011 Warranty 18 DICR NO:04 YES NA NA YES Yes Yes in the FMEA &
the FMEA & line
line
No.Of Past TGW : 47 CFT Members & Sign
No.Of Past TGW Considered (YES) : 45
No.Of Past TGW Not Considered (NO) : 2
Applicable TGW nos : 45
Feed Back Ratio ( in %) : 100%
Format No.: REV No 00
38
Example 20 - Technical Know-How Document
Doc No:
TECHNICAL KNOW HOW DOCUMENT Rev No:
Rev Date:
REF NO: TKH/QA/002 DATE:
PART NO: ALL PRODUCTS PART NAME: STEEL WHEEL MODEL: ALL MODELS CUSTOMER: INTERNAL PROBLEM
BEFORE AFTER
Rectangular slide
More Contact Area
Less Contact Area
Round slide
Problem Faced:-
Weld Shift observed in assembly welding. The problem was observed coming intermittently
Countermeasure Taken:-
1. To replace the rectangular slide rail of assembly welder I with round bars
2 To modify the fasteners to accommodate the round section
Lessons Learned / Technical Knowhow :-

Friction factor has to be considered wherever relative motion between component and machine part is involved, in order to arrest the change in orientation of the
component. This has been added as design input.
Deployment to New Project :-
1. For new machines / manufacturing line. 2. New Development Design Input Checklist.
Prepared By Reviewed By Approved By
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2.5 Progress Control of Target Defects
PURPOSE
• To assure the Mechanism of tracking all the steps during the analysis and ensure the closure of the actions as per defined timelines for each step.
• Availability of progress control list inclusive of all Quality concerns (Warranty, • Updated Progress control sheet (Refer Ex 8).
Customer & Internal). • Effectiveness monitoring mechanism for each defect.
• Defined target time for each step of analysis Eg. Target timeline for steps from • Time line defined for each step in the Cause Analysis Procedure.
immediate containment, cause analysis till PTDB updation and closure with
customer in case of warranty & delivery concerns.
• Availability of Permanent countermeasures as per defined target timelines.
• Mechanism of review of such compiled Progress Control Sheet is existing and
status is known to all related persons.
• Mechanism of Confirming the effectiveness of counter measure (eg. criteria is
defined – where to check , what to check , how long to check and condition of
acceptance etc).
40
Chapter 3
Quality Assurance at the Process Development Stage

Objective: To ensure that all Failure Modes are Identified and Controls including Prevention are established during process
development.
3.1 Process FMEA
PURPOSE
• To assure that PFMEA has been made with a true intent of identifying all possible Failure Modes and the Preventive and Detection controls are available to overcome the
possible causes of failure mode.
• To assure that all previous failure modes on similar products have been considered while preparing PFMEA and the applicable controls are in place.
• Availability of Process FMEA Standard (5W1H). • FMEA Procedure (Ex 21).
• Availability of Core team is identified and defined Selection standard based on • FMEA checksheet (Ex 22).
knowledge. • Review plan.
• Defined RPN Rule meeting customer specific requirement. • PTDB (Refer Ex 19).
• Availability of defined rating tables for Severity, Occurrence and Detection based • Occurrence matrix (Ex 23).
on latest AIAG Guidelines.
• Availability of PFMEA Review check sheet.
• Defined review frequency and conditions for PFMEA Review and it is followed.
• Availability of Countermeasure setup according to the defined RPN threshold, All
RPN is under target score.
• Recommended actions are implemented as per timeline & RPN is updated with
monitoring mechanism established.
• Availability of backup data for Occurrence based on causes and defects.
• All past trouble database are feedback to FMEA (all the failure modes of actual
product are included in FMEA sheet) with feedback ratio of 100%.
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Example 21 - PFMEA - Procedure

PFMEA PROCEDURE SOP
PROCESS APPROACH FOR PFMEA MAKING Date
TS CLAUSE NO. 7.3.1.1 /7.3.3.2 ISO 14001 CLAUSE NO. Page

Rev. No.
Activity/ WHAT Output/Format &
Sl.n Responsibility CONTROL
INPUT Q Pur Engg Prod PPC MR CFT All HOW WHERE WHEN WHY Reference
o (WHO) /CRITERIA
1 2 3 4 5 18 19 20 Instruction
GuideLine for skill

Formulate the CFT Based on Skill Requirement such as
New Products built, Existing Whenever formulate newly requirement.
Head members. Hard skill , soft skill and Technical
1 product(or) process Project Room (or) added/deleted the To form the CFT F1-7101B ……………….
Engineering skills in cause & Effect analysis,
modification stage. members list. F10-7101B
Ranking stages.
F09-7101B
19 F01-7101B
Master schedule ,PFMEA F06-7101B
1.Past Trouble Data base with guide
input check sheet , CFT F06A-7101B
Start to prepare line of update & Diploy the horizantal
members list, simillar process At the time of making fresh F03-7101C
2 CFT diployment ,2. Drawing, 3.Similar part Project Room To make PFMEA ……………….
PFMEA, List of poke yoke , PFMEA. F02A-WI/SOP-
comparision,(Detection & prevention
lesson learnt and past trouble 7101B/01
mechanisim,
data base F07-7101B
WI/SOP-7101B/02
19
Identify the At the time of making fresh
3 CFT Process flow diagram. Operation Name / Using process flow chart. New project -PFMEA PFMEA./ Revised the To make PFMEA F20-7101 ……………….
Number.
existing PMEA.
Customer (or) internal 19 At the time of making fresh Every product

Identify the Customer (or) internal drawings /
4 CFT drawings / Simillar part Process/Function New project -PFMEA PFMEA./ Revised the characteristics fialure ………………. ……………….
Simillar part PMEA
PMEA requirement. existing PMEA. modes to be analysed.
19
F01-7101B
To prevent the F06-7101B
past trouble datas , simillar CFT inputs / Past trouble datas At the time of making fresh
Identify the Potential re-occurrence,warranty F06A-7101B
5 CFT part pfmea,List of poke yoke, simillar part pfmea,List of poke yoke, New project -PFMEA PFMEA./ Revised the ……………….
failures,customer F03-7101C
lesson learnt lesson learnt existing PMEA.
complaints. F02A-WI/SOP-
7101B/01
19
Simillar part PMEA ,Customer To identify the potential F06-7101B
6 CFT
feedback,Field informations
Potential effects Based on product knowledge New project -PFMEA PFMEA./ Revised the
risk. F06A-7101B
……………….
of failure existing PMEA.
19
Based on product functions failure with
Identify the Sev respect to next process , assembly line
At the time of making fresh
Simillar part PMEA ,Customer Rating (S). ,Customer line and enduser .Ranking To identify the severity
7 CFT AIAG -latest manual. PFMEA./ Revised the F03-7101B ……………….
feedback,Field informations should be given for all effects of effects
existing PMEA.
failures and highest ranking should be
taken as severity ranking
19
Identify and mentioned At the time of making fresh To identify the safety &
Customer (or) internal
8 CFT the Class. Customer (or) internal drawing New project -PFMEA PFMEA./ Revised the regulatory and to decide ……………….
drawing
existing PMEA. on Sev rating
19
F01-7101B
Identify the potential To prenvent the re- F06-7101B
past trouble datas , simillar Cause(s)/Mechanism(s) At the time of making fresh
past trouble datas , simillar part pfmea, occurrence .To identify F03-7101C
9 CFT part pfmea, list of poke yoke New project -PFMEA PFMEA./ Revised the ……………….
of Failure and implement list of poke yoke and lesson learnt. the process control F02A-WI/SOP-
42 and lesson learnt.
the same in new project
existing PMEA.
methos using 4M 7101B/01
F07-7101B
Collect and summarize the last 6

Example 22 - PFMEA Review Checksheet
Doc No:
Rev No: 01
PFMEA REVIEW CHECKSHEET Rev Date:
Project name: ABC Customer : ABBA
Part size : XYZ
OBSERVATION
S.NO CHECK POINT Standard COMMENTS
I quarter II quarter III quarter IV quarter
CFT team as per

1 Is CFT team being formed for making the PFMEA ?
procedure
Have process flow chart been considered while All processes defined in
2 making PFMEA ? ( Mention the Rev no. and rev dt PFC should reflect in
of the PFC ) PFMEA.
Have the engineering drawings/engineering

3 Drg No, Rev No & Dt
standards been considered while making PFMEA ?
Have list of special process characteristics have been

4 as per procedure
identifed ?
Have list of new equipment , Tooling and Facilities

5 as per procedure
Requirements been identfied ?
INPUT
Mention the PTD latest

6 Have all PTD information considered ?
updation date.
Mention PFMEA No.,

6 Have similar part PFMEA been considered?
Rev no., Rev dt.
Mention DFMEA No.,

6 Have DFMEA been considered?
Rev no., Rev dt.
Have Customer Complaints / internal rejections been

6 as per procedure
considered?
Have updated occurance backup sheet been Mention the latest

6
considered? updation date
Has the preliminary listing of product and process

6 as per procedure
parameters been considered?
Have potential failure mode been identifed for all

7 as per procedure
process defined in PFC ?
8 Have occurance rate being estimated correctly ? as per procedure
have control method applied as per the criticality of

9 as per procedure
the characteristics ?
ranking for severity ,

occurance and
10 Have ranking for PFMEA done correctly ?
detection as per
procedure
REVIEW
identification of special
Have special characteristics been identifed in the
11 characteristics as per
PFMEA ?
procedure
Are all special characteristics identified by the
12 as per procedure
symbol ?
Have RPN reduction plan been made for failure mode

13 criteria as per standard
which exceed the allowable RPN ?
Are target date , responsibility been defined for

14 as per procedure
counteraction ?
Has key date been replaced by the earliest date

15 as per procedure
mentioned in counteractions ?
Have next review date being defined for reviewing

16 as per procedure
the FMEA?
Prepared By: Reviewed By Approved By
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Example 23 - Occurrence Matrix

Total Quantity Rejected
Rejected parts in
Operation Defect Codes Produced in past pcs per 1000 pcs OCC No.
past 6 months
6 months
Improper Filling 4 10,172 0.39 5
Dia offset / Ovality 0 10,172 0.00 2
Heating & Upsetting
Dia oversize 0 10,172 0.00 2
Dia undersize 0 10,172 0.00 2
Heavy flash 0 10,172 0.00 2
Annealing High hardness 0 10,172 0.00 2
Microstructure not ok 0 10,172 0.00 2
Decarb not ok 3 10,172 0.29 5
Low hardness 0 10,172 0.00 2
Heating & Quenching Quenching crack in bar 0 10,172 0.00 2
Bend in torsion bar 0 10,172 0.00 2
Roller Mark on the bar 0 10,172 0.00 2
Low Core Hardness 2 10,172 0.20 4
Variation in hardness 0 10,172 0.00 2
Low Hardness 0 10,172 0.00 2
Pit Tempering High Hardness 0 10,172 0.00 2
Microstructure not ok 0 10,172 0.00 2
Bend Inspection Bend on torsion bar more than

specification 2 10,172 0.20 4
Bend Correction Deep mark on torsion bar 1 10,172 0.10 4
Stress Releaving Stresses not releaved totally 0 10,172 0.00 2
Coverage not as per specification 0 10,172 0.00 2

Shot Peening
Big particle indentation on rod. 0 10,172 0.00 2
44
3.2 Control Plan
PURPOSE
• To assure identification of Product-Process Characteristics and its control during the manufacturing process and necessary reaction plans for deviant conditions.
• Availability of procedure for preparing control plan including - Input, review • Control Plan procedure (Ex 24).
frequency, format, check sheet. • Control Plan review Checklist (Ex 25).
• Mechanism for identifying process parameters required for product parameters by • Product-Process relationship matrix (Ex 26).
Process validation or product-process characteristic relationship matrix etc. • Prototype-prelaunch-production Control Plan.
• Availability of Control plan from the beginning of process development phase • Guideline for assigning control method based on gravity (Ex 27).
(APQP phase 2- Prototype, Prelaunch and Production control plan).
• Availability of system for identifying control methods of product and process
parameters according to gravity (safety, functional, regulatory).
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Example 24 - Control Plan Procedure

Doc. No. :
ISSUE :
PRODUCTION CONTROL PLAN REV No :
DATE
5. ACTIVITY DETAILS:
Sl.
Item Process Flow
No
START
For New
Control Plan
1. New Product
1 Triggers 2. Engineering Changes
For Revision of
existing Control
Plan
CHANGES 1. Results of Corrective Actions

Change in Location 2. Results of Continuous Improvement
Change in Machine / Tooling 3. Customer Audits and Feedback
Change in Process Parameters 4. Customer Complaints
Change in Process Sequence / methods
5. Warranty Issues
1 6. Inputs from Internal Audits
7. VA / VE 8. FMEA Revision
1. DFMEA 8. Special Prod./Process Charecteristics

1 2. PFMEA 9. Guages and Testing Equipments
3. Engineering Drawing 10. Packaging standards & Specifications
2 Inputs 4. Engineering Specification 11. Process Flow Chart
5. Material Specification 12. Floor Plan Layout
6. Drawings an Spec. changes 13. Charecteristics matrix
7. Eqpts, Tooling & Facilities 14. Lessons Learned from Similar parts

R&D
Form Cross Functional Team with
46 representations from Manufacturing, QA, PE,
3 Team R&D, Maintenance, Tool Room, Purchase,
Example 25 - Control Plan Review Checklist
Format No.:
CONTROL PLAN REVIEW CHECKLIST Rev No:
Rev Date:
Project name: ABC Customer : XXXX

Part size : XYZ
S.NO Check point Evaluation points YES / NO COMMENTS
1 Is customer specifed format used for control plan ? As per procedure no Customer Specified format to be used.
2 Have latest process flow chart been considered while making control plan ? Specify Doc No, Rev No & dt yes
3 Have latest PFMEA considered ? Specify Doc No, Rev No & dt yes
4 Have latest DFMEA Considered? Specify Doc No, Rev No & dt yes
5 Havethe latest Engg Drawing been considered? Specify Doc No, Rev No & dt yes
INPUT
6 Have the latest Engg Spec been considered? Specify Doc No, Rev No & dt yes
Have list of new equipment , Tooling and Facilities Requirements been identfied
7 As per procedure yes
?
8 Have list of special process characteristics have been considered ? As per procedure yes
9 Have the guages and testing equipments been considered? As per procedure yes
10 Have the packaging standards been considered? Specify Doc No, Rev No & dt no Packaging Standard to be prepared.
11 Have the lessons learned from similar parts been considered? Specify Updation date yes
12 Have all process and product control parameter been defined ? As per procedure yes
Have special process and product control parameter been identified with the
symbols ?
14 Have specification for control parameter been defined ? As per procedure yes
REVIEW
15 Have correct evaluation measurement technique been defined ? As per procedure yes
For each of the evaluation measurement technique where sampling technique

has been adopted, Have sample size and frequency correctly defined ?
17 Have correct control method been identifed ? As per procedure yes
18 Have reaction plan been defined for out of control conditon ? As per procedure yes
Have observation observed during trial / ramp up been adressed in the control
19 As per procedure no
plan ?
Production control plan
20 Have controls been extended as per the result of process capability study ? As per procedure YES
REVIEW
21 Have result of MSA been considred while adopoting the evaluation system ? As per procedure YES
Have observation observed during ramp up been addressed in the control plan
22 As per procedure YES
?
Prepared by Reviewed By Approved By
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Example 26 - Product And Process Relationship Matrix

DOC. NO. QD/MR/05
PRODUCT AND PROCESS RELATIONSHIP MATRIX -- ASSY. SHOP REV. NO. - 00
DATE -
PROCESS PARAMETERS
RUST
TIP CO2 CO2 ANTI PROJECTION
AIR COOLING TIP COOLING CO2 PRE TIP WELDING WELDING F.R.P. COATING SEALENT PREVE
SR. CURRE WELD WELD DRESSI WIRE GAS HOLD OFF SQUEEZ SPATTER ELECTRODE PIN SEALEN DEDICATE SEALENT
PRODUCT PARAMETERS TIP DIA. VOLTAGE PRESSU WATER ALLING WATER IMPULSE WIRE SQUEEZ CHANGE FIXTURE GUN/STU COATIN THICKNE PRESSUR NTIVE
NO. NT CYCLE FORCE NG FEED FLOW TIME TIME TIME SPRAY /SPRINGCHANGE T TEMP. D PALLET GRADE
RE TEMP. EMENT FLOW DIA. TIME FREQ. P.M. D P.M. G FREQ. SS. E OILING
FREQ. SPEED RATE FREQ. FREQ.
FRQ,
1 SPOT OFF 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
2 SPOT BURR 3 0 3 3 2 0 3 0 2 0 0 0 0 0 0 0 0 0 0 1 0 2 1 0 0 0 0 0 0 0
3 SPOT MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0
4 SPOT DENT 3 2 3 3 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0
5 SPOT PITCH VARIATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 2 0 0 0 0 0 0 0
6 SPOT SPIKE 2 0 2 0 1 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
7 SPOT WEAK 3 3 3 3 3 0 3 2 2 2 0 0 0 0 3 0 0 0 0 3 0 3 3 3 3 0 0 0 0 0
8 SPOT ON EDGE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
9 NUT OFF 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0
10 NUT MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0
11 NUT THREAD DAMAGE 3 3 3 0 2 0 0 0 0 0 0 0 2 0 0 0 0 0 3 0 2 0 0 0 0 0 0 0 0 0
12 NUT BROKEN 3 3 3 0 0 0 3 2 2 0 0 0 2 0 3 0 0 0 0 0 2 0 3 3 3 0 0 0 0 0
13 NUT BURN 3 3 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
14 NUT THREAD UNDER SIZE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
15 NUT THREAD OVER SIZE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
16 SPOT OBLONG 0 0 1 3 3 0 0 3 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0
17 SPOT DIA. UNDER SIZE 1 3 1 3 3 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
18 SPOT DIA. OVER SIZE 1 3 1 3 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
19 CHIELD PART MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0
20 BKT. OFF WELD. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
21 BKT. SHIFTED 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
22 WRONG SIDE BKT. WELDED 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
23 CO2 WELD. MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
24 CO2. WELD. LENGTH VARIATION 0 0 0 0 0 0 0 0 0 3 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
25 DEEP PENETRATION 3 0 0 0 0 2 0 0 0 3 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
26 BLOW HOLES 0 0 0 0 0 0 0 0 0 1 3 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
27 POROSITY 0 0 0 0 0 0 0 0 0 0 3 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
28 CO2 SPATTER 3 0 0 0 0 3 0 0 0 2 2 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0
29 CO2 BURR 3 0 0 0 0 0 0 0 0 3 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
30 CO2 CRACK 3 0 0 0 0 3 0 0 0 2 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
31 CO2 WELDING UNDER CUT 2 0 0 0 0 3 0 0 0 1 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
32 CO2 PIN HOLE 3 0 0 0 0 2 0 0 0 0 2 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
33 RUSTY/ PITTED 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0
34 DAMAGE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 0 0 0 0 0 3 0
36 STUD MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0
37 STUD BROKEN 3 3 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 3 0 3 0 3 0 0 0 0 0
38 STUD BURR 3 3 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
39 STUD THREAD DAMAGE 3 3 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0
40 STUD BURN 3 3 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
41 STUD THREAD MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
42 WRONG STUD WELDING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
43 GUN MARK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 3 0 0 0 0 0 0
44 CLAMP MARK 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
45 PART MIX UP ( L.H./R.H.) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0
46 NUT THREAD MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
47 PANEL MISLOCATE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
48 DIMENSION VARIATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0
49 SHUNTING PROBLEM 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 0 0 0 0 0 0
50 SEALENT LENGTH VARIATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 0 0 0
51 SEALENT WIDTH VARIATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 0 0 3
52 SEALENT MISSING 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
53 EXCESS SEALENT APPLICATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 0 0 0
CRITERIA
STRONG RELATIONSHIP 3
MEDIUM RELATIONSHIP 2
WEAK RELATION SHIP 1
ZERO RELATIONSHIP 0
48
Example 27 - Guideline for Assigning Control Method based on Gravity
ANNEXURE -I ANNEXURE - II
Page 1 of 1 Page 1 of 1
Control Methods by Gravity CONTROL METHOD CHANGE STANDARD

CURRENT PROCESS CONTROL METHOD NEW CONTROL METHOD
Measurement Equipment/ EXIT CRITERIA
Sl No Charecteristics Symbol Control Methods Control Methods Immediate Permanent
Technique
1. P Y Checksheet
1. Prevention Poka Yoke
2. Prev. maint ch.sheet
Check & implement Product No complaint for continuous 3
100% Visual - 100% Visual & marking
1. P Y Checksheet or process pokayoke months, Poka yoke introduction
2. Detection Poka Yoke
1 Safety 3. SPC X- R chart
4. Run Charts Run chart Additional 100% Visual Check & implement Product No complaint for continuous 3
100% Visual & marking -
& marking (Detection) or process pokayoke months, Poka yoke introduction
5. 100% Checking Automatic / Visual
1. P Y Checksheet
2. Prev. maint ch.sheet 100% check & marking, No complaint for continuous 3
Use of fixture/gauge Fixture/gauge Check & improve over
1. P Y Checksheet Do fixture/gauge months, improvement in
2. Detection Poka Yoke (Detection) validation fixture / gauge usage
2. Prev. maint ch.sheet validation Fixture/gauge usage
2 Regulatory 3. SPC X- R chart
4. Run Charts Run chart Fixture control 100% check & marking, Check & improve over
No complaint for continuous 3
Fixture validation months, improvement in Fixture
(Prevention) Do fixture validation fixture usage
5. 100% Checking Automatic / Visual usage
1. P Y Checksheet
1. P Y Checksheet 100% check & marking, No complaint for continuous 3
2. Detection Poka Yoke 100% testing with Daily poka yoke check Check & improve over poka
2. Prev. maint ch.sheet Do poka yoke & months, improvement in Poka
machine & machine validation yoke sustainance
machine validation yoke sustainance
3. SPC X- R chart
3 Critical
4. Run Charts Run chart
SPC Study - 100% check & marking -
5. 100% Checking Automatic / Visual months
6. Set Up Verification and Set Up Verification and S I

Stage Inspection Format
1. P Y Checksheet Process pokayoke 100% check & marking, Check & improve over poka
1. Prevention Poka Yoke Daily poka yoke check months, improvement in Poka
2. Prev. maint ch.sheet (detection) Do poka yoke validation yoke sustainance
yoke sustainance
1. P Y Checksheet
3. SPC X- R chart No complaint for continuous 3

Process pokayoke 100% check & marking, Check & improve over poka
Daily poka yoke check months, improvement in Poka
4 Major 4. Run Charts Run chart (prevention) Do poka yoke validation yoke sustainance
yoke sustainance

6. Set Up Verification and Set Up Verification and S I Product pokayoke Check & improve over poka
- 100% check & marking months, improvement in Poka
Stage Inspection Format (detection) yoke sustainance
yoke sustainance
1. SPC X- R chart
5 Others 2. Set up verification Set up verification Checklist Product pokayoke Check & improve over poka
- 100% check & marking months, improvement in Poka
(prevention) yoke sustainance
yoke sustainance
3. Periodical Inspection Stage Inspection sheet
Issued By Prepared By Reviewed and approved By
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3.3 Poka Yoke
PURPOSE
• To assure that required Mistake Proofing as per PFMEA & Control Plan is installed on the Shop Floor & Daily Verification Mechanism is in place.
• Availability of Risk Analysis on identified locations. • Poka Yoke Procedure(Ex 28)
• Availability Poka Yoke at all risk location. (3 Proactive approach) • Master list of Poka Yoke
• Availability risk analysis approach during line installation from past trouble • Poka Yoke Installation standard.(Ex 29)
experience.
• Have Potential Risk identified (requested by P-FMEA, QA matrix, QFD table etc.)
50
Example 28 - Poke Yoke Procedure
Page 2 of 4
POKA YOKE
START Conditions Triggering Poka Yoke

1. Adjustments
2. Constant equipment changes
3. Dimensionality, specifications,
1. New Product critical condition
1 Triggers 2. Engineering Changes 4. Safety charecteristics
3. Process Changes 5. Many parts / Mixed parts
6. Multiple steps
7. Lack of or ineffective standards
1. Results of Corrective Actions
8. Rapid repetition
2. Results of Continuous Improvement
9. High volume
3. Customer Audits and Feedback
10. Environmental conditions:
4. Customer Complaints
a. Material/ process handling
5. Warranty Issues
b. Housekeeping
6. Inputs from Internal Audits
c. Foreign matter
7. Results of Internal Rejections
d. Poor lighting
e. Other
1. Before or at feasibility stage

2 Initiation 2. To be initiated prior to tooling for production
1. PFC 9. Similar part Control Plan

2. Similar part FMEA 10. Product reliability & Quality goals
3. PTD 11. Material Specification
4. DFMEA 12. Product Design requirements
3 Inputs 5. Engineering Spec. 13. Process Design Requirements
6. Tooling 14. Drawing & Specification changes
7. System Diagram 15. Customer Complaint/ Internal rejections Refer Annexure for Ex 28
8. Bill of Materials 16. Preliminary listing of product / process
charecteristics
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Example 29 - Poka Yoke Installation Standard

DOC.NO:
POKAYOKE PLAN SHEET
REV.NO:
Various types of POKA-YOKE-RL-1 DATE:
A) Two component feeding at a time D) Wrong fitment G) Weld shift J) Welding on disc only
K)Major scratch, line mark, deep dent,
B) Reverse component loading E) Wrong assembly dimension H) More / less weld penetration
heavy pitting, heavy burr
C) Wrong component loading ( Different product ) F) Weld Miss I) Welding on rim only L) Twisted coil/ strips
M) Opposite stamping / stamping problem N) Dim stamp O) Over lap P) Bad fusion
Q) Under cut, thin down R) B/w crack S) Flaring bulge T) Bad rolling
U) Expander bulge V) B/w air leak W) LVH damage X) Zig zag weld
Y) Porosity, Pin hole Z) Batch code damage / Deep stamp AA) LVH wrong side AB) Exp block mark
AC)Edge deep cut AD)Trim line AE) Flange width variation AF) Short weld
AG) Run out Out of Spec
TYPE OF RAW
BUTT EDGE EDGE VALVE ASSLY. ASSLY.
POKA- MATERIAL COILER TRIMMER FLARING RF-1 RF-2 RF-3 EXPANDER AIR LEAKAGE LPM BC
WELDER NIPPING ROLING HOLE PRESS WELDER
YOKE INSP
A X X X X X X X X X X X X X X X X
B X X X X X X X X X X X X X X X X
C X X X X X X X X X X X X X X X
D X X X X X X X X X X X X X X X X
E X X X X X X X X X X X X X X X
F X X X X X X X X X X X X X X X X
G X X X X X X X X X X X X X X X X
H X X X X X X X X X X X X X X X X X
I X X X X X X X X X X X X X X X X
J X X X X X X X X X X X X X X X X
K X X X X X X X X X X X X X X X X X
L X X X X X X X X X X X X X X X X X
M X X X X X X X X X X X X X X X X X
N X X X X X X X X X X X X X X X X X
O X X X X X X X X X X X X X X X X X
P X X X X X X X X X X X X X X X X X
Q X X X X X X X X X X X X X X X X X
R X X X X X X X X X X X X X X X X X
S X X X X X X X X X X X X X X X X X
T X X X X X X X X X X X X X X X X X
U X X X X X X X X X X X X X X X X X
V X X X X X X X X X X X X X X X X
W X X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X
Y X X X X X X X X X X X X X X X X X
Z X X X X X X X X X X X X X X X X
AA X X X X X X X X X X X X X X X X
AB X X X X X X X X X X X X X X X X X
AC X X X X X X X X X X X X X X X X X
AD X X X X X X X X X X X X X X X X X
AE X X X X X X X X X X X X X X X X X
AF X X X X X X X X X X X X X X X X X
AG X X X X X X X X X X X X X X X X
POKAYOKE REQUIRED
POKAYOKE AVAILABLE
X POKAYOKE NOT REQUIRED
52
Chapter 4
Quality Assurance at Pre-Production Stage

Objective : To ensure structured method for defining and executing the 4M actions necessary for New Product Development to
satisfy all Customer Requirements.
Pre-production QA
PURPOSE
• To assure tracking & completion of items during the Product Development Phase.
• To assure phase wise review mechanism.
• To monitor & control important Quality items & their implementation as per timeline.
• Availability of Timing plan as per phases of APQP and updated regularly in case of • APQP master plan (Ex 30).
any changes with actual status. • Phase wise APQP review report (Internal/Customer) (Ex 31).
• Availability of all elements in APQP timing plan with Customer Build dates. • Action plan/tracker/MOM in case of non-achievement of targets.
• Availability of Internal and customer APQP Review mechanism with planned frequency. • Guideline to identify SC/CC (Ex 32).
• Availability of APQP Status report for each review & detailed action plan in case of • List of SC/CC characteristic.
non achievement of target.
• Rule defined & followed for gateway/phase clearance.
• Mechanism to select Special Characteristics (e.g. SC/CC).
• Availability of customer approved Special Characteristics (e.g. SC/CC) list.
• Availability of Quality Targets at SOP stage (initial process capability, internal
rejection).
• Achievement of defined targets at SOP stage and Action Plan for non achievement.
• Availability of mechanism to manage Safety Characteristics separately from General
Characteristics (targets, frequency of monitoring).
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Example 30 - Apqp Master Plan

MAHINDRA APQP - SUPPLIER PART DEVELOPMENT MONITORING
Supplier Name Supplier Plant Supplier Code

Part No Part Name Issue Date:
Project ECN No SOR/Drawing Level Reason for Re-Issue
Team Members Dept. / Function Contact No. / E-mail Build Level MRD Quantity No. of SCs No. of CCs PIST% PIPC%
CP 1-Jan-09 10
VP0 5-Aug-09 50 SOP Date :
VP1 14-Sep-09 50 Annual Volume : 45,000 P.A

APQP Team Build Details
1PP
2PP
FEU
SOP
Time Scale
Responsible Person 2009 2010
No Project Item (Detail) (supplier)
2008
CP VPO VP1 PP1 PP2 SOP
Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct
Plan
1 Time line / Project Management
P Actual
R Plan
O 2 Initial Design Concept
Actual
D
U Plan
3 Detailed Design
C Actual
T
Plan NA
4 Design FMEA
D
Actual NA
E Plan
5 Design Reviews
S Actual
I
Plan
G 6 Design Verification Plan
N Actual
Plan
P
7 CAD Packaging
Actual
H
Plan
A 8 Design Sign-Off (Drgs & Specs frozen)
S Actual
E Plan
9 DV Testing
Actual
D Plan
10 Tooling & Gauges Manufacturing
E Actual
V Plan
E 11 Manufacturing & Assly Process Flow Chart
Actual
L
O Plan
12 Process FMEA
P Actual
M
Plan
E 13 Control Plans
N
Actual
T Plan
14 CP0 Build Parts
Actual
P
Plan
H 15 Sub-supplier Product Approval
A Actual
S Plan
16 VP0 Build Parts
E Actual
P Plan
17 Floor Plan Lay-out
R Actual
O
C 18 Production Facilities (inc.Test)
Plan A
E Actual
S Plan
S 19 Measurement Systems Evaluation
Actual
D
Plan
20 Operation Sheets
E Actual
54
S Plan
I 21 Recruitment and Training
Actual
G
N Plan
22 Sub-supplier PPAPs
Actual
N
Plan
P
7 CAD Packaging
Actual
H
Plan
A 8 Design Sign-Off (Drgs & Specs frozen)
S Actual
E Plan
9 DV Testing
Actual
D Plan
10 Tooling & Gauges Manufacturing
E Actual
V Plan
E 11 Manufacturing & Assly Process Flow Chart
Actual
L
O Plan
12 Process FMEA
P Actual
M
Plan
E 13 Control Plans
N
Actual
T Plan
14 CP0 Build Parts
Actual
P
Plan
H 15 Sub-supplier Product Approval
Contd...
A Actual
A
S Plan
16 VP0 Build Parts
E Actual
P Plan
17 Floor Plan Lay-out
R Actual
O
Plan
C 18 Production Facilities (inc.Test)
E Actual
S Plan
S 19 Measurement Systems Evaluation
Actual
D
Plan
20 Operation Sheets
E Actual
S Plan
I 21 Recruitment and Training
Actual
G
N Plan
22 Sub-supplier PPAPs
Actual
P Plan
H 23 Packaging Specifications
Actual
A
S Plan
24 Appearance Approval
E Actual
P Plan
25 Production Trial Run
R Actual
O
Plan
C 26 Preliminary Process Capability Study
E Actual
S Plan
S 27 Production Validation Testing
Actual
P
Plan
28 PPAP Approval
R Actual
O Plan
29
Supplier Pre-Production Audit (incl.
V
Run@Rate) Actual
E
O Plan
30 SOP at Supplier
U Actual
T Plan
31 Ramp up activity
Actual
P
H Plan
32 SOP at M&M
A Actual
S
Comments -
Supplier sign-off Mahindra & Mahindra Sign off

Project Team Project Leader Purch / Sales Prod'n Control QA Engineering Production Name Signature Date
Name
Signature
Date
Note: Approval by Mahindra & Mahindra shall not relieve the supplier in any way from its responsibilities.
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Example 31 - Phasewise APQP Review Report (Internal / Customer)

Annexure – I
APQP Status Report
Date : 03/05/2012
Review No. : 00
Supplier Program
Location Nashik Part No. Local Part no.
Supplier Code Part Desc.
Risk Assessment Ch. Let. No.
New: Site Technology Process User Plant(s) Nashik Plant no 1
Other Risks ________________________
Team Members Company / Function Contact No. / E-mail
Mahindra Platform Program Mgr
Program Manager
Quality
STA
Commercial
Supplier Development
Logistics / Stores
St Sourcing
Engineering
Build Level MRD Quantity Concurred PIST % PIPC

%
EP 15/10/10 15 No. of SC No. Of CC
VP 12/8/11 30
PP 10/05/12 80
FEU 30/05/12 300
SOP 08/06/12 1000
APQP Elements GYR Focus Program Completion Resp. Remarks
Status Element Need Date Date Engineer
Rating Initial
Sourcing Decision G 06.05.10 06.05.10
Customer Input Requirements G 06.05.10 06.05.10
Design FMEA G 15.07.10 20.07.10
Design Review(s) G 15.07.10 20.07.10
Design Verification Plan G 15.07.10 20.07.10
Subcontractor APQP Status Y 10.09.10
Facilities, Tools and Gages G 23.11.10 23.11.10
Prototype Build Control Plan G 16.12.10 16.12.10
Prototype Builds G 18.12.10 18.12.10
Drawings and Specifications G 10.12.10 10.12.10
Team Feasibility Commitment G 12.12.10 12.12.10
Manufacturing Process Flow Chart G 15.01.11 15.01.11
Process FMEA G 25.01.11 25.01.11
Measurement Systems Evaluation G 25.01.11 25.01.11
Pre-Launch Control Plan G 30.05.11 30.05.11
Operator Process Instructions G 10.07.11 10.07.11
Packaging Specifications G 06.05.10 06.05.10
Production Trial Run G 11.04.12 11.04.12 Completed for
PP Build
Production Control Plan Y 10.03.12
Preliminary Process Capability Study Y 15.03.12
Production Validation Testing G 10.10.11 10.10.11
Production Part Approval (PSW) R TBD
PSW Part Delivery at MRD R TBD
COMMENTS:
_____________________
56 APQP CO-ORDINATOR
MQS/APQP/F/01 Rev. : 00 25/09/99
Specical
Classify the special charactristics i.e. critical or CFT characterist
significant which requires more process ics
control.
Guide lines
to decide
Prepare the plan for monitoring of these Product
/ Process characteristics CFT product
process
parameters
Get Customer Approval for the same if

required Program Manager / Project
Quality Engineer
Check for the following points before

conducting the study:-
a) Raw material is accepted at inco
ming stage
b) Preventive Maintanence of Project Quality Engineer
theMachines/equipment are done
c) MSA for the instruments are done and is
accepted
Final
Collect readings of 5 Samples per shift for the
Project Quality Engineer Inspection
characteristics decided at 2 hr. intervals from
Example 32 - Guideline to Identify SC/CC

the line Quality Inspector Check
sheet
A
Identify these samples with the serial no. and Final
record the readings in the format
PROCESS FLOW DIAGRAM QUALITY SYSTEM

Contd... Quality Inspector Check
sheet
SELECTION & MONITORING OF SPECIAL CHARACTERISTICS PROCEDURE MANUAL
DOC. NO. : Calculate the Average,Range,Std.Dev,Cp Final

and Cpk as per the formulae
REV. NO. : Project Quality Engineer Inspection
Quality Inspector Check
Activity Responsibility Document Record Frequency
sheet
At new product If Cpk is < 1.33 Investigate the causes and Final
Collect the Data / Information from CFT correct the process parameters further to
development Project Quality Engineer Inspection
customer requirements. proceeding Quality Inspector Check
sheet
Collect the Product function requirements If Cpk is > 1.33 and < 1.67 run the process Final
includes description of the product & At new product
CFT and use x bar r chart to Investigate the Project Quality Engineer Inspection
purpose in brief / Drawing from Engg. development
causes and correct the process parameters Quality Inspector Check
sheet
If Cpk is > 1.67 establish those parameters

Collect the Process function requirements At new product and control limits as standard process Final
includes description of the process & CFT Project Quality Engineer Inspection
development parameters in mass production
purpose in brief from Industrial engg. Quality Inspector Check
sheet
Collect the PFMEA / DFMEA At new product In case of Ramp up refer ramp up plan and Final
CFT Project Quality Engineer Inspection
development exit criteria
Quality Inspector Check
sheet
Collect Past Trouble Database for similar Final

At new product For following the regular monitoring of the
components CFT X bar Chart Quality Engineer Inspection
development special characteristics follow X bar R chart
and the intrepretation of the same. Quality Inspector Check
Interpretation sheet
Based on the above data Review the "Product / Process" characteristics for:-
a) Customer Specified Safety / Regulatory characteristics. Specical Final
b) Engineering Specified Safety / Regulatory characteristics. CFT characterist If any deviations are observed in the
c) Severity rating in the DFMEA / PFMEA of 9/10 and the product/ process characteristics take corrective action and Quality Engineer / Inspection
ics Production Engineer Check
characteristics contributing for the same monitor the effectiveness of the actions taken
d) Repeated Major issues / disruptions in product / process. sheet
e) Comfort related product characteristics
Specical Establish the control limits to be used for Final

Classify the special charactristics i.e. critical or CFT characterist monitoring & controlling the process after Quality Engineer / Inspection
significant which requires more process ics successful CpK study. For details use SPC Production Engineer Check
control. reference manual. sheet
Guide lines
to decide Final
Prepare the plan for monitoring of these Product
/ Process characteristics CFT product Monitor effectiveness by monitoring continual Quality Engineer / Inspection
process improvement in status of Cpk study. Production Engineer Check
parameters sheet
Get Customer Approval for the same if

required Program Manager / Project
Quality Engineer End
Check for the following points before

conducting the study:-
a) Raw material is accepted at inco
ming stage
b) Preventive Maintanence of Project Quality Engineer
theMachines/equipment are done QUANTIFIER
c) MSA for the instruments are done and is SR. NO. QUANTIFIER RESPONSIBILITY
accepted 1
2
3
Final
Collect readings of 5 Samples per shift for the 4
characteristics decided at 2 hr. intervals from
the line Quality Inspector Check PREPARED BY : APPROVED BY :
sheet
DATE LAST REVISED : PAGE 1 OF 1

ORIGINAL RELEASE DATE :
Identify these samples with the serial no. and Final
record the readings in the format
Quality Inspector Check LN/TS/CSP-15 (02 091007) PRINTED COPIES ARE UN CONTROLLED FOR REFERENCE ONLY
sheet
Calculate the Average,Range,Std.Dev,Cp Final

and Cpk as per the formulae
A Quality Inspector Check

sheet
If Cpk is < 1.33 Investigate the causes and Final

correct the process parameters further to Project Quality Engineer Inspection
proceeding Quality Inspector Check
sheet
57
If Cpk is > 1.33 and < 1.67 run the process Final
and use x bar r chart to Investigate the Project Quality Engineer Inspection
causes and correct the process parameters Quality Inspector Check
sheet
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Quality Assurance at Pre-Production Stage

Objective : To ensure structured method for defining and executing the 4M actions necessary for New Product Development to
satisfy all Customer Requirements.
PURPOSE
• To assure availability of required FTG completion as per timeline in project.
• To assure all operators are trained and their skill evaluation is completed as required before SOP.
• To assure availability of phasewise completion of Process Instructions during project development.
• Availability of FTG plan and mechanism to review at each Phase of the project. • List of Equipments, Gauge & Tools.
• Availability of Validation Reports (e.g. CMM Report) for all FTG. • Calibration, PM, Tool Changing Plan.
• FTG is identified with Unique Identification. • Validation Report.
• Availability of training plan for new products and new manufacturing process • Master list of operators, list of training topics, topicwise training manual, training need
according to the Timing plan (plan to deploy skills from leader to all the operators). identification, training plan, topicwise training evaluation record & skill matrix.
• Guidline to prepare Process Instructions (Ex 33).
• Availability of specific Training related to specific operations for Safety
Characteristics (in areas such as Product Knowledge, effect in market, handling
method of product, equipment control) to operators.
• Availability of Guideline to prepare Process Instructions.
• Availability of linkage of Process Instruction manual with process FMEA, control
Plan, Technical Specifications Statement and Parts Drawing.
58
Example 33 - Guideline to Prepare Process Instuctions
Doc No : Contd... A
Work Instruction for Preparation of WI / OS Rev No:
Rev Dt:
Sl. Enter the operation name previous and next to the

Item Process Flow 7 Prev. / Next operation
No current operation being perfomed
START
For New WI / OS
Validity for WI / OS is
generally six months
1. New Product 8 Issue date Enter the issue date and validity
2. Engineering Changes
1 Triggers 3. Process Changes
For Revision of
Refer
existing WI / OS
Control Plan
9 Special Charecteristics Enter the symbol as specified in Control Plan
1. Results of Corrective Actions Safety Regulatory Critical Major
S
2. Results of Continuous Improvement S R C M
3. Customer Audits and Feedback
4. Customer Complaints
5. Warranty Issues
6. Inputs from Internal Audits Enter the total operation time for completing
10 Total Operation time all the operations involved in the process
1. DFMEA 9. Guages and Testing Equipments

2. PFMEA Identify all he personal protective equipments
10. Packaging standards & Specifications
3. Engineering Drawing like Gloves, Safety shoes, Helmet, apron,
11. Process Flow Chart 11 P P E`s goggles etc. required for that particular
4. Engineering Specification 12. Floor Plan Layout
2 Inputs 5. Material Specification process / operation
13. Charecteristics matrix
6. Drawings an Spec. changes 14. Lessons Learned from Similar parts
7. Eqpts, Tooling & Facilities 15. Visual standards
8. Special Prod./Process Charecteristics16. Handling requirements
Insert relevent
Identify all the instructions before starting the graphics / photos
12 Instructions machine
Form Cross Functional Team with representations Insert relevent

from Manufacturing, QA, PE, R&D, Maintenance, graphics / photos
3 Team
Tool Room, Purchase, Marketing, Packing &
Identify the steps and sequence for starting
Despatch as applicable 13 Start up the machine
Enter the name of the process/ function / activity for which Ref. Standard format for
the WI / OS is created. Enter the operation No. as given in WI & O S
Identify the steps and sequence for starting
4 Title the process flow chart the machine and number them and explain
14 Sequence of operation each substeps
Insert relevent
graphics / photos
For WI = WI / xx / yy
For OS = OS / xx / yy
Enter the Document No. as per quality system XX = Deptt code
5 Document No. documentation requirements yy = doc. serial no
15 Defects from previous Identify the defects from previous operation Insert relevent
graphics / photos
operation
Enter the machine name on which the process is

6 Machine name being carried out Identify the steps and sequence of inspection
16 Inspection requirements of component
Insert relevent graphics / photos
A
B
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Contd... B Contd... C
Identify the inspection method

17 Inspection aids (Visual / Touching)
Identify the minimum skill level required for the operation

27 Skill level / process
Identify all the abnormal situations and reactions for the

18 Abnormal situation particular operation / process
28 Safety Charecteristics Identify any special instructions for safety charecteristics

instructions
Identify all the process parameters / settings with
19 Process settings specifications and tolerance and required tools of the
model being produced
Identify any pokayoke assosiated with the operation /

29 Poka Yoke process
Identify the steps for setting up the tools, dies, punches
20 Tooling instructions and removing the same
Identify any special instructions for handling

30 Handling & and storage if required
Identify the tool change frequency for perishable tools and
Storage
tool maintenance instructions for non perishable tools
21 Tool change /
Tool maintenance
Identify the minimum lux level required for the operation

31 Lux Level if required
Identify the SPC requirements for the charecteristics of
22 SPC requirements the operations
Identify the review, approval, revision number, revision

date, history for the document. Identify the nature of the
32 Document control document ( Master/ controlled)
23 Stop / shut down Identify the stop / shut down steps / sequence
F/QA/294 & 295
33 Review of W I Review the W I / OS once in six months.

Identify the significant environmental aspects &
24 Significant Aspects / significant hazards assossiated with the operation /
hazards process
34 M List updation Update Master List of WI & OS
Identify any additional key points / care points as per

25 Key / care points customer requirements
STOP
26 Linkage Link WI / OS to PFC, Control Plan, PFMEA
60
Chapter 5
Quality Assurance at Production Stage

Objective: To ensure application of day to day activities for assuring Product and Process Quality through Daily Work
Management practices with Operator Engagement.
5.1 Modification Management for Process / Plant Stage
PURPOSE
• To assure system for Process/Plant Change exists.
• To assure existence of control mechanism for change items which includes Feasibility Approval, Rampup Planning & Quality Confirmation Before & After Change.
• To assure availability of Risk Management & recovery actions before the process/plant change.
• To assure availability of approval system Eg. PSW or equivalent for process/plant change.
• Procedure for Process Change Management containing Rule for change approval is • Procedure for process change management (Ex 34).
defined, Eg. Customer approval, internal approval. • Process Change Module (Ex 35).
• Criteria to raise the process change (For every 4M change). • PCN summary tracking sheet (Ex 36).
• Change note is initiated for all changes. • Quality comparison before & after change (Refer Ex 35).
• System to inform customer. • Action plan for all 4M related risk.
• Progress control list available for all the process changes with target date, • PSW copy.
responsibility, lot control & cutoff date with recovery action plan in case of delay.
• Feasibility approval from all related department.
• Updation & confirmation of all related documents changed - PFMEA, Control Plan,
Process Instructions etc.
• Comparison of before & after effect of Changes e.g. compare Cp/CpK for variable
data or compare defect % for attribute data - % reduction in blow hole in casting.
• List of risks (stock loss, quality crisis, equipment breakdown, cost etc.) are described
in procedure as well as ECN.
• Risk analysis results are available for all risks and action plan is available in ECN
where there is risk.
• All PSW/PPAP (or equivalent) are maintained for all change requests entered in the
process change list.
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Example 34 - Procedure for Process / Product Change Management

IMS PROCEDURE Doc. No. :
ISSUE :2
CHANGE MANAGEMENT SYSTEM REV No : 0
DATE
START
1. Customer Complaints- Zero Km / Warranty

2. Delivery failure
3. Kaizen Sheets
4. Internal Quality problems ( Rejection / Rework)
Triggers 5. Result of FMEA
6. Product/ Process / System audit
7. Supplier issues
8. Any changes to 4M conditions
Engineering Changes System Changes

Types
Design / Product /
Tooling Changes Process Changes
Change in 1. Results of Audits

1. Change in product 1. Man/ Material/ Method 2. IMS Document Changes
dimension 2. Plant Location / layout 3. Kaizens
Reasons 2. Change in design 3. Sub supplier 4. Other issues
3. Change in VA/VE 4. Inspection & Test method
4. Change in Raw Material 5. New / Modified tooling
6. New Technology / Machine
7. Upgradation or Reassignment
1 of existing tooling
8. Change of sub supplier parts
9. Spl process parameters
Customer Customer Format

or F/QA/299 Refer Annexure for Ex 34
Internally
Initiated
62 F/QA/299 F/MR/20
0 Day
Example 35 - Process / Product Change Module
ENGINEERING CHANGE REQUEST
ECR NO. :
DATE SUBMITTED : A
(IN-HOUSE) PAGE : 1 of 2
Applicant Name : Engg Type of Change : Process Content of Change : Page No. : 2 of 2
Assy. Description : W201-OBJ Permanent Yes OLD PROCESS ( BEFORE CHANGE ) NEW PROCESS ( AFTER CHANGE)
Assy. Part No. : 08-104-00 Temporary No
Child part Desc. : End plug If Temporary , Mention Active Duration
Child Part No. : 08-104-05 NA
Process Name : Roll fitting
SUGGESTED CHANGE : JUSTIFICATION FOR CHANGE Plug locatinh seating dia on date code punching 8.3+/-0.1 Changed to 11.0+/-0.1
Before After 1 . Design/ Specf. Change
2 . New Equipment Installation
3. Improvement in Productivity/ Quality : YES
Plug locator seating dia 8.3 +/-0.1 Plug locator seating dia 11.0+/-0.1
4. Cost Reduction
5. From In-House to Supplier
6. From Supplier to In-House
7. From One Supplier to Another Supplier
8.Capacity UP
9. Requirement of Supplier
* Use back of page for additional information 10. Others (Specify)
SIMILAR CASE DONE IN PAST : NO
FIRST PRODUCTION DATE : MASS PRODUCTION DATE :
CUSTOMER/COLLABORATOR APPROVAL :
REQUIRED ( ) NOT REQUIRED ( YES ) QUALITY DATA : Mandatory for all types of changes
IF REQUIRED PLAN DATE : NA QUALITY DATA ( OLD PROCESS ) QUALITY DATA (NEW PROCESS )
RELIABILITY TEST EVALUATION : REQUIRED ( ) NOT REQUIRED (YES )
ENVIRONMENT EFFECT : NO
HORIZONTAL DEPLOYMENT : NO
Expected Changes required in Following Document /Toolings : ( Tick as applicable)
Document Title Change Applicable TOOLING TOOL NO./ SPECF.
a) Process Sheet NA a) Blank/ Draw/ Piercing/ - NA NA

b)Receipt Inspection Standard NA b) Receiver Gauge -
c) Final Inspection Standard NA c) Jig/ Fixture 08.104&5-00-02
d) PFD NA d) Milling Cutter/Drill/Reamer -
e) PFMEA YES e) Grinding Wheel Grade -
f) Control Plan NA f)Instruments -
g) Work Instructions NA g)Material ;-
h) Drawing NA
I) Rceiver Gauge Drawing NA
j) Jig/ Fixture Drawing YES
K) PSW NA
L) Process Qualification Record NA
AUTHORISATION TO PROCEED WITH CHANGE
NAME DATE SIGN.
MARKETTING NA - - COST DATA ( OLD PROCESS ) COST DATA (NEW PROCESS )
SALES NA - -
ENGINEERING YES
PRODUCTION YES
QUALITY ASSURANCE YES
PURCHASE NA - -
PPC NA - -
Process Change Approval Report :
3. Customer / Collaborator Approval Result (If Required) : NA 4. Overall Judgement : OK
Judgement OK ( ) NG ( ) Approved By :
NA NA
Date :04.04.2012 Head QA
Head Engineering Decision : IMPLEMENTATION DATE :
Change Request Approved YES DESIRED :
Change Request Refused NO ACTUAL :
SIGN. ENGG. HEAD : DATE :
Mass Production Started On :
Note :- Pl. conduct Aspect Impact study ( If req. ) for any change & submit copy of AIA to Sys. Co-ordinator .
F02-7102 REV. No. :
A
Note :- Pl. conduct Aspect Impact study ( If req. ) for any change & submit copy of AIA to Sys. Co-ordinator
F02-7102 REV. No. :
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Example 35 - Contd...
Date:- SHEET
ENGINEERING CHANGE NOTE ECN No.
ASSY. NO 0 8 1 0 4 0 0 DESCRIPTION W201-OBJ CHANGE
changes
CHANGE EFFECT CHANGE
No. of
PART
S.NO. LETTER CHANGE DESCRIPTION AND REASON ON COST LEVEL *
Description Number BEFORE AFTER ( / / -) (A/B/C )
B
1 Plug locator 0 1 1 Plug locator seating dia modified
Cut -off Date Initated Prepared Checked Approved By Approved By Approved By Approved By Approved By
REMARKS:- Implementation By By By Marketing Purchase Engg. Prod. Q.A
Actual Date
Note :- Pl. conduct Aspect Impact study ( If req. ) for any change & submit copy of AIA to Sys. Co-ordinator .
* A… Parts Already Made Cannot Be Used. B…. Change Effected After Parts Already Made are Consumed. C…. Change Only in Drawing.
F01-7102 Rev. No.
64
Example 35 - Feasibility Analysis
TEAM FEASIBILITY COMMITMENT
CUSTOMER : DATE :
PART NAME : PART NO :
FEASIBILITY CONSIDERATIONS
Our product quality team has considered the following question , not intended to be all-inclusive in performing a
feasibility evaluation. The drawing and/or specifications provided have been used as a basis for analyzing the
ability to meet all specified requirements. All "no" answers are supported with attached comments identifying
our concerns and/or proposed changes to enable us to meet the specified requirements
YES NO CONSIDERATION COMMENTS

Is product adequately defined(application requirements, etc. to enable
NA feasibility evaluation ?
X Can Engineering Performance Specifications be met as written ?
X Can product be manufactured to tolerance specified on drawing ?
NA Can product be manufactured with Cpk's that meet requirements ?
X Is there adequate capacity to produce product ?
X Does the design allow the use of efficient material handling techniques?
Can the product be manufactured without incurring any unusual :
NA * Cost for capital equipment ?
X * Cost for tooling ?
NA * Alternative manufacturing methods ?
NA Is statistical process control required on product ?
NA Is statistical process control presently used on similar products ?
Where statistical process control is used on similar products :
X * Are the processes in control and stable ?
NA * Are Cpk's greater than 1.67 ?
Conclusion
X Feasible --------------------Product can be produced as specified with no revisions.

Feasible---------------------Changes recommended ( see attached ).
Not Feasible---------------Design revision required to produce product within the specified requirements.
CFT SIGN - OFF :-
NAME :- NAME :-
DEPTT. :- DEPTT. :-
SIGN. :- SIGN. :-
NAME :- NAME :-
DEPTT. :- DEPTT. :-
SIGN. :- SIGN. :-
NAME :- NAME :-
DEPTT. :- DEPTT. :-
SIGN. :- SIGN. :-
NAME :- NAME :-
DEPTT. :- DEPTT. :-
SIGN. :- SIGN. :-
F02-7101 REV.
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4M RATING GUIDELINE for Risk assessment of Product / Process Changes
High Medium Low
- High skill to operate a special measuring eqpt - Moderate skill to operate a special measuring eqpt - Current skills are adequete
MAN - Special training required to Inspectors - Moderate training required to Inspector - No training required to Inspector
- Addition of skilled / special man power - Upgradation of skills in existing man power - No Addition of man power
- New / complex technology for measurement - Moderate upgradation of measurement technology - No change in current measurement set up
MACHINE - Heavy capex investment in Lab / inspection facility - medium capex investment - no capex investment
QUALITY - Major change in Lab layout - Minor change in layout - No change in layout
- Major validation / testing required - Minor / additional validation / testing required - No additional validation / testing required
MATERIAL - New matl - Customer validation / approval required - Only Customer initimation / approval required - No Customer initmation / approval required
- Directly affecting process chara. - Not directly affecting process chara '- No effect on process chara
- Customer validation / approval required - Only Customer initimation / approval required - No Customer initmation / approval required
- Method of measurement not known / tedious - Method of measurement less known / needs expertise - No change in current measurement processes
METHOD
- Effects human safety / fatigue / Product safety (CC) chara - Effect only Product SC characteristics / human fatigue only - not affecting safety / fatigue
- Heavily effects productivity / efficiency of inspection - Medium effect on productivity / flow of material -not affecting on productivity
- Special High skill set required for design / upgradation - Moderate skill set required for design / upgradation '- Current skill set adequate
MAN - Special training required for Design engineer - Moderate training required for Design engineer '- no specific training requird
- Heavy addition of Skilled man power - An additional resource required - No additional resource required
- New/complex technology (Hardware / software within CAD / - Moderate upgradation in current technology (within CAD / - Current technology (within CAD / CAE) is adequete
MACHINE
- Heavy capex investment / Collaborator inputs required for - Medium capex investment required for design / validation - no capex investment
Design
- New material - Special validation / testing required - Equivalent material - Minor validation / Lab testing required - regular material - No validation required
MATERIAL
- Material severely affects other product Design chara. - Material has moderate affect on other product Design chara. - Material has no effect on other product Design
- New Validation method needs to be devised - Current Validation method needs to be revised - Current Validation method is adequete
METHOD - New / Major review or change required in DFMEA - Minor change / review required in DFMEA - No change / review required in DFMEA
- Completely new design feature / design need - Relatively new design feature / design need - No new design feature / design need
- High skill required to operate - Moderate skill required to operate '- Low or no skill to operate
MAN - Special training required for Operator - Moderate training / OJT required '- no specific training requird
- Heavy addition of man power - Few additional man power (not budgeted for) - No addition of man power
- New/complex technology - Upgradation of current technology - Simple technology / current technology
- Heavy capex investment - medium capex investment - no capex investment
MACHINE
Production / - Major change in layout - Medium change in layout - No change in layout
Mfg Engg - Affecting safety chara. - Partially affecting safety chara. - Not affecting safety chara.
- New material - Major process / tooling validation reqd - Minor process / tooling re-validation reqd - No process / tooling re-validation reqd
MATERIAL
- Directly affecting process chara. - Not directly affecting process chara '- No effect on process chara
- Major change in process flow - Minor change in process flow - No chang in process flow
METHOD - May severely affect human safety/ fatigue / ergonomics - less affect on human safety / fatigue - not affecting human safety / fatigue
- Effect productivity / flow of material Medium effect on productivity/flow of material - not affecting on productivity
- New supplier needs to be explored / developed - Major development with current source - No new development / Current source adequete
MAN
- Special commodity skill set required for Part development - Support in commodity skills required for Part development '- Current skill set is adequete
- New/complex technology - Upgradation of current technology - Simple technology
MACHINE
- Heavy capex investment - medium capex investment - no capex investment
- New material - customer approval required - No new material required - customer approval required - regular material - customer approval not require
Materials
MATERIAL - High RM cost / direct import - Moderate RM cost / direct import '- No cost impact / Local source
- Not easily avaliable - Not easily avaliable easily avaliable
- Major change in Logistics - Moderate change in Logistics - No change in current Logistics
METHOD - May call for heavy liasoning / legal approvals with Govt - May call for moderate liasoning with Govt agencies - No liasoning with Govt agencies
- Effect productivity / flow of material Medium effect on productivity/flow of material - not affecting on productivity
66
Example 35 - Risk Analysis
RISK ASSESSMENT
Part Number Part Name Model / Project Customer ECN Ref No / New Project Date
Criteria Check Point Remarks

Type of Change / New Project Process
Project life time NA
Whether the customer is OEM (or) Tier I (or) Tier II? Tier-1
Product target price NA
General
Annual Volume NA
Existing Process / Product details : Proposed Process / Product Change details :
End plug seating dia 8.3+/-0.1 Modified to 11.0+/-0.1 to aviod plug damage
Risk level Action

required
Categor Low Medium High Target
Area Risk Details Risk Score Action to be taken Responsible Actual Date
y Risk Risk Risk Date
applicable Yes No
(or) Not 1 2 3
Skill to operate a special measuring eqpt. NA
MAN Training required to Inspectors NA
Addition of man power NA
New / complex technology for measurement/ NA

MACHINE eqp.
Investment in Lab / inspection facility NA
QUALITY Validation / testing required NA
MATERIAL New matl - Customer validation / approval NA

required
Affecting process chara. NA
Method of measurement not known NA
METHOD Effects human safety / fatigue / Product safety NA

(CC) chara
Effects productivity / efficiency of inspection NA
Skill required to operate NA
MAN Training required for Operator NA
Tool design to be made and trial to be

New tool/ jigs/ fixtures reqd. Yes 1 1 Yes
conduted with the same.
Capex investment NA
MACHINE
Change in layout NA
Production /
Mfg Engg
Affecting safety chara. NA
New material - process / tooling validation reqd NA

MATERIAL
Affecting process parameters NA
A
Change in process flow NA
METHOD Affects human safety/ fatigue / ergonomics NA
Affects productivity NA
New supplier needs to be explored / developed NA

67
MAN
Skill set required for Part development NA
Investment in Lab / inspection facility NA
QUALITY Validation / testing required NA
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Affecting process chara.
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MSES
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METHOD Effects human safety / fatigue / Product safety NA
(CC) chara
Effects productivity / efficiency of inspection NA
Skill required to operate NA
MAN Training required for Operator NA
Tool design to be made and trial to be

New tool/ jigs/ fixtures reqd. Yes 1 1 Yes
conduted with the same.
Capex investment NA
A
MACHINE
Change in layout NA
Production /
Mfg Engg
Affecting safety chara. NA
New material - process / tooling validation reqd NA

MATERIAL
Affecting process parameters NA
Change in process flow NA
METHOD Affects human safety/ fatigue / ergonomics NA
Affects productivity NA
New supplier needs to be explored / developed NA

MAN
Skill set required for Part development NA
New/complex technology NA
MACHINE
Capex investment NA
New material - customer approval required NA

Materials
RM cost / direct import NA
MATERIAL
Not easily avaliable NA
Shortage of Material NA
Change in Logistics NA
METHOD
Affects productivity / flow of material NA
% OF SCORE OCCURRED 33.33333333
100 % -76 % 75 % -51 % 50 %-25 % 24% to 0%

% OF SCORE DETAILS
High Risk Project Medium Risk Project Low Risk Project No Risk Project
Note :
All Medium & High risks need corrective action plan.
Sign-off
CFT Member / Title / Date CFT Member / Title / Date
COO / Date Head Engineering / Date
Approval Authority
1) No & low Risk -
2) Medium Risk -
3) High Risk -
F04-7102 REV NO :
68
Example 35 - Quality Comparison Before & After Change
TARGET & PROCESS VERIFICATION SHEET
Part Name :
Nature Of
Change/ REASON FOR RESULT -AFTER
New
Product CHANGE CHANGE
Initiated
by &
Part Number :
Approved
By
Changes/
New To avoid plug Plug damage rejection
Model Name : product
Validated damage eliminated .
on
Customer Name :
Quality Rate Quality Rate ManPower

Targets Contents Cp & Cpk Setting Time Cycle time Machine Utilisation METHOD
( Rejection ) ( Rework ) utilisation
Process Detail
Remarks
Before After Before After Before After Before After Before After Before After Before After Before After
PROCESS
Process No :
Name :
Plug
Date code
A90 9000 0 0 0 NA NA 5 Min 5Min 22 sec 22 sec 1 1 1 1 locating
Punching
dia =
Conclusion :
Changes is Validated .
Changes is not validated and retrial to be conducted.
CFT MEMBERS SIGN
1.------------------------------------------------ 2.------------------------------------------------ 3.------------------------------------------------ 4.------------------------------------------------ 5.------------------------------------------------
6.------------------------------------------------ 7.------------------------------------------------ 8.------------------------------------------------ 9.------------------------------------------------
F02 A-7102 REV NO :
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PROCESS CHANGES ACTIVITIES- As On
DOCUMENTS AND RECORDS UPDATION PLAN VS ACTUAL Date :
S.No. Document Applicable ( Yes/No) Resp. T.Date Status
1 Process Flow Diagram NO
2 PFMEA YES Completed
3 Control Plan NO
4 Quality Check Sheet NO
5 Machine check sheet NO
6 One point lesson NO
7 RQA Inspection std. NO
8 Final Inspection Standard NO
9 Work Instrucions NO
10 SOP-QMS . NO
11 Product Drawings NO
12 Cutting Tool Dwgs NO
13 Non-Cutting Tool Dwgs NO
14 Gauges Dwgs YES Completed
15 Past Trouble data Updation YES
16 Kakottra Sheet NO
17 Lesson Learned YES
18 Layout NO
19 PPAP / PSW NO
20 PM checklist NO
21 Inspection Formats NO
22 Training Records NO
Checked By : Approved By :
70
Example 36 - PCN Summary Tracking Sheet
Doc. No.
ENGINEERING CHANGE MODIFICATION PROGRESS TRACKING SHEET
Rev. No. / Date
Customer Change
Feasibility Review Risk Analysis Approval for Drg. Change Apporoval Implementation/ Trail & Internal PSW approval PSW sign - off Affected doc change Start of production
SR. ECN PART NAME / CHANGE DATE OF Proto Sample Approval Status as
NO SR.NO PART NO. DESCRIPTION INITIATION on
Target Target Target Actual Target Target Target Target Actual Target
Actual date Actual date Actual date Actual date Actual date Actual date Target date Actual date
date date date date date date date date date date
SUMO TAIL
Sumo TL Mounting Start
ECN LAMP
1 stud mounting area 9/14/2011 9/16/2011 9/16/2011 9/16/2011 9/16/2011 NA NA 9/20/2011 9/29/2011 9/29/2011 6/10/2011 NA NA NA NA 9/26/2011 9/29/2011 1/10/2011 production Completed
0001D 2823 5440
modified. form 06/10/11
0103/0104
For water ingress

Robo start & end
LOW COST
pt.changed
ECN TAIL LAMP
2 .Overlapping of 10/10/2011 11/10/2011 12/10/2011 11/10/2011 12/10/2011 NA NA NA NA 10/16/2011 10/17/2011 10/14/2011 10/15/2011 NA NA 10/15/2011 10/17/2011 10/20/2011 10/20/2011 Completed
0004P 2702 5440
sealant.sealant
9915/14
increase from 40 + 02
gm to 45 + 02 gms.
D- Design
Note:
P- Process
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5.2 Modification Management for Design (Product) Change
PURPOSE
• To assure system for Design / Product Change exist.
• To assure existence of control mechanism for change items which includes Feasibility Approval, Rampup planning & Quality confirmation before & after Design / Product
change.
• To assure availability of Approval System Eg. PSW or equivalent for Design / Product Change.
• Procedure for Product Change • Procedure for Product Change Management (Refer Ex 34).
Management containing Rule with clear • Product Change Module (Refer Ex 35).
definition of 5W1H & all triggers for • PCN summary tracking sheet (Refer Ex 36).
changes like Customer request, internal • Quality comparison Before & After change (Refer Ex 35).
& Sub-supplier are considered.
• Action plan for all 4M related risk.
• All design (Product) changes after SOP
• PSW copy.
are followed with design (Product)
change notes which include results of
reliability tests.
• Progress control list available for all
the product changes with target date,
responsibility, lot control, responsibility
& cutoff date.
• Feasibility approval from all related department.
• Updation & confirmation of all related documents changed - PFMEA, Control Plan,
Process Instructions etc.
• Comparison of Before & After effect of changes e.g. Compare Cp/CpK for variable
data or compare defect % for attribute data - % reduction in blow hole in casting.
• All PSW/PPAP (or equivalent) are maintained for all change requests entered in the
Product change list.
72
5.3 Control Plan, Parts Drawing.
PURPOSE
• To assure availability of latest Parts Drawing with all Characteristics linked with Control Plan and SOP.
• To assure that Control Plan cover all processes from parts and material receiving to final products.
• To assure all requirements specified in APQP (or equivalent) are described in Control Plan.
• To assure identification of Fool-Proofing Systems (Poka yoke) & Installation.
• Availability of linkage between Part Drawing, Control Plan & SOP. • Drawing with Latest Change Letter.
• Availability of all the documents required at APQP - SOP Phase. Part drawing, • Production Control Plan.
PFMEA, PFD, Control Plan, Process instruction. • Process Instructions.
• Availability of Control Plan covering all processes (Including parts and material • Product v/s Process parameter relationship matrix (Refer Ex 26).
receiving). • Validation report.
• Availability of all the requirements mentioned in the APQP guideline & CC
requirements mentioned in regulatory requirements are covered in the control
plan.
• All SC/CC, Specifications mentioned in the Control Plan are less than Part Drawing
specification tolerance.
• Important process parameters are clearly specified.
• Availability of Back up data to decide the specification & checking frequency for all
important Process Parameters.
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5.4 Material & Part Receiving
PURPOSE
• To assure purchased product conforms to the specified Incoming requirements and necessary reaction plans available for deviant conditions.
• To assure appropriate Storage conditions of purchased parts.
• Availability of packaging Standard sign-off with Sub-Suppliers considering logistics • Approved Packaging Standard (Ex 37).
and storage conditions to avoid part damage. • Incoming Control Plan.
• Availability of system for identifying incoming lots (parts information like Part • Incoming Inspection records.
Name, Part No, Manufacturing date, Shift, Qty etc.). • Defect communication format (Incident Report).
• Inspection of incoming parts as per defined Control Plan and recording of results • Inspection Status Tag.
with verification by supervisor. • FIFO work instruction (Ex 38).
• Availability of system for identifying inspection OK lot with indication (label with
inspection date, OK stamp).
• Mechanism of isolating NC/suspected parts with specific indication. (Defect, date,
responsible person).
• Mechanism of NC parts feedback to supplier within the same day.
• Identification of storage location for incoming parts including location for parts
before and after inspection, parts under development, slow moving parts etc.
• Availability of appropriate storage conditions to avoid part damage due to
surrounding (temperature, humidity etc).
• Availability of FIFO system with clear Work Instructions.
74
Example 37 - Approved Packaging Standard
Packaging Format ( By Road)

Part Name FTS Filter to Pump,FTSMain Line, FTS Return Line Part Number 1001CA6990N,1001CAA7870N,1001CA7250N Supplier Code DN 080 Supply Location (To) NASHIK Project code SOR no.
Project W 408 Supplier Name Supplier location ( From) PP BOX WITH Document Level / Date 1 / 8/10/2009
PUNE
COMPONENET
FIRST LEVEL PACK
Returnable YES NO PART DEFINITION
Collapsable YES NO
Palletised YES NO Part Image* ( Prefered 3D image )
SECONDARY PACK
Carton Box YES NO
Plastic Bag YES NO
Others
REPLENISHMENT BIN QTY
NA
2 HRS 4 HRS 1/SHIFT
INVOICE QTY
2/DAY 1/DAY OTHERS 25 nos. Sketch/Photo of
Secondary Pack ngwith
PACKAGING METHOD *Stretch the image for a clearer view
ROAD PP BOX component placed
Sepearte packing sheet for Air/Train packing is attached ( Page 2) inside primary packing Supplier to Conform to M&M sticker Requirment ( Page 3)
STICKER YES
Required Attached Not Aplicable Sketch/Photo of Primary Pack with component placed inside primary packing. COLOUR YES
Incase of returnable bins, part list of crate, bins to be shown Incase of returnable
SIZE YES
PACK STYLE PART PACKING bins, part list of crate,
bins to be shown SUPPLY METHOD
PLASTIC CRATE PLASTIC COVER
PP BOX PARTITIONS DIRECT VMI LOCAL WAREHOUSE
PP BOX READY FOR Write Place
CARTON BOX FOAM
TROLLEY OTHERS DISPATCH
PALLET HANDLING REQUIRMENTS AT DOCK
BIN Fork Lift
KIT Stacker
OTHERS Manual pulling
Others
OTHERS DESCRIPTIONS STORAGE METHOD
Stackable Packaging YES NO
Sketch/ Photo for (If yes,no of stacks protected)
packing praposal Ready 1) OIL specification
Shelf Life sticker is put on secondary pack YES -
Sticker Photo for Despatch 2) Oil Application DRY WET
Incase of returnable packing 3) Barcoding for Packing YES NO
YES NO -
1) Supplier to collect back crates (Part no, V0/V1, Qty) For C & D parts only
nos or months
2) No of Useable Cycles of crates 4) Caps for all open ends / threads YES NO
PACK DIMENSION ( Outside ) PACK WEIGHT 7.2
OTHERS
KGS (Includes component) 5) Shelf Life Applicable ( if yes , write same in months)
3) Crate Washing Yes No NA Primary MATERIAL USED YES NO
L 2030mm W 500mm H 260mm PACK QUANTITY 40 NOS nos
4) Crate Washing Method 6) Moisture/Rust Protection
Primary Secondary VCI Bag Moisture Bag Others
Secondary MATERIAL USED
L W H Note : 25Nos. Each Part
Wood is prohibited for packing ( except pallet) 7) Rain Protection- Shrink Wrap of primary Packing
YES NO
Department SUPPLIER MM DE MM STA SCM Other Other
Name ASHUTOSH SHARMA
Signature
Date 15.05.2010
Comments
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Example 38 - Work Instruction

WORK INSTRUCTION
Quality Check
TITLE:FIRST Method
Issue Authority : IN AND Issue Date:

FIRST OUT :
Safety
UNFINISHED
Equipments
WHEEL
Doc No: STORAGE Rev Date: -
AREA EYES
TOKEN STAND
TOKEN
PLACED
TROLLEY TO BE
PLACED IN THIS
FIRST
OUT
ARROW
FIRST IN
ARROW
FOR KEEPING PALLETS IN STORAGE AREA
1) MOVE THE PALLET FROM INSPECTION AREA AFTER ENSURING GREEN COLOUR TAG ON IT
2) ENSURE THAT ALL COLUMN IN GREEN TAG IS FILLED WHEEL PLACED IN
THE TROLLEY WITH
3) MOVE PALLET TO WHEEL OK TAG AND KEPT
IN RESPECTIVE
4)FIND AN EMPTY LOCATION AND KEEP THE PALLET IN THE LOCATION LOCATION
5)TAKE CARE THAT THE PALLET DOES NOT HIT ON ANY OTHER PALLETS WHILE MOVING
6)ENSURE THAT PALLET IS WITH IN THE BOUNDARY MARK OF THE LOCATION
7) NOTE THE WHEEL MODEL NAME AND NO PAINTED IN FRONT OF THE LOCATION
8) COME TO THE FIFO BOARD AND TAKE THE TOKEN FOR THAT LOCATION NO FROM THE HOOK ON
THE LAYOUT ON FIFO BOARD
9) LOCATE THE FIFO POUCHES ASSIGNED TO THAT PARTICULAR MODEL
10) FIND THE ARROW "IN" ON THE LEFT SIDE OF THE FIFO POUCH.INSERT THE TOKEN INTO
THE POUCH DENOTED BY THE ARROW
11) ALWAYS INSERT FROM THE LEFT SIDE OF THE POUCH DO NOT TRY TO INSERT FROM THE
RIGHT SIDE. THE POUCH IS SO DESIGNED THAT INSERTING FROM RIGHT SIDE IS NOT POSSIBLE NUMBER
LAYOUT FIFO
12) ONCE THE POUCH IS FILLED 20 TOKENS CAN BE INSERTED IN ONE POUCH REMOVE THE
"IN" ARROW AND HANG IT ON THE HOOK CORRESPONDANCE TO THE NEXT LOWEST POUCH FOR
THAT MODEL AS SHOWN BY YELLOW ARROW MARK
13) IF ALREADY IN THE LOWEST POUCH ALLOTED FOR THAT MODEL, HANG THE ARROW ON
THE UPPER MOST HOOK FOR THAT MODEL
FOR TAKING PALLETS FROM STORAGE AREA

1) FIRST GO TO THE FIFO BOARD AND LOCATE THE POUCH FOR THE PARTICULAR WHEEL MODEL
WHICH IS REQUIRED
TROLLEY PLACED CONTINUOUSLY
2) FIND THE ARROW "OUT" ON THE RIGHT SIDE OF THE FIFO POUCH FOR THAT MODEL. GREEN COLOUR BASED ON TOKENS PLACED IN FIFO
OK TAG LOCATION
3) TAKE A TOKEN FROM THE FIFO POUCH WHICH IS DENOTED BY THE ARROW.
4) TAKE ONLY ONE TOKEN AT A TIME. THE POUCH IS SO DESIGNED THAT ONLY ONE TOKEN CAN BE
TAKEN AT A TIME
5) NOTE THE LOCATION NUMBER GIVEN IN THE TOKEN.
6) GO TO THE LOCATION NUMBER AS GIVEN IN THE TOKEN. ABNORMAL CONDITION REACTION PLAN
7) PULL OUT THE PALLET FROM THAT LOCATION. NO ABNORMAL SITUATION ACTION
8) CARE SHALL BE TAKEN NOT TO HIT THE PALLET ON OTHER PALLETS WHILE TAKING OUT. 1 IF THE PALLET IS FOUND WITH ANY TAG OTHER THAN GREEN TAG
INFORM LINE INSPECTOR AND MOVE PALLET TO THE
RESPECTIVE AREA
9) GO TO THE FIFO BOARD AND HANG BACK THE TOKEN IN THE HOOK PROVIDED FOR THE LOCATION NUMBER.
TOKEN IS MISSING ON THE BOARD INFORM LINE INCHARGE
10) MOVE THE PALLET TO THE RESPECTIVE WORKPLACE. 2
11) ENSURE THAT THE PALLET IS HAVING A GREEN TAG BEFORE MOVING. 3 ANY WHEEL FALLS DOWN WHILE TRANSPORTING INFORM LINE INSPECTOR AND HAND OVER WHEEL TO HIM
12) ONCE THE POUCH IS EMPTY AFTER TAKING THE LAST TOKEN IN THAT POUCH,
TAKE THE RIGHT SIDE "OUT" ARROW FROM THE HOOK AND HANG IT ON THE NEXT LOWEST HOOK
BEFORE PROCEEDING TO STEP NO. 5
12a) IF ALREADY THE LOWEST POUCH ASSIGNED FOR THAT PARTICULAR MODEL IS REACHED,
HANG THE ARROW ON THE TOPMOST HOOK FOR THAT MODEL.
FRESH ISSUE
Revision Date Description Prepared Checked Approved
76
5.5 Check at Line Startup
PURPOSE
• To assure required Start Up activity is defined and adhered to before beginning of the process.
• Availability of Start Up check sheets near machine/line/cell. • Start up check sheet (Ex 39A) (including Poka Yoke).
• Start Up checkpoints including tolerance value in-line with control plan and • Corrective action records.
recorded with actual measured results. • Poka Yoke verification records.
• Availability of system to start production after all parameters are within the value • Reaction Recording Sheet (Ex 39B).
range, close to the target value.
• Availability of system to record occurred troubles with Corrective Actions.
• Verification of Start Up checks and corrective actions by supervisor at defined time
with signature.
• Availability of system to verify Poka Yoke with dummy samples at line start-up with
records.
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Example 39A - Startup Check Sheet (Including Pokayoke)

Month M/c No.
STARTUP CHECK SHEET Insp.Freq. Shiftwise Bay
SSLCL Instruction to operator M/c Type WELDING Page 1 of 2
1 Operator will check the parameters given in this checksheet and inform to team leader if any abnormality observed. Symbol to be put after Inspection
2 Team leader will correct the abnormality immediately and allow operator to run the machine. OK NG Not Run After Correction
3
4
Operator will put symbol after inspection
All the Machine Parameter should be set in MEAN Vaule during check sheet verification.If Not in mean , set the paramater as per adjusment instructions.   - 
MODULE:- Dates
SL
NO.
Check Parameters Shift
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Contents Key Points
A
1s-Check for Unwanted itmes removed form
1 B
the work station.
C
A
2s-Check for required items keeping in
2 B
proper arrangements.
5S Conditions C
Verification. 3s-Check the cleanliness of A
machine,gauges,dummy samples,poke yoke
3 B
samples and floor free from oil leak,coolant,&
metal chips. C
4s & 5S -Check the standardization location A

of used cloth & fresh cloth ,NG Parts,all
4 B
Sampling parts, all gauges,chute and
machine & its accessories. C
A
Safety Gears Check as per the standards all the required
5 B
verification. Safety gears wearing conditions.
C
A
Safety Guard
6 Check the Safety guard sensor for working B
verification.
C
A
Abnormality Review
7 Check for any ubnormal noice& vibration B
in M/C
C
A
Poke Yoke Check the poka -yoke with limit sample for
8 B
Verification cycle start (If A/V)
C
A
Check for rod Clamping Air Pressure
9 B
A
5±1kg/cm2
C
A
Check for Rod Clamping Hydralic Pressure in
10 B
80 to 100kg/cm2 Min
C
A
Check the Pressure Head Pressure in
11 B
4±1kg/cm2
C
A
12 Check the Schedule No 03 B
Process C
Characteristics
Verification. A
13 Check the Weld 2 current in 8.9KVA B
C
A
14 Check the weld 2 cycle time in 20m sec B
C
A
15 Check the cooller Temp in 16 to 25⁰C B
C
A
16 Check any damages in Electrode B
78 C
A
Check the calibration status of Gauges &
17 Instruments. B
( If applicable )
C
A
2s-Check for required items keeping in
2 B
proper arrangements.
5S Conditions C
Verification. 3s-Check the cleanliness of A
machine,gauges,dummy samples,poke yoke
3 B
samples and floor free from oil leak,coolant,&
metal chips. C
4s & 5S -Check the standardization location A

of used cloth & fresh cloth ,NG Parts,all
4 B
Sampling parts, all gauges,chute and
machine & its accessories. C
A
Safety Gears Check as per the standards all the required
5 B
verification. Safety gears wearing conditions.
C
A
Safety Guard
6 Check the Safety guard sensor for working B
verification.
C
Example 39A - Contd.

7
Abnormality Review
in M/C
Check for any ubnormal noice& vibration
A
B
C
Contd... A
A
Poke Yoke Check the poka -yoke with limit sample for
8 B
Verification cycle start (If A/V)
C
A
Check for rod Clamping Air Pressure
9 B
5±1kg/cm2
C
A
Check for Rod Clamping Hydralic Pressure in
10 B
80 to 100kg/cm2 Min
C
A
Check the Pressure Head Pressure in
11 B
4±1kg/cm2
C
A
12 Check the Schedule No 03 B
Process C
Characteristics
Verification. A
13 Check the Weld 2 current in 8.9KVA B
C
A
14 Check the weld 2 cycle time in 20m sec B
C
A
15 Check the cooller Temp in 16 to 25⁰C B
C
A
16 Check any damages in Electrode B
C
A
Check the calibration status of Gauges &
17 Instruments. B
( If applicable )
C
A
Gauges Calibration Check Zero setting of Gauges &
18 and "O" setting Instruments B
verification. ( If applicable )
C
A
Check any damages in gauges &
19 B
Instruments ( If applicable )
C
A
Sign Operator B
C
A
Sign Team Leader B

C
F06-7501 Rev No : 00
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Example 39B - Reaction Recording Sheet

month M/C NO
DAILY MACHINE PARAMETER CHECK SHEET Insp.Freq Shift wise Bay
M/C Type Page 2 of 2
Action taken by the Team Leader incase of NG condition
DATE NG parameter Corrective Action Who Results Sign Remarks
NOTE: During verification of check sheet if any abnormality was found person specified in daily machine checking
work instruction shall take corrective action intiate the correction action.
FORMATE NO:
80
5.6 Control of the Equipment Conditions
PURPOSE
• To assure job set-up is done as per defined Process Controls for required Product Characteristics and validated before start of production.
• Availability of Setup Change matrix & Setup Instruction for each part & approved • Part wise Set up matrix (Ex 40).
by an authorized personnel. • Set up instructions (Ex 41).
• Availability of Set Up matrix on the shop floor near machine. • Set up approval sheet (Refer Ex 40).
• Availability of Linkage between Control Plan, Setup Change Matrix & Setup Check • Set up parameters adjustment guidelines (Ex 42).
Sheet for Characteristics, Tolerance, Frequency, Measurement Method.
• Availability of system to Record Set Up parameters in Set Up check sheets and rule
is defined to start operation only after all set up parameters are OK.
• Easy accessibility of Set Up parameter indicators and possible to check actual value
all the time and also marking of “OK” range in case of analog type indicator.
• Availability of pictorial guidelines for adjustment of Set Up parameters with
responsible person and its availability on shop floor.
• Understanding of operator regarding selection of Set Up parameters and its effect
on product.
• Availability of system to verify Set Up checks and corrective actions by supervisor
at defined time with signature.
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Example 40 - Set Up Approval Sheet

DOC. NO
SET UP VERIFICATION REV. NO
Product -W 201 DATE
Date
Shift
Disc Tooling
S. No Operation Parameters
Number
Time
Spec Unit ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION ACTUAL DECISION
1 BLANKING 2D09-1 Shut Height mm
Shut Height 500±1.0 mm
2D09-2 Cushion Pin Height Above

70±1.0 mm
2 DRAW#1 The Bolster Bed
Die Cushion Pressure 3.0~7.0 Kg/cm2

Die Cushion Pressure 3.0~7.0 bar
Die Cushion Pressure 0.3~0.7 Mpa

70±1.0 mm
3 DRAW#2 The Bolster Bed


70±1.0 mm
4 REVERSE DRAW The Bolster Bed

5 TRIMMING 2D09-5 Shut Height 572±1.0 mm

80±1.0 mm
6 FINAL DRAW The Bolster Bed

BOLT HOLE
7 2D09-7 Shut Height 458+2.0-6 mm
PIERCING
8 BOLT HOLE COINING 2D09-8 Shut Height 448±1.0 mm
2D09-9A 416±1.0 mm
9 VENT HOLE Piercing 2D09-9B Shut Height 416±1.0 mm
2D09-9C 416±1.0 mm
2D10-10A 419±1.0 mm
9 VENT HOLE COINING 2D10-10B Shut Height 419±1.0 mm
2D10-10C 419±1.0 mm
verification of one parameters by supervisor
Operator Sign
Poduction Supervisor Sign
Quality Inspector Sign
Section Head Sign
1 QUALITY APPROVAL SIGN & FREQUENCY ADDED
0 FIRST ISSUE FREQUENCY - 1)EVERY SHIFT. 2)EVERY LINE CHANGE. 3)DIE BREAK DOWN (DIE REMOVED). 4)MAJOR MACHINE BREAK DOWN (DIE REMO
REV DATE REV NO REVISION HISTROY
82
Example 41 - Set Up Instructions
Doc. No. :-
Rev.No./Date :-
SET UP CHANGE PROCEDURE Issue No./Date :-
Page No. :-
MACHINE :- Leakage Testing
Loosened the bolt (2 Nos. at Remove the jig allignment Replace the Upper jig from Insert the jig allignment guide
Remove the Vaccum Upper plate with other side
guide pin (2 Nos. at both pin (2 Nos. at both sides) after
generating pipe of Upper jig both side) of jig by rotating using both hands by holding at allignment of Upper jig with
by pressing the Blue Knob in anticlockwise direction sides) jig handle Upper plate
Connect the Vaccum Tightened the bolt (2 Nos.

Connect the electrical Replace the lower jig from Remove the electrical generating pipe to Upper jig
connector of jig by rotating station using both hands by at both side) of jig by
connector of jig by rotating it by pressing pipe end into rotating in Clockwise
it in Clockwise direction holding at jig handle in anticlockwise direction blue knob direction
RESPONSIBILITY :- Operator / Line Leader

REACTION :- While set up change, if setting is Not Ok, inform Line leader/Shift Incharge/Maintainance Engineer.
CHANGE MANAGEMENT
SR.NO. REV. DATE REV. DESCRIPTION
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Example 42 - Set up Parameters Adjustment Guidelines
SET UP STANDARD
Driver Riser & Lumber Assembly
VARIANT W3M/C MAT
MAN METHOD
Screw Runner Gun DC Tool Shoulder bolt Frame As Per OD Sheet
1.5 to 8 Nm 10 to 50 Nm Riser Bush (IGUS) Continuous Lumber
Mallet T50 Socket Ht adjuster adaptor bracket M4.5 x 20 mm Taptite screw (H.A)
Nut Runner Gun T50 Bit Wire Harness Bush M4 Self tapping Screw
TLS 30 to 55 Nm
Socket M10
4 Way Bit M10 Bolt Riser bracket IB
Scanner Ht adjuster Stopper bracket Riser bracket OB
Screw M4 Tap Tite Footwell Lamp
Recliner Back Holding Spring Mother BarCode Sticker
Inner Recliner Cover (TLS) M6*13 bolt
TD 30 to 55 Nm
Socket M10
4 Way Bit M10 Bolt Riser bracket IB
Scanner Ht adjuster Stopper bracket Riser bracket OB
Inner Recliner Cover (TD) M6*13 bolt
VARIANT
M/C
W4 MAT
MAN METHOD
30 to 55 Nm 4 Way Bit M10 Bolt Riser bracket IB
TLS Socket M10 Scanner Ht adjuster Stopper bracket Riser bracket OB
Inner Recliner Cover (TLS) Air Bag Cable
M6*13 bolt
30 to 55 Nm 4 Way Bit M10 Bolt Riser bracket IB
TD Socket M10 Scanner Ht adjuster Stopper bracket Riser bracket OB
Inner Recliner Cover (TD) Air Bag Cable
M6*13 bolt
84
5.7 Process Instructions
PURPOSE
• To assure preparation of Process Instructions derived from Control Plan, operation requirements etc.
• To assure availability of Process Instructions to the respective operators.
• To assure availability of systems to verify operators are performing as per defined Process Instructions.
• Availability of operation wise Process Instructions in local language including clear • Operation wise Process Instructions (Ex 43).
photograph of exact activity, operation sequence, all quality checkpoints before • Operation Observation Sheet (Supervisors checklist) (Ex 44).
and after each step as per control plan, reaction plan for each step, symbols of SC/
CC, PY, Operator skill etc.
• Availability of Inspection Instructions including all inspection items with sequence
(product characteristics) as per control plan and clear identification with
specifications, what to check, how to check (instrument, location, defect samples,
inspection area etc).
• Availability of Process Instructions for respective operators. Without With
Standardized Standardized
• Availability of mechanism for operator observation at defined frequency to check Work Work
operator working as per Process Instructions and improvement in case of any Instruction Instruction
deviation.
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Example 43 - Operationwise Process Instructions

STANDARD OPERATING SHEET Operation:- Moulding
Department/SBU Signature Document No.
Part Name Name Issue Date
Part No. Authority Prepared By Reviewed By Rev.No.
Date Rev.Date
ijammaodarI : AaproTr ijammaodarI : AaproTr ijammaodarI : AaproTr ijammaodarI : AaproTr ijammaodarI : AaproTr ijammaodarI : AaproTr
CC BB
1 2 3 4 5
@ puranao kpDo sao maSaIna kI safa[- krooM. @ maSaIna kao baMd kr do ijasasao maaolD gama- hao @ phlao T,MaijaSana jvaa[MT lagaayaoM , icat/,anausaar maSaIna @ p,aofa[-la kao maaolD mao banaI laaoiDMga laa[na tk @ saOT ikyao gayao vajana ko Anausaar hI kmpa]ND @ maaolD mao kmpa]nD Dalakr maSaIna ko saa[D mao lagao
@ AavaSyaktaa pDnao pr maaolD kao Tolune tqaa jaayao. mao p,,aofa[-la ka jaoa isara maaolD mao jaanaa hao ]sao laaoD kro. maaolD kOivaTI mao Dalao,. dao puSa baTna dbaayao tqaa Qyaana do ik saBaI pOramaITr
vaayar baùSa kI sahayata sao saaf krooM.(maSaIna caok @ maSaIna ko pàosaosa pOramaITr maSaIna pr lagaI pàosaosa ]sa trf lagaayao.icat/ RH ka hO va LH ko ilayao © Qyaana do ik p,aofa[-la laa[na saoo Aagao yaa pICo laaoD © Qyaana do ik kmpa]nD ka vajana kma yaa jyaada caalaU hao jaayao.
ilasT raoja maSaIna caok krnao ko baad AvaSya Baro.) SaIT ko Anausaar saOT kroM. ]lTa lagaayaoM. na hao.Anyaqaa pIsa irja@T hao jaayaogaa. haonao pr pIsa AnDrifla yaa AaovarFlaao hao sakta © maaolD maSaIna ek baTna sao nahI calanaI caaihe.
© maaolD maoM kao[- rbar tqaa Anya pda-qa nahI icapka © Actual pOramaITr pàosaosa SaIT ko Anausaar hI © Qyaana do ik jaao p,aofa[-la ijasa kOivaTI mao laganaI hao ® irja@T pIsa kao QyaanapUva-k kaT kr dubaara hO. ® maSaIna ek baTna yaa nahI calaanao kI dSaa mao
haonaa caaihyao. Aanao caaihyao. ]sa ]saI kOivaTI mao lagaayao.varnaa pIsa kI ilap dbaogaI maaoilDga kro.(safod maak- lagaakr irmaaolD kro.) ® eosaa haonao pr kmpa]nD ko vajana kI jaa^ca sauprvaa[jar kao saUicat kro.
® icapka haonao pr maaolD Kraba Aayaogaa. ® sahI na haonao pr iSaFT [-ncaa-ja kao batayaoM tqaa AaOr pIsa irja@T hao jaayaogaa. krayao.
sahI haonao pr hI maSaIna calaayaoM. ® irja@T pIsa kao sak,Op kr do.
ijammaodarI : AaproTr ijammaodarI : AaproTr ijammaodarI : AaproTr ijammaodarI : AaproTr “kaya- krnao sao pUva- jaaMcao :
• raojaanaa A iSaFT mao Daily Machine Check Sheet ko saaro Pvaa[MT caOk kro tqaa ]saka sToTsa SaIT mao Baro.
• galat haonao pr iSaFT [ncaaja- kao saUicat kroM.
AA BB AA pyaa-varNa eMva saurxaa inado-Sa:
CC
• p%yaok haqa maoM dao - dao dstanao phnao
• maaoilDMga maSaIna maoM Aayala laIk nahI haonaa caaihyao.
7 8 9 10 sambainQat Da@yaUmaoMT:
@ maaoilDga ko saaro pOramaITr samaaPt haonao pr maaolD @ maaolD mao iDfo@T kI jaa^ca kro. @ sTop nambar 1 va 2 puna : daohrayaoM va B ipbar @ sTop nambar 1 va 2 puna : daohrayaoM va c ipbar jvaa[MT • Asaamaanya isqait inado-Sa
Kaolakr saavaQaanaIpUvak pIsa sao [nsarT inakalao. © maaolD mao AnDrifla ,jvaa[T ko,k ,gaOsa maak- AaOr jvaa[MT lagaanao ko ilayao icat/anausaar maSaIna mao p,,aofa[-la lagaanao ko ilayao icat/anausaar maSaIna mao p,,aofa[-la ka jaoa isara • Final Inspection Std. baa]MDrI saompla
© saBaI pOramaITr samaaPt haonao sao phlao maSaIna Aaovariflaao nahI haonaa caaihe. ka jaoa isara maaolD mao jaanaa hao ]sao ]sa trf lagaayao. maaolD mao jaanaa hao ]sao ]sa trf lagaayao.icat/, RH ka • irvak- ina-doSa
nahI KulanaI caaihe tqaa saavaQaanaIpUva-k [nsarT na ® kao[- BaI samasyaa haonao pr dubaara maaolD kro. icat/, RH ka hO va LH ko ilayao ]lTa lagaayaoM. va hO va LH ko ilayao ]lTa lagaayaoM. va ]sako baad sTop
inakalanao Par jvaa[T k,ok hao sakta hO. (safod maak- lagaakr irmaaolD kro.) ]sako baad sTop 4 sao 8 tk daoh 4 sao 8 tk daoh Significant Characteristic:
® saBaI pOramaITr samaaPt haonao sao phlao maSaIna Kuloana © Qyaana do ik jaao p,aofa[-la ijasa kOivaTI mao laganaI © Qyaana do ik jaao p,aofa[-la ijasa kOivaTI mao laganaI hao ]sa
• pàoD@T :
pr sauprvaa[jar kao saUicat kro tqaa jvaa[T k,ok hao ]sa ]saI kOivaTI mao lagaayao.varnaa pIsa kI ilap ]saI kOivaTI mao lagaayao.varnaa pIsa kI ilap dbaogaI AaOr pIsa
haonao pr dubaara maaolD kro.(safod maak- lagaakr dbaogaI AaOr pIsa irja@T hao jaayaogaa. irja@T hao jaayaogaa. qYaana doM ik pIsa mao bala na Aayao. • pàosaosa:
irmaaolD kro.) ® irja@T pIsa kao sak,Op kr do. ® irja@T pIsa kao sak,Op kr do.
pàosaosa Flaao:
@ kaya- p`NaalaI
Legends: © caOk PvaaM[-T
hmaara laxya
OK kiTMga va iT/imaga va i@lap Packing
maaoliDMga Inspection ® ireo@Sana Plaana Agalao pàosaosa (Operation) kao “0” iDfo@T dogao.
pàofa[la iD/ilaMga [nsaT- laa[na kao icapkanaa [nsarT pOikMga
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Example 44 - Operators Observation Sheet
OPERATOR OBSERVATION SHEET
MONTHS
Employee Name :
Process Name : Test Date Test Date Test Date
Method : Demo Observed By : Observed By : Observed By :
Perform the process not Perform the process in Perform the process not Perform the process in Perform the process not Perform the process in
S.NO PARAMETERS in effective manner. effective manner. OJT given on : Remarks. in effective manner. effective manner. OJT given on : Remarks. in effective manner. effective manner. OJT given on : Remarks.
NOT OK OK NOT OK OK NOT OK OK

QUALITY CHECK SHEET OBSERVATION PARAMETERS.
1 Does the operator checking the Parts as per the quality check sheet ?
2 Does the operator checking as per the quality check sheet?
3 Does the operator assembling the child parts as per quality check sheet ?
4 Does the operator can identify Process parameters ?
5 Does the operator adjusting the process parameter during process ?
6 Does the Operator changing the tools as per quality check sheet ?
7 Does the operator explain the special product characteristics?
8 Does the operator run the process after getting the approval from QA.?
5S- OBSERVATION PARAMETERS.
8 Does the operator conducted the 5S properly during start of shift
9 Does the operator clean the machine , chutes ,tools properly?
10 Does the operator clear the excessive burrs properly during process ?
11 Does the sorting out the all anwanted items ?
12 Does the opertor kept the chutes, machine accessories in proper manner?
13 Does the operator kept his station clean ?
ABNORMALITY HANDLING OBSERVATION PARAMETERS.
14 Does the operator refering the abnormal situation in case of any obnormality?
15 Does the operator using emergency stop button in case of any emergency?
Does the operator do the activity as per abnormality handling procedure? If abnormal
16
occurred.
Does the operator stop, call the team leader , wait for him (or) not during abnormal
17
occurred ?
CONTROL OF NG COMPONENTS HANDLING OBSERVATION PARAMETERS.
18 Does the operator clasifing the the defects as per the A,B,C tag ?
19 Does the operator identifying the defects in the production stage itself ?
20 Does the operator marking the defects with paint marker on the part?
Does the operator classifing the defects like setup or process before putting into the red
21
bin ?
Does the operaotor marking the defects in rejected components before putting into red
22
bins ?
23 Does the operator clear all the rejections with in end of shift?
24 Does the operator know the reason for Defects occuring on the part ?
25 Does the operator kept the A,B,C tag and Rework tag on his station?
26 Does the operator kept the Red paint marker in his station?
27 Does the operator tie the tags with NG components in his station ?
A
28 Does the operator closed the red bin? (or) not during process ?
29 Does the operator clear all the rejections for every lot completion ?
DAILY MACHINE CHECK SHEET HANDLING OBSERVATION PARAMETERS.
30 Does the operator checking process parameter as per DMS. ?
31 Does the operator filled the startup check list in that particular shift ?
32 Does the operator writing the Actual machine Parameters in DMS ?

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Does the operator adjusting the process parameter as per the setting and Re-setting
33
limits?( Machine Parameter only )
12 Does the opertor kept the chutes, machine accessories in proper manner?
13 Does the operator kept his station clean ?
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MSES
Does the operator do the activity as per abnormality handling procedure? If abnormal
DARD
16
occurred.
Does the operator stop, call the team leader , wait for him (or) not during abnormal
17
occurred ?
CONTROL OF NG COMPONENTS HANDLING OBSERVATION PARAMETERS.
18 Does the operator clasifing the the defects as per the A,B,C tag ?
19 Does the operator identifying the defects in the production stage itself ?
20 Does the operator marking the defects with paint marker on the part?
Does the operator classifing the defects like setup or process before putting into the red
21
bin ?
Does the operaotor marking the defects in rejected components before putting into red
22
bins ?
23 Does the operator clear all the rejections with in end of shift?
24 Does the operator know the reason for Defects occuring on the part ?
A
Contd...
25 Does the operator kept the A,B,C tag and Rework tag on his station?
26 Does the operator kept the Red paint marker in his station?
27 Does the operator tie the tags with NG components in his station ?
28 Does the operator closed the red bin? (or) not during process ?
29 Does the operator clear all the rejections for every lot completion ?
DAILY MACHINE CHECK SHEET HANDLING OBSERVATION PARAMETERS.
30 Does the operator checking process parameter as per DMS. ?
31 Does the operator filled the startup check list in that particular shift ?
32 Does the operator writing the Actual machine Parameters in DMS ?

Does the operator adjusting the process parameter as per the setting and Re-setting
33
limits?( Machine Parameter only )
Does the operator record the abnormality against adjusting the process parameter as per
34
the setting and Re-setting limits?( Machine Parameter only )
GENERAL OBSERVATION PARAMETERS.
35 Does the operator perform Cycle of Operation?
36 Does the operator perform the operation within cycle time ?
37 Does the operator produced the components as per Cycle Time?
38 Does the operator filled the houly inspection record properly ?
39 Does the operator kept the NG samples in proper manner ?
40 Does the operator kept the POKE YOKE samples in proper manner ?
41 Does the operator kept the samples which is in chute on a proper manner.
GAUGES HANDLING OBSERVATION PARAMETERS.
42 Does the operator handling the gauge in correct manner ?
43 Does the operator verify the master setting during start of production?
44 Does the operator kept the gauges in correct manner ?
45 Does the operator clean the gauges properly ?
POYE YOKE HANDLING OBSERVATION PARAMETERS.
46 Does the operator by-pass the POKE YOKE during Process ?
SAFETY OBSERVATION PARAMETERS.
47 Does the Technician know the safety of tool ?
48 Does the operator wear the shoes and gloves during process ?
49 Does the duct the shirt during process ?
50 Does the operator follow the safety instructions properly ?
TRCEABILITY OBSERVATION PARAMETERS.
51 Does the operator follow the FIFO ?
52 Does the operator clear the NG at end of every lot?
53 Does the operator mark the lot number on parts (or) tags properly?
54 Does the operator changed the traceability tag to finished bin properly.
WORK INSTRUCTIONS OBSERVATION PARAMETERS.
55 Does the operator refering the work instruction for operation ?
56 Does the operator perform all the key points as per W.I ?
Reviewed By : Reviewed By : Reviewed By :
Approved by : Approved by : Approved by :
F04-6201A Rev No : 00
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Example 44 - Operator Observation Plan
OPERATORS OBSERVATION PLAN SHEET

MONTH OF _______2011 MONTH OF _______2011 MONTH OF _______2011
SL NO NAME STAFF:NO OPERATION DESCRIPTION
WEEK 1 2 3 4 1 2 3 4 1 2 3 4
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
Prepared By : Approved By :
F07-6201 A Rev No : 00
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5.8 Operator Training
PURPOSE
• To assure Operator Training is conducted as per defined plan for required topics influencing Process and Product Quality.
• To assure system of assigning skill level to operator and their deployment accordingly.
• To assure system of controlling Product Quality in case of new/temporary operators.
• Availability of Training material prepared by respective departments on Process • Training Manuals (Ex 45).
Knowledge, Process Instructions, Management of Non-Conforming Parts, Handling • Training procedure (Ex 46).
of Abnormal Situations, Handling of Measuring Instruments, Observance of Items • Operator wise training plan and records (Ex 47).
Control Plans. • New product training manual (Ex 48).
• Availability of operator wise training plan Vs actual status and training records. • New/temporary operators Quality Monitoring sheet (Ex 49).
• Availability of training program on new Product Knowledge including part function, • Skill evaluation Record Sheet (Ex 50).
Change in the new product compare to existing products and training records for
• Operator Observation sheet (Refer Ex 44).
operators (new or existing) who will work on this product.
• Skill matrix with Minimum skill required for each operation (Ex 51).
• Availability of standard to Control Quality in case of new/temporary operators
(Sample inspection of parts produced by new /temporary workers until achieving • Refresher training sheet (Ex 52).
defined acceptance level).
• Availability of system to assign skill level to operators
based on objective Skill Evaluation.
• Availability of plan and records of operator observation to identify Effectiveness of

training and recovery actions.
• Availability of system to confirm operations performed by qualified operators only.
• Availability of system to conduct operator refresher training.
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Product Knowledge
1 Product Details 8
Process Knowledge
1 Moulding 60 – 63
2 Painting 131
3 Rework 132
4 Assembly of Part 133
5 Inspection of Part 134
Example 45 - Operator Training Manual
6 Fallen Top Coat Wheel 135
Operator Training Manual System Knowledge
S.NO INDEX PAGE NO 1 5S 15 – 20
General Information 2 Morning Meeting 22 – 23
1 Introduction About the Company 3 3 Start Up Check Sheet 24 – 25
2 Promoters of the Company 4 4 POKE YOKE 26 - 27
3 Company Layout 5 5 Work Instructions 28 – 29
4 Safety, Health, Environmental And Quality 6 6 Set – Up Verification 32
5 Work Safety 7
7 First - Off Inspection 33
Product Knowledge 8 Periodical Inspection 34 – 35
1 Product Details 8 9 Visual Inspection 36
Process Knowledge 10 Production Log 37 – 38
1 Moulding 60 – 63 11 FIFO – First In First Out 39
2 Painting 131 12 Rework & Rejection Records ( Tally Chart) 40 – 41
3 Rework 132 13 Special Characteristics 42 – 43
4 Assembly of Part 133 14 SPC Chart 44
5 Inspection of Part 134 15 Material Handling 45
6 Fallen Top Coat Wheel 135 16 Non – Conformity Management 46 – 52
System Knowledge 17 Abnormal Conditions 53 – 54
1 5S 15 – 20 18 Operator Adjustment Sheet 55 – 56
2 Morning Meeting 22 – 23 19 Daily Instrument Check Sheet 57 – 58
3 Start Up Check Sheet 24 – 25
4 POKE YOKE 26 - 27
5 Work Instructions 28 – 29
6 Set – Up Verification 32
7 First - Off Inspection 33
8 Periodical Inspection 34 – 35 91
9 Visual Inspection 36
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Example 46 - Training Procedure

DOC NO :
OPERATOR TRAINING FLOW CHART REV NO: REV DATE:
INDUCTION TRAINING
INPUT DOCUMENTS - WORK INSTRUCTIONS,
ABOUT COMPANY
TRAINING MANUAL
OUTPUT DOCUMENTS - FEED BACK FORM
TRAINING LOCATION - TRAINING HALL ORGANIZATION CHART
RESPONSIBILITY - HOD HR & DISC LINE SHOP FLOOR OBSERVATION TIME LINE - FIRST DAY OF PROPOSAL
INPUT DOCUMENTS - DISC LINE TRAINING

MANUAL
TRAINING TOPICS
RESPONSIBILITY - HOD DISC LINE & HR MACHINE KNOWLEDGE INSPECTION KNOWLEDGE TOOL SETTING KNOWLEDGE
TRAINING LOCATION - SHOP FLOOR
TIME LINE - 10 DAYS(1ST DAY OF JOINING TO

01.SAFETY 07.RESPONSIBILITY & AUTHORITY 13.CONTROL OF NON-CONFORMITIES 19.POKE YOKE & KAIZAN
10TH DAY)
FAIL 02.HAZARDS & RISKS ASSESSMENTS 08.PROCESS KNOWLEDGE 14.DEFECTS ANALYSIS 20.WI & OS
OUTPUT DOCUMENTS - FEED BACK FORM,
ATTENDANCE SHEET
03.ASPECTS & IMPACTS 09.PRODUCT KNOWLEDGE 15.DISC REWORK 21.CHECK SHEETS
04.EMERGENCY PREPAREDNESS 10.TOOLING MANAGEMENT 16.ABNORMAL CONDITION 22.CONTROL PLAN
05.FIRST AID 11.MATERIAL HANDLING 17.REACTION PLAN 23.PRESS PARTS & WORKING
06.5 S 12.IDENTIFICATION & TRACEABILITY 18.ACCEPTANCE CRITERIA FOR DISC 24.FIFO & DO, DON'TS
TEST THEORETICAL (WITH * MARKED QUESTIONS)

MACHINE KNOWLEDGE INSPECTION KNOWLEDGE TOOL SETTING KNOWLEDGE
INPUT DOCUMENTS -TRAINING MANUAL,
TOTAL SCORE - 10 TOTAL SCORE - 10 TOTAL SCORE - 10
QUESTION PAPER
RESPONSIBILITY - HOD DISC LINE & HR
TIME LINE - 05 DAYS(11TH DAY OF PROPOSAL TO

15TH DAY)
OUTPUT DOCUMENTS - FILLED THEORETICAL SCORE 90% AND SCORE 90% AND SCORE 90% AND
ANSWER SHEET ABOVE & 0 STAR * ABOVE & 0 STAR * ABOVE & 0 STAR *
FAIL
MARKED QUESTION MARKED QUESTION MARKED QUESTION
INCORRECT INCORRECT INCORRECT
FAIL
PASS
PASS PASS (OR) FAIL
TEST PRACTICAL (WITH * MARKED QUESTIONS)

FAIL MACHINE KNOWLEDGE INSPECTION KNOWLEDGE TOOL SETTING KNOWLEDGE
PRODUCTION EFFICIENCY - 95% OF PRODUCTION & 0.20% OF REJECTION & 0 INCIDENT
SCORE 90% AND SCORE 90% AND SCORE 90% AND

ABOVE & 0 STAR * ABOVE & 0 STAR * ABOVE & 0 STAR *
FAIL
FAIL
PASS
PASS PASS (OR) FAIL
EVALUATION - MINIMUM LEVEL 2 & CRITICAL OPERATIONS LEVEL 3
A
INPUT DOCUMENTS - QUESTION
PAPER,EVALUTION SHEET
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OUTPUT DOCUMENTS - FILLED PRACTICAL
ANSWER SHEET,EVALUTION SHEET, SKILL FOR BOTH THEORETICAL FOR BOTH THEORETICAL &
MATRIX & PRACTICAL 90% OF PRACTICAL 90% OF MACHINE
FOR BOTH THEORETICAL
MACHINE KNOWLEDGE & KNOWLEDGE & 90% OF
For Special charecteristics operators: Badge & PRACTICAL 90% OF
FAIL MACHINE KNOWLEDGE & 0 FAIL 90% OF INSPECTION INSPECTION KNOWLEDGE &
KNOWLEDGE & 0 STAR * 90% OF TOOL SETTING
STAR * MARKED QUESTION
MARKED QUESTION KNOWLEDGE & 0 STAR *
INCORRECT & 95% OF
RESPONSIBILITY - HOD DISC LINE & HR MARKED QUESTION
INCORRECT & 95% OF
TIME LINE - 05 DAYS(11TH DAY OF PROPOSAL TO

15TH DAY)
OUTPUT DOCUMENTS - FILLED THEORETICAL SCORE 90% AND SCORE 90% AND SCORE 90% AND
ANSWER SHEET ABOVE & 0 STAR * ABOVE & 0 STAR * ABOVE & 0 STAR *
FAIL
FAIL
PASS
PASS PASS (OR) FAIL
TEST PRACTICAL (WITH * MARKED QUESTIONS)

FAIL MACHINE KNOWLEDGE INSPECTION KNOWLEDGE TOOL SETTING KNOWLEDGE
PRODUCTION EFFICIENCY - 95% OF PRODUCTION & 0.20% OF REJECTION & 0 INCIDENT
SCORE 90% AND SCORE 90% AND SCORE 90% AND

ABOVE & 0 STAR * ABOVE & 0 STAR * ABOVE & 0 STAR *
FAIL
Contd... MARKED QUESTION
INCORRECT
A
MARKED QUESTION
INCORRECT
MARKED QUESTION
INCORRECT
FAIL
PASS
PASS PASS (OR) FAIL
EVALUATION - MINIMUM LEVEL 2 & CRITICAL OPERATIONS LEVEL 3
INPUT DOCUMENTS - QUESTION

PAPER,EVALUTION SHEET
OUTPUT DOCUMENTS - FILLED PRACTICAL

ANSWER SHEET,EVALUTION SHEET, SKILL FOR BOTH THEORETICAL FOR BOTH THEORETICAL &
MATRIX & PRACTICAL 90% OF PRACTICAL 90% OF MACHINE
FOR BOTH THEORETICAL
MACHINE KNOWLEDGE & KNOWLEDGE & 90% OF
For Special charecteristics operators: Badge & PRACTICAL 90% OF
FAIL MACHINE KNOWLEDGE & 0 FAIL 90% OF INSPECTION INSPECTION KNOWLEDGE &
KNOWLEDGE & 0 STAR * 90% OF TOOL SETTING
STAR * MARKED QUESTION
MARKED QUESTION KNOWLEDGE & 0 STAR *
INCORRECT & 95% OF
RESPONSIBILITY - HOD DISC LINE & HR MARKED QUESTION
PRODUCTION & 0.20% INCORRECT & 95% OF
PRODUCTION & 0.20% INCORRECT & 95% OF
REJECTION & 0 INCIDENT
REJECTION & 0 INCIDENT PRODUCTION & 0.20%
TIME LINE - (11TH DAY OF PROPOSAL TO 15TH REJECTION & 0 INCIDENT
DAY)
FAIL PASS PASS

PASS
LEVEL 1 LEVEL 2 LEVEL 3
OPERATOR OBSERVATION (Freq: Once in a year)
FAIL
FAIL
RE - TRAINING REFRESHER TRAINING (For NEW PRODUCT TRAINING Inputs: (Trg Manual)
operators who re join duty after (Freq: Whenever New Product is * Customer
15 days continuous leave Introduced) * Raw material
FAIL * Configuration
* Process
Output Document: Refresher * Safety
RE TEST & EVALUATION training sheet (F/HR/07) EVALUATION
characteristics
(Pass Criteria - Min.80%)
* Comparison with
similar product
Output Document: Evaluation sheet * Important
dimensions
PREPARED BY : CHECKED BY : APPROVED BY :
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Example 47 - Operatorwise Training Plan & Records

Doc. No:
TRAINING PLAN FOR THE YEAR 2011 - 12 ( TECHNICIANS ) Rev. No:
Rev. Date:
On The Job Training
S.No. Who Where Whom When Jan-11 Feb-11 Mar-11 Apr-11 May-11 June-11 July-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11
Topics Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4 Wk1 Wk2 Wk3 Wk4
SKILLS REQUIRED ( Injection moulding )
1
Krishnan Plan 3 5 5 5 5 5 5
Injecton Molding Operation Sharma PP-2 Shop
Dhariwal Actual 3 6 4
Injection Molding Process Pradip Plan 3 5 5 5 5 5 5
2 Sharma PP-2 Shop
Parameters Devidas Actual 3 6 4
Sh lk
Swapnil Plan 5 6 6 6 6 6 6
3 Troube Shooting Sharma PP-2 Shop
Bhoskar Patil Actual 5 6 4
Ashish Plan 5 6 6 6 6 6 6
4 Mould Change Sharma PP-2 Shop
Bhausaheb Actual 5 6 4
S th
Grinding, Mixing & Pre- Rahul Plan 6 7 7 7 7 7 7
5 Sharma PP-2 Shop Raghunath
Heating Actual 6 6 4
Chaudhari
SKILLS REQUIRED ( General )
Moulding Defects Bhalchandra Plan 22 10 10 10 10 10 10

6 Sharma PP-2 Shop
Identification Dinkar Borole Actual 12 4
HCPP points & inspection Plan 22 10 10 10 10 10 10
7 VJ PP-2 Shop K.L.Baviskar
methodolgy Actual 10 2
Problem Solving by using 7 Patil Nitin Plan 24 12 12 12 12 12 12
8 Selvakumar PP-2 Shop
SQC Tools Madhukar Actual 12 12
Patil Umesh Plan 23 13 13 13 13 13 13
9 Vision Capability Doctor Clinic
Balu Actual 13
Patil Rahul Plan 23 13 13 13 13 13 13
10 Color Identification Doctor Clinic
Prashad Actual 13
SKILLS REQUIRED ( Ultrasonic Welding )
Chaudhari Plan 9 14 14 14 14 14 14
11 Ultrasonic welding operation Sharma PP-2 Shop
Kishor J Actual 10 31 10
Tejam Plan 9 14 14 14 14 14 14
12 Welding trouble shooting Sharma PP-2 Shop Ravindra
Actual 10 31 10
Tukaram
SKILLS REQUIRED ( Foam & Slider Assy )
Patil Rajendra Plan 10 17 17 17 17 17 17

13 Foam Assy operation Sharma PP-2 Shop
Balu Actual 10 31 10
Plan 10 17 17 17 17 17 17
14 Slider Assy operation Sharma PP-2 Shop Mohan Patil
Actual 10 31 10
KNOWLEDGE REQUIRED
Knowlegde on IS, DD, AS Amol Plan 24 18 4 18 18 18 18

15 VJ PP-2 Shop
and WI Chaudhari 10 2
Actual
Plan 26 18 4 18 18 18 18
16 Product Knowledge VJ PP-2 Shop Tambe
Actual 10 2
Swapnil Plan 29 20 5 20 20 20 20
17 Raw Material Knowledge Sharma PP-2 Shop
Madhukar Patil 12 4
Actual
Plan 26 20 5 20 20 20 20
18 5S & Safety VJ PP-2 Shop kamlesh yadav
Actual 10 2
Customer Specific 28 25 12 25 25 25 25
19 Selvakumar PP-2 Shop
S.S.CHAUDHA Plan
Requirements/Safety &
RI
regulatory characteristics Actual 31 5
Plan 28 25 12 25 25 25 25
20 Quality Objectives Selvakumar PP-2 Shop GOLEKAR
Actual 12 12
ASES / AVES & FIREWALL Plan 28 27 13 27 27 27 27
21 Selvakumar PP-2 Shop SAYEED
Knowledge Actual 31 5
LEGEND : Plan
Actual(completed) Approved By :
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Example 48 - New Product Training Manual
New Product Training Manual
S.NO INDEX PAGE NO
1 Part Assembly Photo 1
2 Part Stage wise Photo 2
3 Process Flow 5
4 Special Charactristics 6
5 Special Charactristics Failures & Effect 7
6 Assembly 8
7 Comparison Study of Existing & New Part 11
8 Customer Specific Requirement 12
9 Part Packaging Specification 13
10 Tool Poka Yoke 14
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Example 49 - Operator Verification Record for Ojt

Name Of Operator
VERIFICATION RECORD FOR OJT. Employee No

Process Name
PRODUCTIVITY ASSESMENT QUALITY ASSESMENT

DATE PRODUCTION On the Effectiveness On the Effectiveness Remarks
Re-Trained REJECTED/ REJECTION/REWORK Re-Trained
GAP DUE TO Job verification DUE TO Job verification
PLAN ACTUAL by REWORK QTY DESCRIPTION by
training after trg. training after trg.
Note :
Monitor the opertor 's rate of quality & rate of production contineously for 15 days. After final verification ,deploy the operator for the regular production.
F05-6201A. REV NO : 00
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Example 49 - New / Temporary Operators Quality Monitoring Sheet
DATE
NEW OPERATORS HOURLY PRODUCTION REPORT SHIFT
M/c No : MODULE EMP- NAME

1st 2 nd 3 rd 4 th 5 th 6 th 7 th 8 th
Hour Hour Hour Hour Hour Hour Hour Hour
Hourly TOTAL
TIME ……….. TIME ……….. TIME ……….. TIME ……….. TIME ……….. TIME ……….. TIME ……….. TIME ………..
PRODUCTION TARGET
PRODUCED QTY
PRODUCTION GAP
REJECTION QTY ( Put Qty & Lot No)
TYPE OF REJECTION
REWORK QTY ( Put Qty & Lot No)
TYPE OF REWORK
VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY & VEF OK REJ QTY &
QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No QTY QTY Lot No
ABNORMALITY (POWER CUT REJECTION)
NO PLAN
N/M
N/T
B/D
DOWN TIME (MINTS)

T/S
SETUP
NO OPR
OTHERS IF SPECIFY THE CONTENT
NEW OPERATORS PRODUCING COMPONENTS VERIFICATION CONTENTS DURING EVALUVATION
Components Checking Qty :

( 2 Nos/Hr to be Checked as per quality check sheet )
OK Qty :
REJECTION QTY
Type of Rejections :
If Rejection Occurred, Check Previous one hour produced

parts as per NG tracking sheet( F05-8301) and mention the
status
OJT ( If rejection occurred due to operator lacking.
Mentioned the date & time of OJT )
OJT -Effectiveness : Mention the Effectiveness OK (Or)
Not 0K
Trained / Verifed By : ( Team Leader)
Note : Team Leader has to verify the product specification as operator follows
F10-6201A Rev No : 00
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Example 50 - Skill Evaluation Record Sheet

MGI COUTIER EXOTECH INDS PVT LTD
Doc.No:
OPERATOR SKILL LEVEL CARD Rev. No:
Rev. Date:
Objective : To measure and achieve the skill level of operator to perform, on the process
Procedure : Supervisor / Manager to take Work Instruction , Start-up check sheet and let the operator actually perform(1) the start
up of process (2) perform work as per Sequence operation sheet &(3) perform checking as per Control Plan
Evaluation : Based on the observation of the operator , supervisor to do the evaluation using the rule for marking
Section : Renault L90 Operation : Assembly

NAME OF EVALUATOR :- Date of Evaluation :
NAME OF OPERATOR:- PROCESS NO 4010

Can perform
Cannot perform the Can perfom the Can perform the
the process in
process in time & process but not proces but some
time following
unaware of quality with quality key times misses the
SR NO PARAMETERS all quality
key points points quality key points
keypoints
0 1 2 3
Does operator identify all parts, sub-parts on work station( e.g. Size & type of
1 tubes, connectors)
2 Does operator know & able to perform set-up
3 Does operator able to perform start-up checks
4 Does operator know the function of emergency stop button
5 Does operator perform all steps in correct sequence( as mentioned in W.I.)
6 Does operator checks quality check points during operation
7 Does operator able to recognise non-conformance parts
Does operator follow the non-conformance handling instructions ---

8 (a) Labelling NC parts
(b)Filling all details of non-conformance on lable
©Keeping part in RED bin & inform supervisor
9 Does operator check poka-yoke with dummy sample
10 Does operator understand & maintain 5S in his area
11 Does operator know the care to be taken for Safety characteristics
12 Does operator wear safety equipments during work
13 Does operator understand traceability of the part
14 Does operator know the handling of measuring equipments on work station
15 Does operator identify & implement small improvements on his work station.
Sub-total=
Total Marks
Effectiveness Evaluation Marks

Theory Examination Marks
Total
EVALUATOR REMARKS :-
Training Needs Identified :
SCORING REQUIREMENT
FOR LEVEL -I 20%-40&
FOR LEVEL -L 41%-60%
FOR LEVEL -U 61%-80%
FOR LEVEL -O 81%-100%
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Example 51 - Skill Matrix with Minimum Skill required for each Operation
“A Basic knowledge only “C Can work independently
SKILL MATRIX B Can work under supervisor” D Can teach to others “
Process
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Number
CCDC/FIREWALL
PAD PRINTING
Section:
% 1M2J
Number of
INSPECTION
PRINTING &
ASSEMBLY
CLEANING
MARKING
CUTTING
PACKING
process per 1M2J
Month: Operation person
Name
Name Process Photo Plan Act
Minimum skill reqd for each operation
1 ANIL SHARMA SUPERVISOR 2 6 ok
2 RAMESHWAR OPERATOR 2 3 ok
3 MUKESH SHARMA OPERATOR 2 2 ok
4 SHIV POOJAN OPERATOR 2 2 ok
5 PADAM BIST INSPECTION (CCDC) 2 4 ok
6 NAVEEN INSPECTION 2 4 ok
7 JAGAT INSPECTION 2 3 ok
100%
8 SANJAY CUTTING 2 3 ok
9 MUKESH CLEANING 2 3 ok
10 VINOD MARKING 2 2 ok
11 OMPREKASH OPERATOR(PAD PRINT.) 2 2 ok
12 RANJEET OPERATOR(PAD PRINT.) 2 2 ok
13 YESPAL OPERATOR(PACKING.) 2 4 ok
14 RAJU OPERATOR(PACKING.) 2 4 ok
Plan 2 2 2 2 2 2 2 2
Number of person per process
Act 10 2 14 5 5 4 2 2
1J2M ok ok ok ok ok ok ok ok
1J2M% 100.00%
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Example 52 - Refresher Training Record

Doc. No:
REFRESHER TRAINING RECORD Rev. No:
Rev. Date:
CHECK LIST FOR REFRESHING TRAINING TO J-1/ J-2 EMPLOYEES
AFTER RESUMPTION FROM LONG LEAVE / ABSENCE BEYOND 15 DAYS
NAME & TKT No.
DEPT / SECTION / MODULE
ABSENT FROM : RESUMED ON :
S. No. PARTICULARS YES NO

1 ARE THERE ANY QUALITY FLASHES /
ANY QUALITY ISSUES, WHETHER,
A. INTERNAL
B. FROM CUSTOMER
C. IN WARRENTY
D. FROM VENDOR
DURING ABOVE PERIOD
2 IS THERE ANY CHANGE IN EXISTING
A. PROCESS PARAMETER
B. CHECKING FREQUENCY
C. EXISTING PROCEDURE / SYSTEM
D. LAYOUT ETC.
DURING ABOVE PERIOD
3 INTRODUCTION OF ANY NEW SYSTEM /
METHOD DURING ABOVE PERIOD
IF ANSWER TO ANY OF THE ITEMS IN 1,2

& 3 ABOVE IS YES , THEN HAS IT BEEN
COMMUNICATED TO THE EMPLOYEE
4 POINTS RELATED TO SKILL MATRIX ARE

REFRESHED
THE EMPLOYEE HAS BEEN UPDATED ON THE ABOVE POINTS
SUPERVISOR'S SIGN E
DATE
N.B DULY COMPLETED SHEET TO BE SENT TO HRD FOR RECORDS.
The objective of introducing the above format is that, when an employee resumes his duty from long absence, he in
different frame of mind. Further, there could be some chanes in process, major/ minor
100
5.9 Control by SPC sheet
PURPOSE
• To assure Process and Product Quality Through Statistical Process Controls.
• Availability of MSA for Gauges and Instruments used for SPC (Attribute and variable • SPC Procedure.
gauges). • MSA Reports.
• Availability of system to calculate Process Capability of required Characteristics • Control Charts (Ex 53).
periodically and to modify control limits based on results. • Process Capability Plan and Results.
• Availability of Drift Rules and Countermeasure Actions. • Drift Rules and Countermeasure Records (Ex 54).
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Example 53 - Control Charts

AREA ( Machining / Starting Characteristic Sample Size & UCL ( X ) CHART ANALYSIS
Assembly) : Date : Name : Frequency :
LCL ( X ) LAST ESTABLISHED CURRENT SIGN
Part No: Process Name : Type of Instrument : Part specification : UCL ( R ) X
Process No: USL: LSL: LCL ( R ) R

Description :
SPC CHART
Machine No : Cp
Cpk
UCL= X+ A2 * R
AVERAGES ( X BAR CHART )
X = AVERAGE OF X
LCL= X - A2* R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
UCL=D4 R
RANGE (R CHART)
R = AVERAGE OF R
LCL=D3 R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
X1
X2
MESUREMENTS X3
X4
X5
SX
X
R
DATE
TIME
EMP. NO.&INITIAL
Note:Min.once in 3 months to be reviewed Process capability THIS PROCESS MUST BE IN CONTROL BEFORE CAPABILITY IS DETERMINED
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Example 54 - Drift Rules & Countermeasure Records
Special Cause Situation Pattern Action Responsibility Special Cause Situation Pattern Action Responsibility
Any point above UCL or Xbar & R chart

1. Stop process & inform supervisor Operator 2/3 of the plotted points are Xbar & R chart
1. Stop process & inform supervisor Operator
below LCL 20.00
between 1/3 region 20.00
19.00
between control limits. 19.00
18.00
2. Verify all process parameters as per Shift supervisor 18.00
1. Verify all process parameters & reset it Shift supervisor
17.00 17.00
process sheet & reset it if required. as per process sheet
Outside Dia.
Outside Dia.
16.00 16.00
15.00 15.00
14.00 3. If required make why-why analysis. CFT Team 14.00 2. Recalculate control limit, plot & QA
13.00 13.00
analyze it.
12.00 12.00
11.00 11.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3. If required make why-why analysis. CFT Team
USL UCL USL UCL
Sample No. Sample No.
LSL LCL LSL LCL
Mean Outside Dia. Mean Outside Dia.
7 points in row on one side Xbar & R chart

1. Stop process & inform supervisor Operator 1/3 of the plotted point are Xbar & R chart
of the average. 20.00
between 2/3 region 20.00
19.00
between the control limits. 19.00
18.00
1. Mean may get shifted, first set the Shift supervisor 18.00
17.00 17.00
process at mean & verify it again. as per process sheet
Outside Dia.
Outside Dia.
16.00 16.00
15.00 15.00
14.00 2. If required make why-why analysis. CFT Team 14.00

2. Recalculate control limit, plot & QA
13.00
13.00
analyze it.
12.00 12.00
11.00 11.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3. If required make why-why analysis. CFT Team

USL UCL USL UCL
LSL LCL LSL LCL
7 points in a row Xbar & R chart

1. Stop process & inform supervisor Operator Any non –obvious pattern. Xbar & R chart
consistently increasing. 20.00 20.00
19.00 19.00
18.00
1. Verify all process parameters & reset it Shift supervisor 18.00
17.00 17.00
as per process sheet as per process sheet
Outside Dia.
Outside Dia.
16.00 16.00
15.00 15.00
14.00 2. Process average changing, set the Shift supervisor 14.00 2. Make Root – Cause analysis, CFT Team
13.00
process at average. 13.00
Recalculate control limit & verify it.
12.00 12.00
11.00 11.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3. If required make why-why analysis. CFT Team 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
USL UCL USL UCL
LSL LCL LSL LCL
7 points in a row Xbar & R chart

consistently decreasing. 20.00
19.00
18.00
17.00
as per process sheet
Outside Dia.
16.00
15.00
14.00 2. Process average changing, set the Shift supervisor

13.00
process at average.
12.00
11.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3. If required make why-why analysis. CFT Team
USL UCL
Sample No.
LSL LCL
Mean Outside Dia.
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5.10 Inspection of Work In Process / Finished Parts
PURPOSE
• To assure the Quality of Work In Progress parts through references (visual/boundry sample).
• To assure the verification of Inspection Equipments through defined check ups.
• Defined Inspection carried out as per the Control Plan and recorded (measurable • Inspection Standard with visuals and boundary/Limit samples (Ex 55).
values). • First Piece approval sheet.
• System available for confirmation of Manager or Supervisor at a fixed time (For • Inspection Equipment verification sheet.
example, by signature). • Reaction Rule if equipment is NG.
• Availability of Inspection Criteria Chart (specification value) and values/boundary • Reaction Recording sheet (Refer Ex 39B).
samples at work station.
• Use of Standard for first Product Control at line start-up.
• Availability of system for checking Inspection Equipments by Master and results
are recorded.
• Defined Inspection Frequency. (At the beginning and end of the shift, tooling
change, etc.) Note: Only for equipment.
• Availability of system to take action in case the Inspection Equipment is NG,
a. Immediately stop delivery and production.
b. Take action based on “Equipment control standard” as follows:
- the root cause analysis and countermeasure.
- In case NG products delivered, inform to the customer and take action.
- Check all suspicious lots and record result.
- Report to management and action by management.
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Example 55 - Inspection Standard with Visuals & Boundary / Limit Samples
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5.11 Control of Delivery Process
PURPOSE
• To assure the Quality of Finished Parts through better Storage Practices.
• To assure Quality of Finished Parts through proper Handling.
• Availability of system for locating Finished Good in defined Inspection OK area with • FIFO standard (Refer Ex 38)
tags on all individual boxes/parts. • Partwise location matrix.
• Definition existing for identifying Parts less than unit packaging (for example, at • Work instruction for packaging (Ex 56).
the end of shift) with indication of the storage area. • Inspection Tags / stickers.
• Availability of FIFO system with clear Traceability (By control sheet). PROTECTIVE CARDBORD OR OR
• Availability of Pictorial Packaging work instruction including packaging equipment
FOAM SHEET OR
at packing station as per Customer Approved Packaging Standard. PLASTIC BAG
STYROFOAM RING CARDBOARD CUT-OUT
• Definition existing for Storage of individual parts and there is no mix up of different
WHEEL
parts.
DOUBLE BOX
106
Example 56 - Work Instruction for Packing
DOC NO
WORK INSTRUCTION FOR PACKING AND STACKING REV NO
Eff. DATE
PART NAME : MODEL :
1 2 3
PART / PP BOX DETAILS
Part Image :
Length 519.35 mm
Width 325.24 mm
Height 264.92 mm
Material
# Keep the pieces one by one # Close the box after Placing 50 Nos. # Stack 2 Columns in a Pallets as Shown in Exxtral- CNU 012
pieces should not be in oposite direction the Picture Colour
# Use separate Boxes for RH / LH # Identify with Packing Label # Use separate Pallets for RH / LH BLACK
# Total Pieces per Box 50 Nos. # Stack the Boxes in the Wooden pallets # Total Pieces per Row 2x50 =100 Nos.
DON’T DON’T
PP Box Image :
4
# Stack 3 Rows in a Pallets as Shown in # Don't Stack the components in the # Don't use if the PP Box in Damage
the Picture Opposite Direction condotion
# Use separate Pallets for RH / LH
# Total Pieces per Pallet 3x100 = 300 Nos.
REVISION STATUS
Rev. No. Description Rev. Date

External Dimensions (PP Box)
Length 1100 mm
1 Don't Photos Included for better understanding of upnormal situation 08.01.07
Width 560 mm
Height 325 mm
Reviewed By : Approved By :
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5.12 Storage of Work In-Process / Finished Parts
PURPOSE
• To assure the storage of Work in Process / Finished Parts through structured Handling practices.
• To assure Quality by maintaining Cleanliness in the area.
• Availability of Defined location for Finished Parts and marking the status of Work • Storage Guidelines.
In Process (ex- lines drawn on floor, area bound by chains). • WIP status tags.
• Availability of Maximum stacking limit in each area with stacking limit number • Definition of Maximum stacking height.
clearly visible to avoid falling down of Packaging. • FIFO for WIP parts (Refer Ex 38).
• Availability of appropriate Storage place for preventing parts from the Outside
Environment (Rain, wind, etc.).
• Defined Responsibility for Storage and Movement process.
• Availability of storage area free from dirt, splash of oil and metal chips.
• Availability of system for controlling FIFO through computer to prevent manual
error.
• Availability of Processes directly connected (for eg.-One piece flow).
• Packaging defined to prevent Stock between two processes are protected from
damage by touching and condition like dry temperature.
• Availability of defined storage area part wise and No mix up of different parts.
108
5.13.1 Check / Calibration / Maintenance
PURPOSE
• To assure working condition of Machines through Regular checks.
• To assure working conditions of Fixtures through Regular checks.
• Availability of system for carrying out Maintenance of Machines as a planned • Annual Maintenance Plan (Ex 57).
activity(annual plan) and recorded. • PM check sheet (Ex 58).
• Availability of validity control on each facility. • List of Critical Spare Parts (min, max & re order level and actual stock) (Ex 59).
• Modification of Preventive Maintenance frequency based upon the earlier results. • Bought out Tooling Acceptance Plan.
• Availability of Validity due date on each machine .
• Availability of PM checklist with what to check, How to check and which inspection
equipment to be used.
• Availability of list for Critical Spares and Monitoring Mechanism (min, max & re
order level and actual stock).
• Availability of Bought out Tooling Acceptance plan with application.
• System available for identifying Fixtures with unique number and Calibration Plan
is followed.
• Definition of Wear Part replacement frequency exist, followed and required stock
is maintained.
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Example 57 - Annual Maintenance Plan

MAINTENANCE PLAN-08
May-08
Aug-08
Sep-08
Nov-08
Dec-08
Feb-08
Mar-08
Jan-08
Jun-08
Oct-08
Apr-08
Jul-08
SR. Machine
NO. Name
1 Omega 450
2 Blow 10 Ltr.
3 Endura 330
Machine Not Available.
Ultra sonic
4
welding
Machine Not Available.
5 Compressor
6 Crane
Hopper
7
Dryer
Cooling
8
Tower
Monthly
Half Yearly
Yearly
Note-Green colour indicates work is completed
110
Example 58 - Preventive Maintenance Check Sheet
Document No.
MACHINE PREVENTIVE CHECK PONTS Rev No.
Rev Date.
D6
No of
SL.no Points points Who What
HY2
1 D1 3 Refill the lubrication oil in the oil cups
M1 M3 2 D2 1 Check the rightness of the setting value of push buttons,keys on Screen.
W2
3 D3 1 Clean the plastic material if present on the heater bands and nozzle
Y3 HY1 4 D4 1 Clean the exterior part of the machine
5 D5 2 Check the safety doors are functioning properly.
6 D6 1 Check oil level
7 W1 1 Check lubrication mist level .
8 W2 3 Clean the interior parts of machine
HY5 9 W3 6 Clean the dust in the ventillation fans
W4 W4 10 W4 2 Check tightness of nuts and screws of injection unit and clamping unit
11 W5 1 Check the voltage to earth line
12 M1 14 Refill the grease in to the bushing of platen
D1 D4 13 M2 1 Clean the interior part of electric box and check contiuity of wires
W2 14 M3 2 Inspect the oil filter,return line and at inside tank
D3
15 M4 Check and tighten the oil hoses and connectors.
16 HY1 1 Tighten the screws of the bearing stand at hydraulic motor and injection screw connection point.
W2
17 HY2 Tighten all the screws at clamping mechanism.
D2
18 HY3 Check and clean the oil cooler lines
D1
W3 19 HY4 3 Tighten the position sensors screws without varying the existing position.
20 HY5 1 Tighten the terminal screws of power supply wires in controller box.
D5 21 HY6 1 Clean the cooling line of hopper throat.
Y2 22 Y1 Check and tighten all the screws in the machine
W1
23 Y2 Check the limit switches and hydraulic safety device for the safety gates and if required replace.
24 Y3 1 Check the platen parallelism.
25 Y4 1 Check the oil condition.
M2 HY5
M4
Legends:
Sl.no Item Details
1 D Daily
2 W Weekly
3 HY Half yearly
4 Y Yearly
HY6
5 Operator
M3 6 Maintenance technician
7 External
Y4
W3
HY3
Prepared by: Reviewed By: Approved by:
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Example 58 - Preventive Maintenance Monitoring Sheet (Contd...)

PREVENTIVE MAINTENANCE MONITORING SHEET
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
D1 D1
D2 D2
D3 D3
D4 D4
D5 D5
D6 D6
Sign
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
D1 D1
D2 D2
D3 D3
D4 D4
D5 D5
D6 D6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
D1 D1
D2 D2
D3 D3
D4 D4
D5 D5
D6 D6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
D1 D1
D2 D2
D3 D3
D4 D4
D5 D5
D6 D6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
D1 D1
D2 D2
D3 D3
D4 D4
D5 D5
D6 D6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
D1 D1
D2 D2
D3 D3
D4 D4
D5 D5
D6 D6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12
W1 M1
W2 M2
W3 M3
W4 M4
W5
1 2 1
HY 1 Y1
HY 2 Y2
HY 3 Y3
HY 4 Y4
HY 5
HY 6
112
Example 59 - List of Critical Spare Parts
LIST OF MACHINES
Inventory Level
Sr. Critical Spare Lead Time for
Name Of Machines Capacity Make Location ID No. Reorder Level
no. Parts Req. procurement Min. Max. Spares inventory
1. contactor 2. 1. With in an hour 1. 1 For Each 1. 2 For Each After issuing min stock materials
1 Blow Molding Machine 10 ltr. Jagmohan Shop Floor BMM-01 yes
Heater 2. 4 DAY 2. 1 For Each 2. 1 For Each raised the PO immediately
1. SSR 1. 1 DAY 1. 1 For Each 1. 1 For Each After issuing min stock materials
2 Injection Molding Machine 450 Ton Feromatik Melacron Shop Floor IMM-01 yes
2. Heater 2. 4 DAY 2. 1 For Each 2. 1 For Each raised the PO immediately
1. SSR 1. 1 DAY 1. 1 For Each 1. 1 For Each After issuing min stock materials
3 ENDURA 330 Ton Electronica Shop Floor IMM-02 yes
2. Heater 2. 4 DAY 2. 1 For Each 2. 1 For Each raised the PO immediately
4 Ulta Sonic welding Machine 1900 ENERGY MARKETING ENGINEERS Shop Floor USW-01 HORN 4 DAYS …. …. NO ………
5 Lumps Grinder Big 15 kw Made in China Grinding Room GR-01 Blade 2 DAY …. …. NO ……….
1. AIR FILTER 1. 1 For Each 1. 1 For Each After issuing min stock materials
6 Compressor 11kw Chicago Pneumatic Shop Floor CM-01 2 DAYS yes
2.ULTRA OIL 2. 5 LTR. 2. 5 LTR. raised the PO immediately
1. Blade
7 Cutting Machine 1 1 HP Siemens Grinding Room CT-01 Within an hour .. .. NO ….
2. Belt
1. Blade 1. 1 For Each 1. 1 For Each After issuing min stock materials
8 Cutting Machine 2 1 HP Siemens Shop Floor CT-02 1 day yes
2. Belt 2. 1 For Each 2. 1 For Each raised the PO immediately
9 Bench Drill 0.5 HP Darshan Electrical Works. Shop Floor BD-01 Belt Within an hour 1 Set 2 Set NO …
10 Fan 1 HP Almoneda Shop Floor Fan-01 .. .. .. .. …. … …

Maktech
11 Hand Drill 438 watts Shop Floor HD-01 Carbon Brush .. .. .. … … ..
( Makita Corporation )
12 Cooling Water Pump 5 HP Siemens Pump Room CWP-01 .. .. .. .. …. …. …
13 Cooling Tower HIMGIRI Near Pump Room COTO-01 .. .. .. .. … … …
14 Hand Grinder 240 Watts BLACK & DECKER shop floor HG-01 Wheels Within an hour 1 Set 2 Set NO … …
15 Weighing Scale 3 kg PHOENIEX shop floor WS-01 .. .. .. .. … … …
1. contactor 1. With in an hour 1. 1 For Each 1. 2 For Each After issuing min stock materials
16 CRANE 15 TON SAICO Shop Floor CR-01 yes
2. push button 2. With in an hour 2. 1 For Each 2. 1 For Each raised the PO immediately
1.Contactor 1. With in an hour 1. 1 For Each 1. 2 For Each After issuing min stock materials
17 Hopper Dryer 42.7 KW PRASAD KOCH Shop Floor HDR-01 yes
2. PID Controller 2. 1 DAY 2. 1 For Each 2. 1 For Each raised the PO immediately
18 Electric Screw Driver 01 115 Watts Einhell Assembly SRD-01 Carbon Brush Within an hour 1 Set 2 Set NO .. ..
19 Electric Screw Driver 02 115 Watts Einhell Assembly SRD-02 Carbon Brush Within an hour 1 Set 2 Set NO .. ..
20 Riveting Gun 100 Watts Avdel Assembly RG-01 .. .. .. .. .. .. ..
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5.13.2 Check / Calibration
PURPOSE
• To assure working condition of Gauges through Regular checks.
• To assure working conditions of Tools through Regular checks.
• Availability of system for carrying out Calibration of Gauges as a planned activity • Annual Calibration Plan (Ex 60).
(annual plan) and recorded. • List of Gauges with validity control.
• Availability of validity control on each Gauges / Measuring Instruments. • Skill matrix of the certified calibrator.
• Availability of sticker / tag to indicate Validity on each gauge / Measuring Instrument • Daily check sheet (Ex 61).
which the Operator can easily recognize within the validity period. • Annual Plan for performance / endurance / reliability test.
• Use of Checks, Calibrations are standardized with flow chart/picture.
• Defined system to collect 3 documents of record in case of calibration by external
company. (Calibration Result, Calibration Certificate, the Calibration contractors
linked to National standards) and similarly available for internal calibration.
Availability of system to certify the Person In charge of Internal Calibration through
International Standard (ISO17025, etc.).
• Availability of Daily check sheet for Instruments / Gauges on the shop floor.
• Availability of system for confirming items of standard, and check results are
recorded with measurable value.
• Availability of system for carrying out Performance, Reliability & Endurance test. for
the products as per predefined frequency and corrective and preventive actions are
taken in all cases of failures.
114
Example 60 - Annual Calibration Plan
CALIBRATION PLAN Format No :
SR. NO. Description ID No. Range Frequency Location P/A Apr'10 May'10 Jun'10 Jul'10 Aug'10 Sep'10 Oct'10 Nov'10 Dec'10 Jan'11 Feb'11 Mar'11
1 Thread Ring Guage TRG-01 GO M5 6g 1 year Incoming QA P

A
2 Lux Meter Lx-101 2000 -19990 Lux 1 year L-90 Firewall P
A
P
3 Surface Plate LMX/SP/001 1600*1000 mm 1 year Incoming QA
A
P
4 Lever Dial LMX/DI/01 0 to 0.80 mm 1 year Incoming QA
A
5 Dig. Micrometer P
MM-02 0 to 25 mm 1 year Incoming QA
A
6 Dig. Micrometer MM-01 1 year Incoming QA P
0 to 25 mm
A
7 Dig. Vernier VC-01 0 to 150 mm 1 year Incoming QA P
A
8 Dig. Vernier VC-03 0 to 200 mm 1 year Incoming QA P
A
9 Bevel Protector BP-01 0° to 90° 1 year QA P
A
10 Shore Hardness Tester HT-01 0-100 shoreA 1 year Incoming QA P
A
11 Flush pin guage FPG-01 8.40mm 1 year Incoming QA P
A
12 Dial Thickness Gauge LMX/TG/01 0 TO 10 MM 1 year Incoming QA P
A
13 Taper Gauge TG-01 3.5 TO 15 MM 1 year Incoming QA P
A
14 Taper Gauge TG-14 5 TO 15 MM 1 year L 90 H/L Line P
A
15 Pistool Caliper LMX/PC/01 0 TO 50 MM 1 year CMM P
A
16 Measuring Pins LMX/MSP/01 4.05 - 8.00 1 year Incoming QA P
A
17 Digital Height Gauge LMX/HG/01 0 - 600 mm 1 year Incoming QA P
A
18 Magnetic 'V' Block LMX/MVB/01 1 year Incoming QA P
A
19 Magnetic 'V' Block LMX/MVB/02 1 year Incoming QA P
A
20 Push Pull Meter LMX/PPG/01 0-30 Kgf 1 year Incoming QA P
A
21 Radius Guage RG-01 1-7 mm 1 year Incoming QA P
A
22 Thread Plug Guage TPG-01 1 year Incoming QA P
A
A
A
25 Torque Wrench TW-01 0-120 Kgf.cm 1 year Incoming QA P
A
26 Stainless Steel Measuring Scale LMX/SC/01 0 - 1000 MM 1 year L-90 Firewall P
A
27 Stainless Steel Measuring Scale LMX/SC/02 0 - 1000 MM 1 year Incoming QA P
A
P
28 Pressure Gauge STPG-35 0 to 10 Kg/Cm2 1 year UV Line-01
A
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Example 61 - Daily Check Sheets

INSTRUMENT CHECKLISTS
INSTRUMENT NAME: WORK STATION:
INSTRUMENT CODE: MONTH
SL NO: CHECK POINTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Remarks
Clean the
1 instruments before
start
Instrument free
2
from damage
check the
3 calibration sticker
on the instruments
Storage, handling
of equipements per
4
instruction prvided
by manufacturer.
Check with master
and enter the
measurable value
5 Not applicable
Ex slip
gauge5.0mm,10.0m
m Etc.
Inspector signature
Prepared and Approved by: LEGENDS √ Checked and used
Rev no Rev Date Revision summery Reason for revision

New check sheet New check sheet
116
5.14 5S
PURPOSE
• To assure application of 5S standard on floor.
• To assure operators involvement for maintaining the standard.
• Availability of 5S evaluation standard consisting, Zones, Zone Leaders, 5S score • 5S Evaluation standard.
criteria, frequency with application. • 5S Check sheet.
• Standard available for 5S confirmation and evaluation on regular basis (if any • 5S Evaluation Plan (Ex 62).
problem arises immediate action taken by zone leader).
• Standard exits for cleaning (method, timing, frequency, etc.) and it is carried out.
(Prevent dust and oil splash, clean if it becomes dirty).
• Standard available for taking action on fallen parts,if any, immediately.
• Defined place for measurement instruments, tools and gauge.
• Standard clothes defined for Operators (shoes, safety goggles, protective caps and
helmet etc).
117
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Example 62 - 5S Evaluation Plan

DOC. NO
5S MAPPING AREA WITH PLAN REV. NO
DATE
Welding Quality Standards Room Stores PAINT SHOP
ZONE -1 ZONE -2 ZONE -3 ZONE -4
MAINTENANCE DEPARTMENT PRESS SHOP
ZONE -5 ZONE -6
PLAN 2011
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
SL.NO AREA TARGET
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
ZONE-1
1 80%
ACTUAL
ZONE-2
2 80%
ACTUAL
ZONE-3
3 80%
ACTUAL
ZONE-4
4 80%
ACTUAL
ZONE-5
5 80%
ACTUAL
ZONE-6
6 80%
ACTUAL
TOTAL
118
5.15 Process Conditions Maintenance / Control
PURPOSE
• To assure cleanliness on Floor through Standard Practices.
• Availability of Identification Status clearly with tag attached on the unfinished • Standard for cleaning.
product with reason of the break. • Plan, Frequency and status of cleaning of interoperational packaging.
• Availability of Cleaning Standard (frequency, plan and actual status, cleaning • Break- Tags for planned breaks (Tea/Lunch/Meeting etc).
guideline) for Interoperation handling Equipments and performed accordingly.
• Availability of means to prevent entry of dust, oil, particles, metal powder, etc. on
the line.
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5.16 Standard for Management of Non-Conforming Parts
PURPOSE
• To assure timely action on the Non-Conforming part by responsible authority
• To assure effective feedback mechanism to defect generation stage for initiating immediate Containment Action.
• Availability of Procedure for NC Management on shop floor along with • Non-Conformance handling flow chart.(Ex 63)
responsibilities & timeline for each activity (from identification to disposal) along • Defect samples/visual.(Ex 64)
with application and records. • Limit Sample validation plan.
• Good understanding of system by operator. • Validation Reports
• Clearly defined Non-Conformity in the station with measurable parameter or • Defect Feedback recording sheet.
drawing or photograph or master for OK and NG.
• Defined validation frequency for Master Samples and applied with maintenance of
master for OK and NG.
• Mechanism is defined to give immediate feedback of defect to source of generation
and rule is implemented (Even for single defect)
120
Example 63 - NC Handling Flow Chart
Doc No: WI / QA / 028 WORK INSTRUCTION
Issue Authority: Head QA
HANDLING OF NON CONFORMING PARTS
R / W OPERATOR INSPECTOR LINE IN CHARGE HEAD REJECTION YARD
Part Dimension out of Defect on part beyond the
Take Corrective action
Enter the defect in rework Spec. acceptable limit against the Problem &
tally chart Record it
Perform the Rework as per REFER THE WORK

INSTRUCTION # : Exceed Line Stop YES Press Line Stop
Button & Inform to the
the Rework instructions 5,6,7 16,17 & 30 Limit ? Line In charge
Put Tic mark on the part NO
Exceed Line Alarm YES Inform to Line

send to Re inspection Level ?
Operator & Line In
charge
NO
Enter the rejection NO Is the Part Rework YES Tally the number of rejected
Tally chart able ? Parts in the Rejection voucher
Mark the part on the rework

area & write the defect / code
Enter the defect in tally chart

Mark part on the rejected
area and write the defect / Damage the rejected parts by
code on it. Spray red paint press
Keep the part on the Rework
on the part and put in REFER THE WORK INSTRUCTION # : 56
trolley / pallet & put the - 60 & 121
rejection bin
Rework Tag
Send the parts to rework

station for Rework
Dispose the damaged parts
Re inspection
NO
YES Two tic
Is the part
NO reworked
YES correctly as per At the end of shift count
the rework the number of parts in the
instructions ?
NO Is the part Red bin & enter in the Red
rework able for bin record, Verify The Qty
second time ? against the Rejection tally
YES chart
Fill the Re inspection records
Keep the parts on the

Accepted trolley / pallet & put
accepted tag.
Move to next operation
Check the rejection and send

to rejection yard
APPROVED BY
1 0 Fresh Issue CHECKED BY
S.NO REVISION NO . DESCRIPTION DATE PREPARED BY
121
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Example 64 - Defect Samples / Visual
Back Plate Riveting Extrusion Crack

Specification : 0.85mm to 1.15mm
Limit : >= 0.85mm & <=1.15mm
Defect : < 0.85mm & > 1.15mm
Limit Samples
Limit Samples
0.85mm 0.9mm
Defect Sample
Defect Samples
0.75mm 1.5mm
122
5.17 Dealing With / Reuse of Non-Conforming Parts
PURPOSE
• To assure proper classification of Rework and Rejected parts.
• To assure necessary Actions are taken on Reworked parts.
• Availability of Decision Matrix for every level of defect (both part level and assembly • Decision matrix for each defect (Ex 65).
level). • Rework Flow Chart (Ex 66).
• Availibility of Rework Instructions at respective (online/offline) Workstation. • Rework Instructions (Ex 67).
• Availibility of Trained Operators for carrying out Rework. • Rework & Re Inspection records (Ex 68).
• Defined rule for marking Rework / Re-inspect past and put OK parts in the process
before inspection stage.
• Availability of records for Reworked parts.
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Example 65 - Decision Matrix for each Defect REWORK MATRIX FOR W/R-M&M Doc No:RW/AAP/00
REV:00/19.03.09
REWORK MATRIX FOR W/R-M&M Doc No:RW/AAP/00
REV:00/19.03.09
Problem -Travel noise : -

Sr.No Model Frequen No of times RE - USEABLE PARTS REJECTED PART
Resp.
cy re use
Re use able
parts & subassy
once in a day
Bolero Front photos

one time
Electric
QA
1
Window
Regulator
Qty LH-1.RH-1 RH-1 LH-1 LH-3.RH-3 1no LH-1.RH-1 LH-1.RH-1 LH-2,RH-2 LH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-3.RH-3 LH-3.RH-3 LH-1.RH-1 LH-1.RH-1
Part No 124558 124565 125565 3236 82B4 124559 125562 124562 124630 1257 124560 124561 2159 168482 168466 2005 124779
Part Name CENTRE PLATE MOTOR MOTOR STAR HEAD MAIN ARM PWR GEAR SECTOR - RH GEAR SECTOR - LH SUBARM SPINDLE LONG CHANNEL SMALL CHANNEL ANGLE PIECE BALL JOINT BIG RIVET PWR SECTOR RIVET
MOUNTING BOLT BALL JOINT RIVET
PWR ASSEMBLY RH ASSEMBLY LH SCREWS PWR ROLLER
PART PHOTO ROLLER

once in a day
Bolero Rear
one time
Electric
QA
2
Window
Regulator
Qty of Use LH-1.RH-1 RH-1 LH-1 LH-3.RH-3 LH-4 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-4
Part No 126563 124565 125565 3236 82B4 124564 125562 124562 2005 126730 5206 124779
Part Name MOTOR MOTOR STAR HEAD

CENTRE PLATE MOUNTING BOLTS MAIN ARM PWR GEAR SECTOR - RH GEAR SECTOR - LH BIG RIVET ROLLER SMALL RIVET SECTOR RIVET
ASSEMBLY RH ASSEMBLY LH SCREWS PWR
PART PHOTO
once in a day
Bolero Front
one time
Manual
QA
3
Window
Regulator
Qty of Use LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-2.RH-2 LH-1.RH-1 LH-1.RH-1 LH-3.RH-3 LH-2.RH-2 LH-2.RH-2 LH-3 LH-1.RH-1 L
Part No 4451 124226 1503 4453 4458 4461 1202 1102 1152 1252 4455 1257 1654 4454 4456 4405 4305 2204 1607 4406 4409 1608 1606
Part Name HANDLE SHAFT TORSION SPRING - TORSION SPRING - COMPRESSION CO

CENTRE PLATE PINION CLUTCH LONG CHANNEL SMALL CHANNEL CUP - RH CUP - LH MAIN ARM SPINDLE GEAR SECTOR - RH GEAR SECTOR - LH SUB ARM BIG RIVET - RH BIG RIVET - LH SPIRAL SPRING ROLLER SMALL RIVET WASHER SMALL RIVET
ASSY RH LH SPRING
PART PHOTO
once in a day
Bolero Rear
one time
Manual
QA
4
Window
Regulator
Qty of Use LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-4.RH-4 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1
Part No 126412 1253 1203 82B4 1202 1102 126228 1252 1152 2055 1154 126730 2005 5206
Part Name TORSION SPRING - TORSION SPRING - HANDLE SHAFT

CENTRE PLATE CLUTCH PINION MOUNTING BOLT CUP - RH CUP - LH MAIN ARM GEAR SECTOR ROLLER BIG RIVET SMALL RIVET
RH LH ASSY
PART PHOTO
once in a day
one time
LTV Manual
QA
5 Window
Regulator
Qty of Use LH-1,RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-3.RH-3 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1,RH-1 LH-2,RH-2 LH-1,RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-3.RH-3
Part No 4451 1653 1202 1102 1503 162434 3228 1202 1102 162427 162428 163427 163428 2257 1256 162510 4405 4305 3229 162429 2204 3228
Part Name TORSION SPRING - TORSION SPRING - HANDLE SHAFT BALL JOINT
CENTRE PLATE CLUTCH PINION BALL JOINT RIVET CUP - RH CUP - LH MAIN ARM - RH MAIN ARM - LH GEAR SECTOR - RH GEAR SECTOR - LH SPINDLE SUB ARM LONG CHANNEL BIG RIVET - RH BIG RIVET - LH SMALL CHANNEL SPIRAL SPRING BALL JOINT RIVET
RH LH ASSY. ROLLER
PART PHOTO TORSION SPRING SMALL CHANNEL SPIRAL SPRING THREDED BOLT
once in a day
1246
one time
MNAL Manual
QA
Window
Regulator
Qty of Use LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1 LH-1.RH-1
the Defect on the job.
Do the Verification & take Decesion on

Reworkable Part .
If the defect is not reworkable Res

Is it No then put "SCRAP" on tag &
Reworkable? update the record In register.
Fill the scrap note & Record it.
Yes
Identify the Rework to be done & Resp: Inspector
who will do it.
Example 66 - Rework Flow Chart Call the operator who will do

Rework, instruct him about
Resp
Yes defect & do the Rework the part
Is it online Inspe
Doc. No: after existing work load is over.
A
REWORK PROCEDURE Rev No:
Rev. Date:
1
Rework?
No (Offline Rework)
Collect All The Parts from all Resp: Super Visor/ Inspector
Rework/Rejection Bins & Take it to the Do the rework on defective parts in rework
Rework Station. area only.
Read the Defect written on the tag attached Resp: Operator

to the Part. Do the Rework of defects as per Rework
Instruction .
times till part not get rejected)

(Re -Rework allowed N no. of
If Part has rejection tag then Send the
parts to the rejection area & do the entry in
the Rejection Register. Fill the scrap note
Resp: Inspector
& Record it.
Inspect the Reworked Part
If Part has Hold/ Rework Tag then check Resp: Inspector Resp: Inspector Yes
the Defect on the job.
No No
If the defect is not reworkable Is it
Do the Verification & take Decesion on then put "SCRAP" on tag & Is it O.K?
Reworkable ?
Reworkable Part . update the record In register.
Yes
If the defect is not reworkable Resp: Resp:
No ` Put rework OK tag on Re Inspected jobs
Is it then put "SCRAP" on tag & Inspector/Eng.
after rework & keep the part again at the
Reworkable? update the record In register.
station from where it was taken out.
Yes
Reviewed By: Approved By:
Identify the Rework to be done & Resp: Inspector
who will do it.
Call the operator who will do

Rework, instruct him about
Resp:
Yes defect & do the Rework the part
Is it online Inspector/Operator
after existing work load is over.
Rework?
No (Offline Rework)
Do the rework on defective parts in rework

area only. A
Do the Rework of defects as per Rework Resp: Operator

Instruction .
ot get rejected)
lowed N no. of
125
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Example 67 - Rework Instruction

OIA (OPERATOR INSTRUCTION AID)
Plant Name Operation Name Doc. No. Approvals : Signature :
Product Operation No: : Issue Date

Line Part Number : Rev Level Manufacturing Engineer Name : Date :
Model Rev Date Page :
Description of Work steps
H3 H4 H5 H 6
H2 H 7
H 1 H 8
Place the assembled part on the table and remove

Place the Glove box on the fixture as shown in Disassemble the knob assembly from the Glove
Screws on the part & disassemble as shown. Remove glove box inner and glove box outer Remove the knob assy from the Glove box outer
figure box outer ( screws 2 nos removing)
Latch pin missing
Remove the latch pin fully by using mallet Remove spring knob , knob holder Remove all the child parts Assemble 2nos of Latch pin with knob Assemble spring knob & push the latch pin fully
H H H H
H H
H H
Assemble the knob assy with outer as well as Inspect the part as per instruction given in Rw Put OK mark on rework tag and reworked part
Put the rework sticker number in part Track the rework number in rework register
inner and outer ( 8 nos of screws ) instruction _sample-143 should be approved by line supervisor or QC
Personal / Product
C
Characteristics Class Specification & Tolerance Gauge Description Sample Size Freq. Control Method Reaction Plan Protective Equipment
O (mandatory for this process)
N
T
R Gloves Safety Goggles
O
L
P
O
I Process Specific Icons
N
Safety/ Quality Poke
Delta Critical
T Ergonomics Check Yoke
S Rev status
Q1 : Nil
Format No. I/MF/FR-004a Rev Date : Nil
Record Type : Official Retention period : While ACT
Originator : Manufacturing 1 of 2 Issue date : 28.10.06
126
Example 68 - Rework & Re-Inspection Record
Doc.No:
REWORK RECORD Rev. No:
Rev. Date:
REWORK TRACEABILITY RECORD ( YELLOW BIN ) MONTH:- June, 2011

QTY DATE OF RE-
IDENTIFICATION BEFORE IDENTIFICATION AFTER Status REWORK
SR. NO. DATE LINE NAME PART NAME IN DEFECT REWOK DONE PARTS SALVAGED RE- INSPECTIO
REWORK REWORK (Ok/Reject) DONE BY,
NOS INSPECTION N DONE BY
1 6/16/2011 Assembly Process Latch 5 Not Operating Batch Code No. : 0128 Pawl replaced Rework Ok Tag Carrier Plate, Cable, Bush 6/16/2011 Ok PVP JP
Dimension of Bush
2 6/23/2011 Assembly Process Latch 2 Noise Batch Code No. : 0174 Rework Ok Tag Pawl, Carrier Plate, Cable 6/24/2011 Ok PVP VB
corrected
127
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5.18 Mixing of Non-Conforming Parts
PURPOSE
• To assure Non-Conforming parts does not Mix-Up with OK parts.
• Mechanism defined for immediately marking and putting the Non-Conforming • Stagewise Defect Monitoring sheet (Ex 69)
parts in the red bin • Cross Verification records (Refer Ex 69)
• Mechanism for cross checking Red bin Quantity with the defect record. • Non conformance Handling Flow Chart. (Refer Ex 63)
• Mechanism for segregating rejected parts through preventive method and • Scrap Records
automatically dumping in NC bin thus no chance of mix up.
128
Example 69 - Stagewise Defect Monitoring sheet
129
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5.19 “Unusual” Product & Equipment Situation
PURPOSE
• To assure specific treatment for suspected parts due to Abnormal Situation
• To assure appropriate Analysis and Reverification is done.
• Availability of definition of different Abnormal Situations related to each Part and • Abnormal situation & reaction plan (Ex 70)
Equipment. • Reaction Plan for Part fallen (Ex 71)
• Display of Abnormal Situation Instructions on shop floor • Abnormal rejection & analysis records (Ex 72)
• Availability of reaction plan for each Abnormal Situation on Product, Process, and • Fallen parts trend chart and action plan
Machine and followed accordingly.
• Availability of records for each Abnormal Situation
• Identification of “Fallen Part” as “Unusual” and set the rule to investigate the cause
and take action.
• Monitor trend of Fallen Parts quantity and take action.
• Immediate Cause Analysis of Abnormal Situation and maintain records of
retroactive confirmation
130
2 DUE TO ANY REASONS, 1. If 5 nos. of disc having same 1. If 5 nos. of disc having same defect comes If 5 nos. of disc having same defect
WHEN ANY TYPE OF
REJECTABLE DEFECTS HAS
defect comes continuously, reject the continuously, inform the inspector of that stage, comes continuously
BEEN PASSED OUT OF disc (spray Red paint . Show operator and line in charge and show the 1. Try to find out the change in
DIMENSIONAL INSPECTION defected disc to supervisor defected disc. existing situation.
immediately 2. Along with line supervisor, find the root 2. Try to rectify the cause of this
2. Pass on the information to cause of problem and try to rectify it. change.
inspectors at other inspection tables (If the reason is not easily identifiable or cannot 3. Give sufficient training to people if
and ask them to check this defect be easily rectified, put some control by which needed.
also. defect can be easily identified.) 4. Follow up the steps taken.
3 DISC PASSED Any type of rejectable defect disc, If defect is coming immediately inform line Any type of reject able defect disc,
WITH OUT supervisor. Show the defected disc to the by any reason, been passed from
by any reason, been passed from
concerned inspector, operator and line in charge. inspection
DIMENSIONAL inspection, inform the supervisor 2. Immediately raise a QUALITY ALERT and 1. Try to find the cause for the
INSPECTION immediately. Show the defected display at Final Inspection station , Stage change.
disc to supervisor. inspection area and at the stage where this 2. Rectify the reason for the change
Example 70 - Abnormal Situations & Reaction Plan

Pass on the information to defect is generated. Show the defect and Quality 3. According to need, update the
inspectors at other inspection Alert to the inspector, operator and supervisor in FMEA, Control plan, WI, SI, OS etc.
all shifts and get their signature in Quality Alert 4. Impart training to people if
tables and ask them to check this
3. Along with line supervisor, find the root necessary.
defect also. cause of problem and try to rectify it. 5. Follow up of the action taken
OPERATION STANDARDS A
ISSUING AUTHORITY : LOCATION -
ISSUE DATE :
TITLE : ABNORMAL CONDITION AND REACTION
DOC No: Standards room engineer to analyse the problem and
PLAN FOR PA R T REV DATE : NIL PAGE :1 OF 2 4
IF THE INSPECTION GAUGE/
INSTRUMENTS FALLS
If the inspection gauge/ Send this gauge/ instruments to Standards room Standards room engineer
take suitable action
instruments falls down/broken and request for calibration. For the time being
DOWN/BROKEN/ NOT
immediately stop inspection with to analyse the problem
In case anything ''ABNORMAL'' happens arrange a spare gauge/ instruments of the same
WORKING/ANY OTHER DEFECT
that gauge/ instruments. Show specification. Segregate the previous lot which and take suitable action
1) STOP THE PRODUCTION that gauge/ instruments to
supervisor.
is produced by this instrument/gauge
2) CALL THE SUPERVISOR & DETAILS ARE GIVEN BELOW
REACTION PLAN
No ABNORMAL CONDITION
OPERATOR ENGINEER HEAD OF THE DEPARTMENT
WHEN DISC FAIL 1. When 'MARU A'/Functional When 'MARU A' defect comes immediately When any 'MARU A' defect comes
1 inform line in charge. Show this defected disc to check whether any disc have been 5 IFIFPROCESS
PROCESS If the process Parameter is out of If the process Parameter is out of If the process Parameter is out of
IN DIMENSION defect comes Put the disc in PARAMETER IS OUT OF
the concerned inspector, operator and line in send to end customer/next process. If PARAMETER IS specification stop the machine specification analysis the problem and specification Do root cause analysis
INSPECTION rejection bin after painting red. SPECIFICATION for the problem and take appropriate
charge yes, then immediately inform OUT OF take corrective action and record it and
Immediately inform supervisor countermeasure to stop this problem
2. Immediately raise a QUALITY ALERT and marketing deptt and customer. Check SPECIFICATION inform to Production -Head
Show the defected disc to display at Final Inspection station , Stage all the disc gone to customer in the According to need, update the
supervisor inspection area and at the stage where this same batch code. documents like Control Plan, FMEA,
2. Inform the inspector in the defect is generated. Show the defect and Quality Do root cause analysis for this defect SI, WI, OS etc. and train people.
other inspection tables and ask Alert to the inspector, operator and supervisor and take appropriate countermeasure
them to check this kind of defect in all shifts and get their signature in Quality
Alert
to stop this defect.
According to need, update the
OPERATION STANDARDS
ISSUING AUTHORITY : LOCATION -
3. Inspect 100% all the Disc in the same batch documents like Control Plan, FMEA, IF THE PROCESS
ISSUE DATE :
code as of the defected part. If any defected part SI, WI, OS etc. and train people. 6 TITLE
CAPABILITY IS LESS THAN
:IfABNORMAL
the Process capability is less AND1.Immediately
CONDITION REACTIONstop the line. 1. Analyse the special cause
is gone to end customer/next process, DOC1.33/IF
No: THE AVERAGE OR than 1.33 or PThe
LAaverage/range
N FOR PAR T 2.Seggregate the REV Lot DATE
100%.: 2.Verify the corrective
NIL action.
PAGE :2 OF 2
immediately inform Quality In charge RANGE GOING TO OUT OF going out of control limits in SPC 3.Analyse the special cause. 3.Taking preventive action for
CONTROL LIMIT IN X & R
CHART In case anything ''ABNORMAL''
chart. happens
4. Immediately taking corrective action for improve the process capability.
1.Immediately stop the line. the special cause, Then run the Line.
2 DUE TO ANY REASONS,
WHEN ANY TYPE OF
1. If 5 nos. of disc having same 1. If 5 nos. of disc having same defect comes If 5 nos. of disc having same defect 1)inSTOP
2.Inform to the Line charge. THE PRODUCTION
5.100% Inspection to be initiated on line.
defect comes continuously, reject the
disc (spray Red paint . Show
continuously, inform the inspector of that stage,
operator and line in charge and show the
comes continuously 2) CALL THE SUPERVISOR & DETAILS ARE GIVEN BELOW
BEEN PASSED OUT OF 1. Try to find out the change in
DIMENSIONAL INSPECTION defected disc to supervisor defected disc. existing situation. REACTION PLAN
immediately 2. Along with line supervisor, find the root No ABNORMAL CONDITION
2. Try to rectify the cause of this OPERATOR ENGINEER HEAD OF THE DEPARTMENT
2. Pass on the information to cause of problem and try to rectify it. change.
inspectors at other inspection tables (If the reason is not easily identifiable or cannot 3. Give sufficient training to people if
and ask them to check this defect 7 IF: POKA
NOTE YOKA NOT If Poka Yoka
ABNORMALCONDITION is not working
MUST BE RECORDED If Poka
ONYoka
SHOPis notFLOOR
working, taking
LOG short term
SHEET verify the POKA
& ABNORMAL YOKA &
CONDITION
be easily rectified, put some control by which needed. Immediately inform to line supervisor corrective action & run the production as
also. defect can be easily identified.) WORKING IN NEXT
WILL BE DISCUSSED DAY MORNING MEETING. evaluate it. It is suitable for
4. Follow up the steps taken. check the components produced for
retroactive confirmation. Inform the
B
regularly, then analyze the problem & find the
root cause, taking the preventive action apply
APPROVED BY it
that problem then approved it
& where it is necessary apply
1 0 inspector in the inspection
Fresh Issue tables and for trials. Then the trials are ok, thenCHECKED
act theBY
ask them to check this kind of defect action & revise the POKA YOKA & apply it for
to all other areas in their
DISC PASSED If defect is coming immediately inform line Any type of reject able defect disc, S.NO REVISION NO . REJECT THE DESCRIPTION
NC COMPONENT. regular action.
PREPARED BY department. Ensure the
3 Any type of rejectable defect disc,
training for all their
WITH OUT supervisor. Show the defected disc to the by any reason, been passed from
by any reason, been passed from
concerned inspector, operator and line in charge. inspection department people.
DIMENSIONAL inspection, inform the supervisor 2. Immediately raise a QUALITY ALERT and 1. Try to find the cause for the
INSPECTION immediately. Show the defected display at Final Inspection station , Stage change.
disc to supervisor. inspection area and at the stage where this 2. Rectify the reason for the change 8 IF MACHINE / If the machine or tool is break down. immediately inform to the Head of the Analyze the root cause & take
Pass on the information to defect is generated. Show the defect and Quality 3. According to need, update the TOOL Inform to the line Engineer & take the department & Raise the Break down report the preventive action, If the
inspectors at other inspection Alert to the inspector, operator and supervisor in FMEA, Control plan, WI, SI, OS etc. immediate corrective action for the cause is common cause, then
BREAKDOWN to Maintenance dept, then taking corrective
all shifts and get their signature in Quality Alert 4. Impart training to people if problem as per mention in the work
tables and ask them to check this action, then change the tool/machine spare revised the FMEA & change
3. Along with line supervisor, find the root necessary. instruction or operating standard. the control plan also.
defect also. cause of problem and try to rectify it. with quickly. Record the problem & what is
5. Follow up of the action taken
the corrective action taken & how much the
down timeless.
Standards room engineer to analyse the problem and

IF THE INSPECTION GAUGE/ If the inspection gauge/ Send this gauge/ instruments to Standards room Standards room engineer
4 INSTRUMENTS FALLS
DOWN/BROKEN/ NOT to analyse the problem 9 WHEN THE PERSON If the person working in In case of any minor injury, get the injury Find out the root cause of the
WORKING/ANY OTHER DEFECT immediately stop inspection with
that gauge/ instruments. Show A
arrange a spare gauge/ instruments of the same
specification. Segregate the previous lot which and take suitable action WORKING IN inspection station is injured: B
dressed by an authorized person. injury
that gauge/ instruments to
INSPECTION 1. Inform supervisor in case of In case of major injury, transfer the person Try to eliminate the cause or
supervisor. STATION IS INJURED minor injuries to a nearby hospital with the help of HR protect from injury by the cause
2. If it is a major injury, carry the Any type of injury has to be reported to Impart training to people in
person to medical room and Quality In charge. required
inform the supervisor
5 IFIFPROCESS
PROCESS If the process Parameter is out of If the process Parameter is out of If the process Parameter is out of
PARAMETER IS OUT OF
PARAMETER IS specification stop the machine specification analysis the problem and specification Do root cause analysis 10 IF THE DISC IS If the DISC is fallen at processing stage
or Any where like material handling etc.
1. verify the Fallen Disc in Tally Chart. 1. Verify & approve the Corrective 131
SPECIFICATION for the problem and take appropriate FALLEN 2. Take immediately corrective action. action & Poka Yoke.
OUT OF take corrective action and record it and 1.Enter the fallen DISC in Tally Chart.
2. Evaluate the Poka Yoke & If it is Ok
countermeasure to stop this problem 2. Locate the fallen DISC at the Fallen
3. Analyze the Problem & make POKA Yoke
SPECIFICATION inform to Production -Head wheel trolley & sent to Rework. apply it Horizontal deployment.
According to need, update the
In case anything ''ABNORMAL'' happens
1) STOP THE PRODUCTION
R EVALUAT 2) CALL THE SUPERVISOR & DETAILS ARE GIVEN BELOW
PLIE IO
UP
REACTION PLAN
NS
AS
ABNORMAL CONDITION
TAN
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No
MSES
DARD
IF POKA YOKA NOT If Poka Yoka is not working If Poka Yoka is not working, taking short term verify the POKA YOKA &
7 Immediately inform to line supervisor corrective action & run the production as
WORKING evaluate it. It is suitable for
check the components produced for regularly, then analyze the problem & find the that problem then approved it
retroactive confirmation. Inform the root cause, taking the preventive action apply it
& where it is necessary apply
inspector in the inspection tables and for trials. Then the trials are ok, then act the
ask them to check this kind of defect action & revise the POKA YOKA & apply it for
to all other areas in their
REJECT THE NC COMPONENT. regular action. department. Ensure the
OPERATION STANDARDS training for all their
ISSUING AUTHORITY : department people.LOCATION -
ISSUE DATE :
TITLE : ABNORMAL CONDITION AND REACTION
Example 70 - Contd... DOC No:
8 IF MACHINE /
PLAN FOR PA R T
If the machine or tool is break down. REV DATE :
immediately inform to the Head of the NIL PAGE :1 OF 2
Analyze the root cause & take
TOOL Inform to the line Engineer & take the department & Raise the Break down report the preventive action, If the
BREAKDOWN In
immediatecase
correctiveanything
action for the ''ABNORMAL'' happens
to Maintenance dept, then taking corrective cause is common cause, then
1) STOP
problem as per mention in the work
THE BPRODUCTION
action, then change the tool/machine spare revised the FMEA & change
instruction or operating standard. the control plan also.
2) CALL THE SUPERVISOR with & quickly.DETAILS ARE
Record the problem & whatGIVEN
is BELOW
the corrective action taken & how much the
REACTION
down timeless.
PLAN
No ABNORMAL CONDITION
WHEN DISC FAIL 1. When 'MARU A'/Functional When 'MARU A' defect comes immediately When any 'MARU A' defect comes
19 WHEN THE PERSON If the person working in In case
inform ofinany
line minor
charge. injury,
Show thisget the injury
defected disc to Find out
check the root
whether cause
any disc of been
have the
INWORKING
DIMENSION defect comes Put the disc in
IN inspection station is injured: dressed
the by aninspector,
concerned authorized person.
operator and line in injuryto end customer/next process. If
send
INSPECTION rejection bin after painting red.
INSPECTION 1. Inform supervisor in case of charge
In case of major injury, transfer the person Try to
yes, eliminate
then immediatelythe cause
inform or
Immediately
STATION IS INJURED minor injuries inform supervisor
2.
toImmediately raise a QUALITY
a nearby hospital with the ALERT
help ofand
HR marketing
protect from depttinjury
and customer. Check
by the cause
Show the defected disc to display at Final Inspection
2. If it is a major injury, carry the
supervisor Any type of injury has tostation , Stage to
be reported all the disc
Impart gone to
training to customer
people inin the
person to medical room and inspection area and at the stage where this same batch code.
2. Inform the inspector in the Quality In charge. required
defect is generated. Show the defect and Quality Do root cause analysis for this defect
inform the supervisor
other inspection tables and ask Alert to the inspector, operator and supervisor and take appropriate countermeasure
them to check this kind of defect in all shifts and get their signature in Quality to stop this defect.
Alert According to need, update the
If the DISC is fallen at processing stage 3. Inspect 100% all the Disc in the same batch documents
1. like Control
Verify & approve Plan, FMEA,
the Corrective
10 IF THE DISC IS 1. verify the Fallen Disc in Tally Chart.
code as of the defected part. If any defected part
or Any where like material handling etc. SI, WI, &OS
action etc. Yoke.
Poka and train people.
FALLEN 1.Enter the fallen DISC in Tally Chart. is2.gone
Taketoimmediately corrective
end customer/next action.
process, 2. Evaluate the Poka Yoke & If it is Ok
2. Locate the fallen DISC at the Fallen
3. Analyze inform
immediately the Problem
Quality &Inmake
chargePOKA Yoke
wheel trolley & sent to Rework. apply it Horizontal deployment.
for fallen Disc.
2 DUE TO ANY REASONS, 1. If 5 nos. of disc having same 1. If 5 nos. of disc having same defect comes If 5 nos. of disc having same defect
WHEN ANY TYPE OF
defect comes continuously, reject the continuously, inform the inspector of that stage, comes continuously
BEEN PASSED OUT OF disc (spray Red paint . Show operator and line in charge and show the 1. Try to find out the change in
DIMENSIONAL INSPECTION defected disc to supervisor defected disc. existingthesituation.
11 IN CASE OF POWER 1. Redo operation and check the At the end of shift, tally the actual Analyse problem and take corrective /
immediately 2. Along with line supervisor, find the root 2. Try toaction
prventive rectifywhenever
the cause of this
necessary
FAILURE DURING piece. components in the
2. Pass on the information to cause of problem and bin with
try to theit.record.
rectify change.
OPERATION 2. Check 5 atcomponents last tables
inspectors other inspection (If the reason is not easily identifiable or cannot 3. Give sufficient training to people if
produced
and ask them fortoretroactive
check this defect be easily rectified, put some control by which needed.
confirmation.
also. If not OK keep it in defect can be easily identified.) 4. Follow up the steps taken.
abnormal bin, fill the sheet and
inform supervisor
3 DISC PASSEDAny type of rejectable defect disc, If defect is coming immediately inform line Any type of reject able defect disc,
WITHLEVELOUT supervisor. Show the defected disc to the by any reason, been passed from
ALARM by any reason,
-ANY FIVE
Inspector beenthe
to inform passed from
concerned Supervisorinspector,
to take corrective
operator andaction
Analyse the problem and take corrective /
PIECES OF SAME DEFECT concerned line in charge. prventive
inspection
12 DIMENSIONAL inspection, inform and
machine operator the supervisor
supervisor 2.immediately action whenever necessary
COMES SIMULTANEOUSLY Immediatelytoraise
stop the defect
a QUALITY ALERT and 1. Try to find the cause for the
INSPECTION immediately. Show the defected
about the defect To discuss
display theInspection
at Final problemstation
in next, Stage
day change.
disc to supervisor. morning meeting.
inspection area and at the stage where this 2. Rectify the reason for the change
Pass on the information to defect is generated. Show the defect and Quality 3. According to need, update the
inspectors at other inspection Alert to the inspector, operator and supervisor in FMEA, Control plan, WI, SI, OS etc.
all shifts and get their signature in Quality Alert 4. Impart training to people if
tables andMUST
NOTE : ABNORMALCONDITION ask themBEto check this
RECORDED ON SHOP FLOOR find LOG SHEET & necessary.
ABNORMAL CONDITION
3. Along with line supervisor, the root
WILL BE DISCUSSED IN defect
NEXTalso.DAY MORNING MEETING. cause of problem and try to rectify it. 5. Follow up of the action taken
APPROVED BY
S.NO IFREVISION NO . GAUGE/

THE INSPECTION DESCRIPTION
If the inspection gauge/ Send this gauge/ instruments to Standards room
PREPARED BY Standards room engineer to analyse the problem and
Standards room engineer
4 INSTRUMENTS FALLS
DOWN/BROKEN/ NOT
immediately stop inspection with to analyse the problem
WORKING/ANY OTHER DEFECT arrange a spare gauge/ instruments of the same
that gauge/ instruments. Show specification. Segregate the previous lot which and take suitable action
that gauge/ instruments to
supervisor.
132 5 IFIFPROCESS
PROCESS
PARAMETER IS OUT OF
If the process Parameter is out of If the process Parameter is out of If the process Parameter is out of
PARAMETER IS specification stop the machine specification analysis the problem and specification Do root cause analysis
SPECIFICATION for the problem and take appropriate
OUT OF take corrective action and record it and
countermeasure to stop this problem
Example 71 - Reaction Plan for Fallen Parts
Doc No: WORK INSTRUCTION ISSUE DATE :
Issue Authority:
REACTION PLAN FOR FALLEN PART PAGE :1 OF 1
START
PART IS FALLEN
Identify the Part by paste the

fallen wheel sticker
ENTER THE FALLEN PART IN

TALLY CHART
Locate the Part separately in
Inspect the following

parameters of the Part
INSPECT
INSPECT
VISUAL THE RUN OK
OK DEFECTS AT
DISC CROWN OUT
AREA (DENT,
SCRATCH ETC.)
N
O
T
O
K
N
O
T
Sent to Rework
station for Rework O
K
REINSPECTIO
N VISUAL
DEFECTS
(DENT,
SCRATCH
ETC.)
N
O
OK T
O
K
ENTER THE MOVE TO ENTER THE TALLY
REJECTION BIN
TALLY CHART CHART
PASS THE PART FOR NEXT OPERATION

NOTE :PART-A LINE IN CHARGE VERIFY THE FALLEN PART-A TALLY CHART & TAKE CORRECTIVE ACTION FOR REDUCE THE FALLEN PART-A PROBLEM.
APPROVED BY
1 0 Fresh Issue NIL CHECKED BY
S.NO REVISION NO DESCRIPTION REV DATE PREPARED BY
133
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Example 72 - Abnormal Rejection & Analysis Record
ABNORMALITY RECORD SHEET Doc No.:

Date :
CLASS : ( Put the tick mark in relavent box)
ROOT CAUSE ANALYSIS ( Filled by Production )
Suspected M/C
Fallen parts Air / Hydraulic pressure Low
Parts Breakdown
Missing (or)
Damaged
Unidentified jig /
Light Not equipment.( In Operator
Fire fixture,missing Tag in
glowing Jig,Fixture and injury
Bins
Non-Cutting
Tools)
If others
( Pl specify )
DETAILS :
Bay : _______________ Process Name : __________________ Person Involved : _____________
CORRECTIVE ACTION
( Filled By Production with support of other depts )
Date of Occurrence : _____________ Time of Occurrence : _________ Duration : __________________ ACTIVITY Responsibility Target Date Completed Date
TEMPORARY ACTION
Person Noticed : _________________ Incharge of Shift : ____________ Shift :- ------------------------------
Part Produced : _________________ Part Name : ___________________
PERMANENT ACTION
DISPOSITION :
Suspected Inspected Qty Qty After After Inspected

Part Name Lot No Rework qty Approved by Verification of Counter Measure implementation.
Qty Qty Accepted Rejected rework , rejected qty by
Head - PRODUCTION
Effectiveness of Countermeasure.
W-1 W-2 W-3 W-4 W-8
Time Frame For

Verification
Head -Production Head-Quality. Head - Production.

F01-GL/QSP-7501 REV NO : 00
134
Example 72 - Abnormal Rejection & Analysis Record (Contd...)
History of Abnormalities
QA- Period Chec Result & Sign Effectiveness verification Verified By
Prod-
Date Shift ARP NO Operator
Incharge
Incharg Bay no Abnormality
e Start time End Time Total Time Shift Inch. Qa Inch. week-1 week-2 week-3 week-4 WEEK-8 Signature (Head - Mfg)
F02-GL/QSP-7501 REV NO : 00
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5.20 Safety Characteristics
PURPOSE
• To assure effective control on Safety Characteristics to protect the customer from receipt of any single defective part.
• Availibility of all CC Characteristics (identified by Supplier and Customer) on all • NC Handling Flow for Safety Characteristics (Ex 73).
documents and indicated on the station/machine. • Records of Spot / Cause analysis & action related to Safety Characteristics (Ex 74).
• Mechanism to check all parts with Gauge or Instruments (check also with Pokayoke). • Specific Rework & re-inspection records for Safety Characteristics (Ex 75).
• Mechanism is defined to identify Root Cause, take countermeasures and Retroactive • Operator qualification & recertification records who are working on Safety
confirmation, even in case of single non conformity for Special Characteristics. Characteristics station.
• Availability of records for action (non-conformity, date of action, timing,
responsibilities, number of parts blocked, etc.)
• Mechanism to Carry out 100 % inspection and monitor Process Capability through
online SPC charts.
• Definition for Retention period of records as per customer’s requirement period is
available.
• Mechanism defined to mark or to keep records of repaired safety parts for
traceability (with records of 100% check and approval signature) (Defined similar
instructions to sub-suppliers).
• Availability of Marking on part with Productions Number to be able to read by
operator. (clearly stamped with no print missing, no stain, and no unclear print).
• Defined rule that only the qualified operator operate. (ID card reader, password,
photo etc).
• Availability of Records of Trained and certified operators with certification.
• Mechanism for periodical recertification training and maintain records.
136
Example 73 - NC Handling Flowchart for Safety Characteristics
Doc No: WI / QA / 010 WORK INSTRUCTION
Issue Authority: Head QA HANDLING OF NON CONFORMING PARTS FOR SPECIAL CHARACTERISTICS
R / W OPERATOR INSPECTOR LINE IN CHARGE HEAD MANUFACTURING HEAD REJECTION YARD

Part Dimension out Defect on part beyond the
Take Corrective action
Enter the defect in Rework of Spec. acceptable limit against the Problem &
tally chart Record it
Perform the Rework as per REFER THE WORK

Exceed Line Stop YES Press Line Stop
Button & Inform to
INSTRUCTION # :
the Rework instructions 5,6,7 16,17 &30 Limit ? the Line In charge
Put Tic mark on the part NO

& put 'R' Punch on
rework part for
identification Exceed Line Alarm YES Inform to Line
Operator & Line In
Level ? charge
send to Re inspection
NO
YES
NO Is the Part
Enter in the rejection
Rework able
Tally chart ?
Mark the part on the rework
area & write the defect /
code
Tally the number of Rejected

Mark part on the rejected Parts in the Rejection
area and write the defect / voucher
code on it. Spray red paint Enter the defect in tally chart
on the part and put in
rejection bin
Keep the part on the Rework
REFER THE WORK INSTRUCTION # :
trolley / pallet & put the 56 - 60 & 121
Rework Tag
NO Damage the rejected parts by
Send the parts to rework
Analyze the Rework Sheet press
* Find the cause of the defect & try to eliminate it.
station for Rework *Find the ratio of rejection parts because of Rework. Find the
cause of this defect & eliminate it.
*inform operator/supervisor about the defects,cause,action
Re inspection taken etc in the shop floor meeting.
*make the change in documents if needed (CONTROL PLAN,
YES Two tic FMEA,START UP CHECK LIST,W.I, OPERATOR
INSTRUCTION)
*Impart training if needed.
NO *Follow up this corrective action.
YES Is the part
At the end of shift count Dispose the damaged parts
reworked
correctly as per the number of parts in
NO Is the part the rework the Red bin & enter in
reworkable for instructions ?
& Verify the 'R' the Red bin record,
second time ?
Verify The Qty against
the Rejection tally chart
YES
Fill the Re inspection records
Keep the parts on the

Accepted trolley / pallet & Find the rejection try to eliminate it.
put accepted tag. Inform operator/supervisor about the defects,cause,action
taken etc. in the shop floor meeting.
*Make change in documents if needed (CONTROL PLAN,
Move to next operation FMEA,START UP CHECK LIST,W.I, OPERATOR
INSTRUCTION)
* Impart training if needed
*Follow up this corrective action
Analyze the rejection and

send to Rejection yard
APPROVED BY
S.NO REVISION NO . DESCRIPTION DATE PREPARED BY
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Example 74 - Record of Spot / Cause Analysis & Action

Doc No
SPOT ANALYSIS Issue No/Dt
Rev No/Dt
Date- Shift-
Part Name ( Details like TD/TLS, W1/W2/W3/W4, LHD/RHD, 2WD/4WD) -
Defective part quantity-
Part Level (Incoming / In house)-

Traceability Details-
Who detected this defective part ( Incoming inspector, assembly operator, Inprocess inspector, line supervisor, quality engineer, M/C Itself)-
Observed defect related to CC ( Write if any visual defect or error message given by m/c)-
Defect Detection level (Incoming / in process)-
Probable causes for observed defect-
Immediate observation found-
Further disposal action to be taken on defective part & suspected parts ( Qty gone ahead till FG & WIP or child part ) -
Actions taken on the Process ( tools , Fixture , Pokayoke etc. )
Reported By- (Sign) Approved By- (Sign)

(Name)- (Name)-
Note : To be strictly followed on Critical, Safety, SC/CC locations
138
05/008-00
Example 75 - Specific Rework & Reinspection Records for Safety Characteristics

MONTH - STATION - LINE REJECTION SHEET - Safety Characteristics station
DATE
SHIFT
SR.
NO.
PART NAME S/P A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B
REASONS
S
1
P
S
2
P
S
3
P
S
4
P
S
5
P
S
6
P
S
7
P
S
8
P
S
9
P
S
10
P
S
11
P
S
12
P
S
TOTAL REJECTION
P
Operator Signature
Teal leader Signature
Supervisor sign.
S- Supplier
P- Process
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5.21 Traceability
PURPOSE
• To assure all processes (material, machining, assembly, delivery) of the safety characteristics parts are controlled with lot, and the records retained for the defined period,
(Traceability to be confirmed by practice.). The records should contain: lot number, tooling / mold number, dates of manufacture, inspection and delivery, including quantities.
• The availability of standards of lot control and operation. (Definition of lot number, lot size, indication, how to record, how to search, how to link to quality record, etc.)
• Traceability is within 2 hours. Lot identification including component parts is • Traceability Standard/flowchart (Ex 76)
possible. Delivery history (date, place, number) of searched parts can be specified • Traceability record.
• Recorded in control sheets and history by production month/date can be found
• There is a standard for the lot control to make a clear definition of: lot number,
tooling/mold number, dates of manufacture, inspection and delivery, including
quantities.
140
Example 76 - Traceabillity Standard / Flow Chart
Doc No
FLOW CHART FOR TRACEABILITY OF ABC Rev No
Date
PAINT START
Paint Manufacturing Batch No: Steel Manufacturing by Steel Supplier Heat No: XXXXXX (Alpha- Numeric Code)
by Supplier XXXXXXX
Steel is rerolled to more than one Coils Each Coil has Unique code No. = Mother Coil No.
Mother Coil is Pickled and Oiled Unique label containing its Mother Coil No. is retained.
XYZ Recieves XYZ
Paint Records Mother Coil is slitted to more than one Child Coils Each Coil has Unique label containing its Mother Coil No.
Batch No.
In the eg: shown, the Mother coil no. for
Coils Received at XYZ Yard. SSWL Assigns SSWL Code Each Coil has Unique label containing its Mother Coil No. code 'F' in case of Rim and 'O' in case of
No. for each Coil Disc, will be recorded in Log Sheet &
Matl.
Year Code Rim Type Rev. satus batch code register.
XYZ Consumes XYZ
Paint Coil Loaded on CTL M/c. Batch Code Assigned and stamped Batch Code (material code) is changed whenever each
Records
08 09 F 2 5JX14 01 A R1 Mother coil is changed. Assigned Batch Code is recorded in Log
Batch No. MIG WIRE
Sheet
Month Unit no. Product Line 1
On Part B as shown above eg:-

Details of all child coils including date of processing and Batch Code Register tells how many child coils are processed, with date, M I G Wire Manufacturing by Batch No: XXXX
assigned batch code is recorded in Batch Code Register from each Mother coil. Wire Supplier
The Material On Part B as shown below eg:-
Code starts from
Rev. satus Month
'A' for the first
XYZ Recieves MIG Wire Batch No: XXXX
Mother Coil of 01 A A I O
each month Batch Code Record maintained.
Product Year Matl. Code Rim and Disc assembled and welded in Assembly line. Batch
Code punched on the Wheel flange.
XYZ Records Batch No. Batch No: XXXX
of MIG Wire
Part C send for painting. Record of Batch Code of

Part A CODING LOCATION Part B CODING LOCATION Date of painting is Paint used for each day is
stamped on the wheel maintained in paint shop
with metal ink after
Part A Part B
On Part C as shown below eg:-
inspection.
Date Year M/c No
Part C Despatched to Vehicle Manufacturer 15 10 07 A 2 39B

Customer ( OE communicates data to
Month Shift Product
Manufacturer) and get XYZ
fitted on the vehicle
Date & Matl. 2
Vehicle send to dealer Dealer Communicates data
to Vehicle Manufacturer
Product Code
Vehicle sold to User Dealer obtain the following
data:-
Part C CODING LOCATION i. ii Part C batch code
ii. Part A batch code
Part C iii. Part B batch code
User finds problem in Vehicle user intimates

Part C Dealer
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5.22 Improvement Activity in the Shop Floor
PURPOSE
• To assure Quick Resolution of all Concerns and Sustenance of Defined System.
• Mechanism for daily meeting at defined time for Quality Concern review. (Internal, • Records of Daily Meeting for Quality Concerns (Ex 77).
sub supplier and customer) • Daily Work Management checklist for Supervisor (Ex 78).
a. Customer and warranty complaint - Each problem. • Layered audit checklist (Ex 79).
b. Sub supplier line rejection and internal complaints - Top defects.
• Defined Agenda and Attendees with meeting records.
• Availibility of non-conforming parts during discussion.
• Mechanism to Horizontally deploy actions to other lines/shops.
• Defined system to monitor countermeasures along with target date, responsibility
and status. Of achievement (open/closed).
• Defined mechanism to Follow Progress Monitoring and confirm completion of all
actions as per target date.
• Defined system for system sustenance check (Layered Audit) by Top management.
Take countermeasure on the gaps and ensure closure of all gaps.
• Defined system for Daily Works Management check by supervisor. Take
countermeasure on the gaps and ensure closure of all gaps.
142
Example 77 - Records of Daily Meeting with operator (Team Performance Centre)
Daily Work Management
* Daily Update the trend for
1 Production Plan v/s Actual
2 Customer Line Stoppage
3 Inhouse line Stoppage
4 Down Time
5 Safety Calender
6 Absenteeism
7 Customer Quality Issues
8 Internal Quality Issues
9 Cost of scrap
10 Operator Feedback
* Discuss the same with the operator at the time of shift start or at the time of major issue observed
* Take the feedback from the oerpator for each concern
* Take action and fill the 8Ds
* Monitor the effectivenss of the action plan
* Close the concern if the actions are effective
TEAM PERFORMANCE CENTER
DELIVERY TEAM COMMUNICATION QUALITY
Production Customer Line Customer Top Customer

Stoppage
Shift A Area Top Concern Operator Feedback Action Who When Concern
G8D s
Plan Rejection
IPPM
Operator Feed Backsxls
1 2 9 10
Operators Photo 16
Inhouse line FIRE Internal Top Inhouse
Down Time
Stoppage WALL Rejection Line Concern
Operator Feed Backsxls
3 4 DOCK
11 12
Shift A Leave Calender
AUDIT Operator Feed Backsxls
Safety
Absenteeism Trend Analysis
Calender
Customer Concern Yesterday:
Operators Photo 17
5 6 13
Layout Training Plan Shift A Operator Suggestions:

COST
7 8 Cost of Scrap Over time

Operators Photo
Change Implementation
14 15
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Example 78 - Daily Work Management Checklist for Supervisor
Dates 8/10/2011 8/11/2011 8/12/2011 8/13/2011 8/14/2011 8/15/2011 8/16/2011 8/17/2011 8/18/2011 8/19/2011 8/20/2011 8/21/2011 8/22/2011 8/23/2011 8/24/2011 8/25/2011 8/26/2011 8/27/2011 8/28/2011 8/29/2011 8/30/2011 8/31/2011
Sr.
No Check points
1 Abnormal Situations
Is Abnormal situation displayed on the work stations
Is it being followed
Is the area defined for keeping the Fallen parts seperately
Is the separate bin with Lock & Key available to keep the fallen parts
According to reactivity defined in abnormal situation , records are available.

2 Work Instructions
Is Work Instructions of Running parts is displayed at station
Operator is aware of points to check at respective station
Whether records are maintained as per work instructions
3 Set up changeover Instructions
Is setting change over instruction displayed at corresponding station
Is set up approval checksheet available at the station
Is set up approval records are updated by operator as per set up happened

Is set up table conditions are displayed at the work station
Are the parameters from control plan included in set up table condition
Is set up approval record signed by superviosr
4 Inprocess Inspection / patrol inspection
Is Inspection sheet / register / format available on the station or with Operator

Are Inspection records updated as per the frequency defined in C.P. / WI
SOP
Is Inspection records are confirmed / signed by supervisor
5 Daily Preventive maintainence checklist
Is daily preventive checksheet is displayed near the work station
Is it being updated at the start of the shift
Whether all required checking facility is easily visible and accessible.
6 Defect Display
Are all the defects defined with Photographs / Limits samples showing OK &
NOK conditions
Is operator aware of all the defects displayed at respective stations
Limits samples are displayed with their Validity
Limit samples are within their validity period.
Master samples are placed in their defined place
Master samples is kept with its validity tag
Master samples is within its validity period
7 First Piece Approval
Is first piece approval record updated by operato
Is it signed by superviso
are the inspection details/ criterions / specification are matching with contro
plan / work instruction
8 Daily start up checklist
Is start up checksheet is available at statio
Is it updated at the start of shift
Are characteristics from C. P / WI included in Start up checklis
9 Non Conforming part handling situation
Is NON conforming part handling procedure displayed near each work station
Is Operator aware & able to read the procedure
Is that procedure being followed.
10 Whether Bin to keep NOK parts is available
11 Rework Instructions are displayed near Rework Station
12 No part is kept w/o identification
13 Status of items mentioned on daily communication board is updated
14 Gauges & tools
Is the place for keeping the gauges / tools defined
are the gauges / tools are kept in their respective places
Is the validity period is indicated on all gauges
are all the gauges are maintianed within the Validity period
145
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Example 79 - Layered Audit Checklist
146
5.23 Activity to Achieve the Internal Process PPM Target
PURPOSE
• To assure effective & timely achievement of internal process Quality Targets through structured Analysis activity (Eg. QRQC)
• Availability of Quality results graph (per day, include target value) of each process/ • Daily Quality Graphs including traget value for each process.
line at shop floor. • Records of daily meeting with operators (Refer Ex 77)
• Mechanism to follow PDCA for all causes on daily basis and display on shop floor. • Daily PDCA for internal concerns (Refer Ex 77)
• Mechanism defined for daily shift wise meeting with operators and recording their
feedback.
• Mechanism to Display nonconformity parts occurred on the day and make workers
confirm it and share information.
• Mechanism defined to analyse Non-conforming parts in manufacturing process as
per analysis procedure.
• Defined system to collect NC parts as and when defect occurs and analyze
immediately.
147
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Chapter 6
Control of Sub Suppliers

Objective: Management of Sub Supplier through defined supplier selection process and to ensure QMS.
6.1 Sub Supplier Sourcing & Quality Assurance Contract
PURPOSE
• To assure Selection of Suppliers based on QMS.
• To assure the mechanism of Contract with sub supplier on Quality requirements.
• Availability of standard for Supplier selection covering Quality requirement. • Procedure for Supplier Selection (Ex 80).
• Mechanism of Evaluation for New Supplier Selection with defined Standard • Supplier selection criteria (Ex 81A) & Selection Evaluation Standard (Ex 81B).
covering Quality, Manufacturability, QMS Check points with acceptance criteria for • Supplier Quality Manual(Ex 82).
selection on board. • Contract for Supplier Quality manual with All Suppliers.
• Availability of Quality requirements for Sub Suppliers (Including control plans,
process change, first products control, management of non-conforming parts).
• Mechanism of communicating & Contracting Quality requirements with all
Suppliers.
148
Example 80 - Procedure for Supplier Selection (Flow Chart)
PROCEDUREPROCEDURE PROCEDURE
Process No.
Process No.
PROCED
Process No.
Title Title : Supplier
: Supplier selection,
selection, evaluation,evaluation, & performance
& performance Title for
monitoring monitoring
: direct
Supplier for direct
selection, Title : Supplier
evaluation, & performance monitoring for direct selection, evaluation, & perfo
material.material. material. Issue Issue material. Issue
Flowchart of Events Description of Activity Flowchart of Events

Responsibility
Flowchart of Events Description of Activity R
Input 15 Update supplierdocuments and customer HOD

1 As per requirement like new7product
Raise enquiry to
developmet, problem with 7 HOD
Raise CRM,
enquiryPPC,
along with &
MQC release
STP of technical
approved list 15 Based on STP ,
the pe
Business
Plan
1 Purpos1 eDecission
: for Thexisting
is prosupplier,
cedurcapacity
e definconstraints,
epotential
s the suppliers
pcustomer
rocessfeedback
to eva&luate & sespecific
lect nerequirements
w supplietorspotential
basedsuppliers
on their ability to & review every
development supply products meeting
continuous improvement decide quality,
the
8 Offer from potential cost & delivery requirements.
new supplier development.
8 Obtain technical & commercial offer from suppliers. HODP.O.STP/ ,
with ref. to format - New supplier selection . 16 Release P.O. / sheduling 16 Release
suppliers
agreement for bulk supplies. production / cus
2 Scope of Application: Direct Materials supplier.
9 Release
2 Identify the potential supplier trial P.O.by the customer.
if not specified 9 HOD
Relase trialMQC
CRM, lot P.O. along with the technical requirement.
& STP
2 Identify potential
17 Monitor 17 Monitor supllier
supplier(s)
10 Obtain sample performance. HOD
based STP
on the su,
3 Terms & abbreviations: HOD SPT - Head of department steel purchase 10 Obtain sample from supplier along with inspection report / test In case the rating i
certificate & offer to QA / MQC
18 Inform to action plan.
HODMFL STPto,
3 Obtain registration HOD MQC - Head of Metallurgical Quality Control
3 Otain filled registration form from supplier (technical & commercial HOD MQC & STP supplier. Supplier Rating
P.O. - (FM/STP/11).
details Purchase order
11 Sample No
11 In case of sample is not approved than take corrective action and HOD STP ,
approval 18 Communicate th
resubmit fresh samples for19approval
Review the List of
4 Based on the requirement & information provided by the supplier HOD CRM, MQC, STP, MQC &
performance. approved for corrective ac
4 Deicde whether
whether to audit the supplier or not. yes QAS suppliers
to audit 19 Review the perf
No
12 Release pilot lot P.O.
Yes 12 Relase pilot lot P.O. along with the technical requirement. the list
HODof approv
STP ,
Record 20 In case of deve
concern
5 Conduct audit 5 Carry out technical & comm13
ercArrange
ial asseTrial
ssmelotnt. HOD QAS, MQC, STP & MQC MFL will conduct A
verification at Supplier end along with product
13 Ask supplier to submit samples of significant lot size along with HOD STP ,
PPAP document.
21 In case there ar
4 Process Quantifiers: No
Supplier schedule Vs actual be removed from a
6 Are supplier(s) tech. & Supplier
6 Review thePerformance. trialYlot
14 Is whether
assessment & decide
es No the
to select or drop
14 Decide whether to seek re-submission with corrective action.
HOD QAS, MQC, STP & MQC
HOD STP ,
will be tretated as n
comm. capable supplier. Approved
yes
Yes
Process Owner: Process Owner: Approved by: Process Owner Approved by:
Effective Date: Effective Date: Effective Date:
Signature: 5 Process flow chart, description and responsibility:

Signature: (see next pages)Signature: Signature: Signature:
Page 2 of 5 Page 3 of 5 Page 4 of 5
149
Process Owner:
Approved by:
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Example 81A - Supplier Selection Criteria

Doc No:
POTENTIAL SUPPLIER SELECTION CRITERIA Rev No:
Rev Dt:
SCORE GUIDELINES
ASSESMENT
S.No. PARAMETER Weightage SCORE
RESULT 3 2 1 0
1 QUALITY MANAGEMENT SYSTEM CERTIFICATE 12 ISO /TS 16949 :2002 Available ISO9001 certification avaialable Certification in plan No certification avaialable & No plan available
1. Less compared to competitors 1. Equal compared to competitors or 1. High compared to competitors 1. Very High compared to
2 IN HOUSE REJECTION % 3
2. Less than 1.0 % 2. 1.0 % ~ 4.0% 2. 4.0% ~10 % competitors or ( 2.) > 10.0%
100 % availaibility (all testing facility 75 % ~ 95 % of testing facility < 75% of testing facility avaialble in < 50 % of testing facility avaialble in
3 TESTING FACILITY AVALABILITY 2
avaialble in house ) avaialble in house house house
1. Less compared to competitors - High compared to competitors or 1. High compared to competitors 1. Very High compared to
4 CUSTOMER LINE REJECTION 3
2. Less than 50 PPM - 50 PPM ~100 PPM 2. 100 PPM ~ 400 PPM competitors or ( 2.) > 400 PPM
1. Less compared to competitors - Equal compared to competitors or 1. High compared to competitors or 1. Very High compared to
5 DELIVERY FAILURE PPM 3
2. Less than 200 PPM - 200 - 500 PPM 2. 500 - 1000 PPM competitors or ( 2.) >1000 PPM
1. Less compared to competitors - High compared to competitors or 1. High compared to competitors 1. Very High compared to
6 WARRANTY REJECTION 3
2. Less than 50 PPM 50 PPM ~100 PPM 2. 100 PPM ~ 400 PPM competitors ( 2.) > 400 PPM
QUALITY SELF ASSESSMENT BY SUPPLIER

7 8 > 80% > 50% >30% < 30%
(F/QA/328)
Score achieved in parameter 1 X weightage of parameter 1 + Score achieved in parameter 2 X weightage of parameter 2 + …………………..Score achieved in parameter 7 X weightage of parameter 7
SCORE CALCULATION =
Maximum score of parameter 1 X weigtage of parameter 1 + Maximum score of parameter 2 X weightage of parameter 2+ ………………… Maximum score of parameter 7 X weightage of parameter 7
ACTUAL SCORE ACHIEVED Date:
Name of Supplier -----------------------Fill in the name of Supplier------------------------- SELECTION CRITERIA

Item Maximum Score
A / NA? Weightage Effective Score % Score SCORE ACHIEVED JUDGEMENT
No. Score Achieved
1 A 36 12 0 Approved for supply without SSWL Quality assesment (For R M Supplier)

RATING ≥75%
2 A 9 3 0 Approved for supply after SSWL Quality assesment (For Local Slitting Supplier)
3 A 6 2 0 = TOTAL Approved for supply After SSWL Quality assesment

EFFECTIVE SCORE RATING 50% - 75%
4 A 9 3 0 (Note: Provided after assessment, score is greater than or equal to 75%)
/ TOTAL
5 A 9 3 0 MAXIMUM SCORE
RATING < 75%
Rejected for supply
6 A 9 3 0 (After SSWLQuality Assesment)
7 A 24 8 0
Rejected for supply
RATING < 50%
For Packaging supplier the criteria will be RATING < 40%
TOTAL MAX. SCORE 102 TOTAL EFFECTIVE SCORE 0 0%
Sign Head Purchase Sign Head QA Sign GM (W)

DECISION FOR -----------------------Fill in the name of Supplier-------------------------
150
Example 81B - Supplier Selection Evaluation Standard
Supplier assessment and Evaluation Form Supplier assessment and Evaluation Form
DOC NO. : DOC NO. :
REV. NO. :
REV. NO. :
DATE :
DATE :
Name : Telephone :
A- Quality System Evaluation (Considered for Approval)
Address :
Fax : Sl Yes/ Max Scored
Points for Evaluation
No No Remarks Points Points
Date of Assessment :
1 Quality System
Name of the Partners/ Directors :
Does the supplier have appropriate
Persons(s) Contacted 1.1 3
ISO 9000 approval
Does the management review the
1.2 3
Description of the Items Under Consideration : quality system?
Does the supplier have an adequate
1.3 3
quality manual?
Does the management team include
1.4 3
technically capable personnel?
Is the availability of technically
1.5 capable supervision satisfactory for 3
the entire working hours?
Do they have sufficient experience in
Maximum Applicable Points Percentage (%) 1.6 handling items similar to those under 3
consideration?
Total Points Scored Rating : A RA RE R
Remarks Engineering Control and
2
Documentations
Recommendations For Do they preserve drawings and

specifications provided by customers
Approval 80% & Sample QA REP: 2.1 3
above
properly and do they ensure latest
Pilot lot specifications are followed?
Do they preserve customer inspection
Restricted Approval 70 to 79% Designation:
2.2 reports and other communications 3
To be Re-evaluated 60 to 69% Purchase Rep:
and they are available for reference?
Is the communication to workmen
Rejected Less than Designation : and inspectors about latest
60% 2.3 3
specifications, inspection procedures
satisfactory?
Does the supplier have a reliable
2.4 change control process for customer 3
initiated revisions?
3 Procurement
Issued by Prepared by: Reviewed & approved by: Are suppliers evaluated and
3.1 3
monitored?
Are there criteria to evaluate
3.2 3 for Ex 81B
Refer Annexure
suppliers?
Does the supplier have an approved
3.3 3
supplier list?
Are records of rejection / defects
3.4 3
tracked and logged? 151
Issued by Prepared by: Reviewed & approved by:

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Example 82 - Supplier Quality Manual

SUPPLIER QUALITY ASSURANCE MANUAL SUPPLIER QUALITY ASSURANCE MANUAL
DOC NO. : SQM-01 DOC NO. : SQM-01
REV. NO. : 0 REV. NO. : 0
DATE :
DATE :
Sec A - Table of contents
Sec Ref Title No of pages
Sec A Table of contents
Sec B Issue / Amendment record
Sec 1 Introduction to SQA manual
Sec 2 Supplier selection procedure

SUPPLIER QUALITY ASSURANCE MANUAL Sec 3 Supplier Quality requirements
Sec 4 Supplier Delivery requirements
Sec 5 Supplier performance rating
Sec 6 Problem reporting and counter

measures
Sec 7 Environmental requirements
Sec 8 Substances of concerns reporting
Sec 9 Modification Management

152
6.2 Method of Sub-Supplier Quality Assurance
PURPOSE
• To Assure QA Standard for Sub-suppliers.
• To Assure Quality during New Product Development at Sub-Suppliers.
• To assure Quality Targets Achievement through Quality Concerns Analysis & Tracking.
• Availability of List of approved Sub Suppliers. • Approved List of Sub-Suppliers with QMS status.
• Availability of QMS Certificate for all the Sub-Suppliers. (Including Raw material • ISO/ TS16949 Certificate copy for Sub-suppliers.
Suppliers). • APQP Timing Plan for Sub-Suppliers parts. (Refer Ex 30).
• Mechanism is available for monitoring the expiry date of QMS Certificate. • Launch Readiness Audit Reports.
• Defined Timing Plan for New Part Development for at least 4 to 6 critical items for • Detailed Root cause analysis for Sub-Suppliers Quality Concerns (Refer Ex 14).
all sub suppliers for New Projects. (Critical items include:-PFC, Prod CP, PFMEA, FTG, • Progress control list for Sub Supplier concerns (Refer Ex 8).
Packaging sign off sheet, SOP). • Sub-supplier PPM Targets.
• Use of 8D methodology to analyze the top concerns for incoming, car makers and • Sub-supplier ppm monitoring sheet.
warranty.
• Use of Progress control List for Sub-supplier Quality concerns without any delay.
• Mechanism of Launch Readiness audit for Sub-suppliers.
• PPM targets are given to each supplier based on their previous year’s performance.
• PPM Monitoring for All suppliers Monthly basis.
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6.3 Planning for Sub-Suppliers Audit & Assistance
PURPOSE
• To Assure Sub-supplier QMS sustenance through Evaluations
• To assure Rank up activity at poor performing supplier.
• Availability of Audit Plan for sub-supplier and adherence. • Sub-supplier Audit Plan
• Mechanism to Monitor Actions decided during audit • Sub-supplier Audit Check sheet (Ex 83)
• Availability of defined Criteria for deciding and reviewing Audit Frequency • Monitoring of Audit Results & Action plan.
• Mechanism of Rank up activity for red suppliers • Worst supplier identification standard (Refer Ex 82)
154
Example 83 - Sub Supplier Audit Check Sheet
Supplier Process Audit Check Sheet Supplier Process Audit Check Sheet
DOC NO. : DOC NO. :
REV. NO. :
REV. NO. :
DATE :
DATE :
New
Re-Audit SCAR Ref:
Audit
Good
SCORE
Ref
Poor
Fair
Date Report No Auditor Audit Check List Reference / Remarks
NO
Good No
SCORE
Ref
Poor
Fair
Audit Check List Reference / Remarks

NO
No Are all Line Gauges working & are they within
b
their calibration periods?
Is the Inspection Instruction and control plan
1
Gauges
a
present near the area of work? Are Approved Boundary Samples Present and in
b
Check issue level of Control Plan against Engineering c good order? (Only If required by Control
Control Plan)
c
Is the Inspection Instruction and Control Plan
is correct ? 3 a Is all SCRAP placed in reject or spoilage bins?
Are all the operation standards are displayed
d Is all scrap reported and recorded.
Non Conforming Product

near the area of work? b
Manufacturing Process Control
(On Job Card or spoilage sheet)

Are all the operation standards are referred in
e Do Operators know how to deal with Non-
the control plan? c
Conforming material?
Are the all the operation standard and work Is all Non-Conforming material segregated,
f
instructions are current and updated. d
Identified and labeled?
Has a First Off been done, is it recorded? ( i t df P d 1150)
g Is the inspection record sheet completed as per Is the Non-Conforming material
e
the control plan. documentation completed correctly .
Have appropriate supervision been informed &
Are the SPC charts filled in correctly? f
h corrective actions taken (where appropriate) ?
Are Batch numbers of materials present on
If control plan require off line tests e.g. 4 a
i paperwork (if appropriate)?
Hardness, UTM etc. Are they being done ?
When something goes wrong with the Process.
Is the product appropriately identified and
j Do Operators document the fault & corrective Traceability segregated at key production stages:- Is there a
b
actions on their Inspection Record Sheet risk of mixing ( eg LH with RH etc).:- correct use
of colour pallet markers
Does process qualification done at periodical ( h )
K
intervals?. Can the product be traced back to raw material
c batch numbers , sub batches & tape used (as
Are safety characteristics being identified and appropriate) ?
L
referred in the control plan
5 a Is the Product correctly labeled (Qty/Bar code) ?
Use of Mistake proofing and working on the
M
area? Is the correct (customer specified) packaging
being used ?
Packaging
Have machine setting and tool changes are b

N clearly identified and followed. (Cartons/dividers/Containers/pallets)
(Deviation present for non std packaging)
2 a Are all the Line Gauges Present Yes / No?
Are the product pallets & cartons in reasonable
c
order, free from product mixing (RH / LH) risks
Is there an Operator training matrix present on
6 a
:-
Issued by Prepared by: Reviewed & approved by: l / ll / d
Are ALL appropriate Operators listed on this
b
matrix?
People
Do the training records confirm that the Refer Annexure for Ex 83

c operators present on the line/cell are trained to
perform their tasks?

155
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6.4 Modification Management
PURPOSE
• To assure Sub-suppliers Product & Process Modifications with validations.
• Defined Procedure for Sub-supplier Product & Process with Responsibility and • Sub-supplier Change management procedure (Ex 84).
Timing. • Progress control list for Product & Process changes (Refer Ex 36).
• Availability Progress list for all Sub-supplier changes with Individual change notes. • ECN / PCN for Changes(Refer Ex 35).
• Use of Product quality and process capability for before and after change. • Process Capability /Product Results before & after Change (Refer Ex 35).
• Use of PSW / PPAP (or equivalent) standard after change. • PSW (Or Equivalent PPAP Records).
• Availability PPAP documents for all changes.
156
Example 84 - Sub Supplier Change Management Procedure
Doc no:
CHANGE MANAGEMENT PROCEDURE - Outsourcing RevNO
Rev Date
1. Purpose: To Define & establish the procedure for Process / Product Change at Supplier End
2. Scope/ coverage : For all products & processes of Wheels
3. Responsibility ; Purchase
Flow Chart for Supplier Initiated Process Change
Document /
Resp
Process Flow Records
Input for Change Input for Change: ECN/ Supplier R&D/

1 Supplier Initiated Initiated format supplier
Reject Proposal
F/PUR/03 F/PUR/03
stating Reason
Feasibility & Feasibility & 5 Days

Not OK Not OK Risk Analysis
2 Risk analysis by Risk analysis by As mentioned
supplier check sheet
R&D
OK OK
2 2
Tracking Sheet Supplier
3 Prepare Activity plan for change Prepare Activity plan for change Action Plan
F/PUR/02 Head R&D
F/PUR/04 F/PUR/04
Initiate SRCA Initiate SRCA 2 Days SRCA / Risk

4 Supplier
Analysis sheet
2 Days
5 1 Approval of SRCA ECN/ SRCA Head R & D
Include Sample Tryout
& Sample Approval by
ABC
Process / Part/ Tooling 15 Days ECN/ SRCA

Supplier
modification and Process Process
6 Head QA
1 validation validation
PPAP Approval, if
required. PPA to be
done by ABC 15 Days
7 Implement the change in Supplier /
Process/ Tooling/Part -- (PPA)
Head QA
1
Observe Process
Capability Before and
After change
Observe the Not OK
-- Supplier -
8 process
stability Head QA
7 Days
OK
Update PFC,PFMEA,CP,WI & PFD,PFMEA,CP,
9 Supplier
other records 5 Days SOP, etc.
10 Supplier -
PSW Sign off if required --
Head QA
Sign off -SRCA

15 Days Supplier -
11 --
Head QA
F/PUR/02
Change Management
12 F/PUR/02 QA
Summary Sheet
2 Parameters to be monitored will be
decided by CFT based on the
nature of change Change
Monitor Effectiveness of management Supplier
13 change 3 lots Tracking sheet/ QA
PSW sign off
Prepared By: Reviewed By: Approved By:
157
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List of Abbreviations
• APQP Advanced Product Quality Planning • KM Kilometer
• AFS Automotive and Farm Sector • KRA Key Result Area
• AIAG Automotive Industry Action Group • LOI Letter of Intent
• BOM Bill Of Material • MM Materials Management
• CC Critical Characteristics • MMA Mass Manufacturing Approval
• CDMM Component Development & Materials Management • MOM Minutes Of Meeting
• CFT Cross Functional Team • MOP Measures Of Performance
• CIR Customers Input Requirements • MP Mechanical Prototype
• CL Change Level • MRM Management Review Meeting
• CP Control Plan • MSA Measurement System Analysis
• CSI Customer Satisfaction Index • MSES Mahindra Supplier Evaluation System
• CSR Customer Specific Requirement • NTF No Trouble Found
• CMM Co-ordinate Measuring Machine • NDF No Defect Found
• DFMEA Design Failure Mode And Effective Analysis • PFC Process Flow Chart
• EN Or ECN Engg Notice / Engineering Change Notice • PFMEA Potential Failure Mode And Effective Analysis
• EP / VP Engineering Prototype / Validation Prototype • PIPC Percentage Indices Process Capable
• FTG Facilities, Toolings And Gauges • PIST Percentage Inspection Points Satisfying Tolerance
• FIFO First In First Out • PM Preventive Maintenance
158
• PO Purchase Order • SOP Standard Operating Procedure
• PP Production Prototype • SPC Statistical Process Control
• PPAP Production Part Approval Process • SOR Statement of Requirement
• PLC Programmable Logic Controller • SQA Supplier Quality Assurance
• PPM Parts Per Million • SOD Severity Occurrence Detection
• PTDB Past Trouble Data Base
• PSW Part Submission Warrant
• PTR Production Trial Run
• PY Poka Yoke
• QA Quality Assurance
• QC Quality Control
• QFD Quality Function Deployment
• QMS Quality Management System
• QTY Quantity
• RPN Risk Priority Number
• SCM Supply Chain Management
• SC Significant Characteristics
• SCAP Suppliers Corrective And Preventive Action Plan
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t i f i e d
Ce r
Mahindra & Mahindra Ltd.
Component Development & Materials Management
Supplier Quality Development
AD-Annex, Akurli Road, Kandivali (E), Mumbai- 400 101
ANNEXURE – A
The Annexure contains complete procedures of the excerpts mentioned in the MSES Manual.
1. Audit Check Sheet (Refer Ex 1)
Doc No.
Process & Product Audit Check Sheet Rev No.
Date
Process Name : Date :
Part No : Shift :
Part Description : Area : Incharge :
Customer : Machine No./ Name :
Operator :
ACCEPTANCE CRITERIA :
CATEGORY : RATING CRITERIA :

Strong Area Must score 50% in all sections M - Must If zero in M,score will be -5
VI - Very Important If zero in VI,score will be -2
Weak Area Not meeting above requirement I - Important If zero in I,score will be -1
I – SYSTEM CHECKS
Sl Categor Weightage Points Score
Check Item Result Remarks
No y (a) (b) (a x b)
1 ) Incoming Packing Condition (If Applicable)
1.1 Any damage in package? I 0.5
1.2 Any mix up? I 0.5
1.3 Any dust or dirt? I 0.5
1.4 Are all products/ packages identified? I 0.5
1.5 Strapping (Three strap radially and one on the circumference). I 0.5
1.6 Wrapping (To be completely covered with gunny bags) I 0.5
2 ) Raw Material/Storage (If Applicable)
2.1 Is the Raw material properly identified. I 0.5
2.2 Is the area marked for keeping raw material. I 0.5
2.3 Is there any wrong identification? I 0.5
2.4 Is checklist for material receipt available & being followed? I 0.5
2.5 Is the prctice being followed as per control plan/ receiving M 1
inspection standard ?
2.6 Is FIFO followed for RM. I 1
2.7 Are self life for items (wherever applicable) defined and are disposed I 1
of immediately on expiry date.
2.8 Is the tags available? I 1
2.9 Is the RM grade / Section correctly used. M 1
2.10 Are batch numbers of raw materials present on paper work? I 0.5
2.11 Can the product be traced back to the raw material batch numbers & VI 1
sub batches(if appropriate)?Check for mother coil no. & Heat no.
3 ) Receiving process ( If Applicable)

3.1 If control plan instructions followed? I 0.5
3.2 If records are maintained properly? I 0.5
3.3 If records are in good condition? I 0.5
3.4 Is supplier list available? I 0.5
Is NG and OK material properly seggregated and stored seperately
3.5 VI 1
with tags at appropriate location?
4 ) Control Plan related
4.1 Is Control Plan available for this process. I 1
4.2 Are latest process plan / work instructions/operation standards I 0.5
displayed near the machine / working area.(Check with master)
4.3 Are the check sheets / formats/stage inspection reports used on line are I 0.5
numbered in accordance to the reference given in control plan.
4.4 Is recording being done as per control plan.(verify stage inspection I 0.5
report & set up verification sheet)
4.5 Are required inspection conducted in accordance to the frequency & I 1
Sample size defined.
4.6 Is the Reaction plan available & followed. I 0.5
4.7 If anything goes wrong with the process,Do operators document the I 0.5
fault & corrective action on the inspection record sheet or job card?
5 ) Operating Instructions/Work Instructions/Operation Standards

5.1 Are all the product OI/WI sheets available at the location? I 1
5.2 Are OI present that are listed on the control plan? I 0.5
5.3 Are the statements in OI are valid(Machine settings/ gauge indexes) I 0.5
etc?
5.4 Are the SPC charts filled in correctly(if appropriate)? Are they I 0.5
referenced on OI ,Insp. Instruction & Control plan?
5.5 Is OI require off line test ex) Hardness, weld penetration ,are they I 1
being conducted?
5.6 Is the operation following the sequence of steps used as per the WI M 1
to OS?
6 ) Inspection & Testing
6.1 Is the check sheet/stage inspection report filled for all the details as I 1
required in the control plan.
6.2 Is the Set up approval done. M 1
6.3 Is the First piece & Last piece kept and identified. I 0.5
6.4 Are the tools & gauges appropriate to the process being followed?. I 1
6.5 Is start up checklist being identified? I 1
7 ) Process Flow
7.1 Is the Process Flow Chart available. I 0.5
7.2 Is the Process sequence as per the PFC. M 1
8 ) Material Identification & Traceability
8.1 Is the Inspection tag available. I 0.5
8.2 Do the traceability system being followed as per work instruction. VI 1
Check with disc/rim
9 ) Gauges & Fixtures
9.1 Are there proper storage facilities for the tools. I 0.5
9.2 Are there appropriate records for details of tool change, repair of tools I 1
and tool life.
9.3 Are required gauges / inspection fixtures / instruments available.Do I 1
the instruments checklist followed?
9.4 Is storage of gauges done properly and at an identified location. I 0.5
9.5 Are the gauges/surface table oiled and covered properly when not in I 1
use?
9.6 Are the gauges duly identified & Calibrated. VI 1
9.7 Are all line gauges working? M 1
9.8 Are some process gauge / jig for fool proofing made. I 1
9.9 Verification status of Tool change programme / Fixture validation / I 1
condition of tools / Physical dimensions check.
9.10 List of Gauges & Fixtures and their use adhered to control plan – I 0.5
Check with List of Tools & Gauges.
10 ) Calibration
10.1 Are equipment used calibrated. M 1
10.2 Is the Instrument / Gauge identified in line with Control Plan. I 0.5
11 ) Process Yields
11.1 Productivity (Wheels / hr ), at present Vs claimed in the feasibility - 1
sheet.
12 ) Process Control
12.1 Is there system and recording of first piece approval. M 1
12.2 Are process capability studies being used to evaluate production I 1
processes.
12.3 Are important process / parameters made clear to operators. I 1
12.4 Do people trained on safety & special characteristics? M 1
12.5 Do the skill matrix available(Check with the person working in the I 1
area with the skill matrix)
12.6 Are process sheets available on line. I 1
12.7 Is consolidated list of important parameters available. I 1
12.8 Is internal quality standards available. I 1
12.9 Are special requirements from customers incorporated in the I 1
inspection std.
12.10 Are limit / master samples displayed at inspection area. I 1
12.11 Are the parts properly identified/Details of rejection written on the VI 1
part.
12.12 Are the area for OK and NG products duly marked. I 0.5
12.13 Is there any system made to prevent mixing of parts (OK & NG). M 1
12.14 Is identification done for rework area / Reinspection after Rework. M 1
12.15 Are Inspection points clear and adequately lighted. VI 1

12.16 Is there any proper feedback system available among the operators? I 0.5
12.17 Is the mistake proofing validated & working at the time of Audit. I 1
12.18 Is the operator aware of mistake proofing? I 0.5
12.19 If the mistake proofing is malfunctioning whether line is stopped and I 1

informed to concerned person?
12.20 Is the process qualification done. I 0.5
12.21 Is control chart followed. I 0.5
12.22 If the process go beyond thecontrol limits, resetting the process is done M 1
or not?
13 ) Control of NC Product
13.1 Is the NC product kept separately. M 1
13.2 Is the NC Product Identified. M 1
13.3 Entry in the Reaction log. M 1
13.4 Corrective & preventive action. I 0.5
13.5 Do the operators know how to deal with the NC product? M 1
13.6 Details of Concessions, if any. I 1
13.7 Do the rework & repair instructions available and followed? M 1
14 ) Kaizen & Countermeasure related
14.1 Is there any activities identified under Kaizen and have been I 0.5
implemented.
14.2 Check whether effectiveness of Kaizen is monitored regularly. I 1
14.3 Are the countermeasures given being implemented. I 1

14.4 Are the results monitored after implementation of given I 1
countermeasure.
15 ) Safety related
15.1 Are the hazardous wastes disposed off effectively. I 0.5
15.2 Are MSDS available for consumables used at appropriate stations. I 0.5
15.3 Are Instructions for safety wear on shop floor / process displayed. I 1
15.4 Are the containers storing hazardous material duly identified (whether I 0.5
applicable).
15.5 Is the safety Work Instructions available & adhered. I 0.5
15.6 Do the waste bins identified & waste disposed according to the I 1
category?
16 ) House Keeping & Machine Maintenance
16.1 Is the work place is clean, 3S around the place. I 0.5
16.2 Is the Autonomous maintenance done/ checklist followed? I 0.5
16.3 Are the machines free from oil leakage, damage etc., I 0.5
16.4 Is there availability of preventive maintenance plan. I 1
16.5 Check for implementation of preventive maintenance plan. I 1
16.6 Is machine history card available and updated. I 0.5
16.7 Is monthly machine downtime record being maintained. I 0.5
16.8 Is corrective measure plan available and implemented for downtime. I 0.5
16.9 Are the countermeasures given implemented on time. I 1

16.10 Are spares for machines available and labeled properly near or on the I 0.5
machine.
16.11 Is Autonomous Maintenance check sheet for machine available & I 0.5
filled.
16.12 Are the proper facilities (trained manpower, tools & equipment) I 0.5
available for carrying out maintenance of production equipment.
16.13 Is there proper lighting and Ventelation? I 0.5

16.14 Skill matrix with production records - verification. I 0.5
16.15 Gauges,toolings and fixtures are properly identified and should be I 0.5
reasonably clean?
17 ) Training
17.1 Training on Control Plan, Process drawing, Work Instructions, I 1
Reaction plan, Inspection methods, one point lessons etc.,
17.2 Any Casual labors training. I 1

18 ) Quality Record
18.1 Are quality records easily retrievable / legible / indexed /identified I 0.5
Total Score
 OK No Discrepancy (2 Points) Maximum score is points

s Minor Discrepancy (1 Points) 1.0 - Weightage given to the parameters which are
directly affecting the product quality
 Major Discrepancy Improvement Required (0 points)
0.5 - Weightage given to the parameters which are
NA Not Applicable indirectly affecting the product quality
II - PROCESS CHECKS
Sl
Process Parameter Specification Observation Score Remarks
No
Total
II - PRODUCT CHECKS
Sl
Product Parameter Specification Observation Score Remarks
No
Total
Auditor : In charge :
Each parameter is given equal points.If found OK 1 point, not ok 0 point.If special character is found not ok,
total score will be 0 and other characters is not Ok reduce 1 from total score for each not OK character. Both
process & product scores will be
IV – CORRECTIVE ACTION PLAN
Sl Section
Corrective Action Resp Target Date Auditor Sign
No Reference
2. Warranty Procedure (Refer Ex 9A)
Procedure No
PROCEDURE FOR WARRANTY HANDLING Page No
Page issue No
Issue date
TITLE :- WARRANTY HANDLING
Signature
Input What Where Output When Who How
START
Attend the Warranty

meeting at customer
end.
As per customer's
Receipt of the warranty complaint from the customer through
--- (1)TKML :- Once/month. Warranty formats requirement/monthl QA email / phonecall
Telephone call / Warranty analysis meeting
Other customer email y
monthly to get data or
nil rejection from
customer.
Conduct the data analysis and the preliminary joint analysis (

Visual inspection & feel) with the customer at warranty cell
and decide
a) Accept claim - Confirmed by visual inspection
b) Accept claim - needs further investigation at plant
Joint analysis report As per customer's
c) Reject claim
Customer given samples Warranty cell & Parts accepted / requirement/monthl QA/ Marketing Joint analysis format.
d) New claim rejected y
e) Rare claim
Claim accept -a) The part in which defect is confirmed is sent

to scrap yard
Joint analysis report b) Carryout Testing like Axial play & torque ,Push out & Plant Warranty log After initial analysis QA Warranty log
pullout ,Dimesional in plant standard room for the parts in
which defect is not evident.
Joint analysis report with

Customer given samples Claim Reject : Reject claim and handover parts to customer Warranty cell NTF records After Initial analysis QA
customer.
Claim for Old cases (Whose actions are completed).Verify the
Observations after
Customer given samples failure mode by visual / dimensional / metallurgical inspection Plant After initial analysis QA Analysis report
analysis
Claim for New cases

Receive the rejected part from customer or bring the rejected
After receipt of part Cause analysis In DICAR
Customer given samples part to Sona . Enter the details in the Warranty log In the Warranty log Update warranty log QA
at Sona format
form.Analyse the part for failure mode, immediate information
to CFT
Update the Information indicators -Trend graph / Pareto chart

for Kilometers,Date of MFG part , Zone wise ( Dealer wise ),
Customer wise, Defect wise & NTF trend
Analyse the warranty trend and if the trend is above the alarm
target limit
Monthly Quality report
(1) Immediate actions
Analyse and initiate monthly improvements plans to improve Monthly Monthly Quality Meeting
plans
Warranty Log the trend Warranty register /Yearly QA Format
(2) Monthly / Annual
Information by Email to all
improvement plans
1) Trend crossed the target line concenred
2) Trends are running very near to the target line
3) New defect
4)post modification failure
Capture the possible causes.Find the root cause by QC story

Warranty analysis After cause
For the accepted claims appraoach for top three claims.Prepare corrective action plan QC STORY Engg/QA/MFG Hard copy
report analysis
& send to customer .
PFMEA/WI/CONTROL After customer's

After customer approval Modify the documents and Update PTDB. Updated PTDB Engg/QA/MFG Soft copy/Hard copy.
PLAN ETC approval
END
3. Procedure for Cause Analysis (Refer Ex 11A)
CAUSE ANAYSIS PROCEDURE SOP

Page
TS CLAUSE NO. 8.4, 8.5.2, 8.5.2.1, 8.5.2.2 , 8.5.2.3, 8.5.2.4 & 8.5.3 ISO 14001 CLAUSE NO. 4.5.3
Rev. No. 04
1 PURPOSE
To establish and maintain a system for taking corrective and preventive actions.
2 SCOPE
Applicable to Customer return , warranty return , as well as inhouse rejections ( Monthly Basis) .
3 PROCESS OWNER
3.1 Head quality assurance is overall responsible for implementation of this process approach.
3.2 Respective section incharges are responsible for implementing of the immediate and permanent countermeasures decided by CFT/ team.
3.3 Respective section incharges are responsible for analyzing the potential non-conformances with concerned CFT and submit the countermeasure report to head quality assurance.
3.4 Other specific responsibilities are as given in the procedure by means of flow chart.
4 Quality Records
Doc.No. Description Retention Period Responsibility Location Method Of Disposal
F07-8204 Defect information cum countermeasure report Current financial year+1 year back Relavent sec.head Defined place Sale to scrapper
F02-7103 Action plan Current financial year+1 year back Relavent sec.head Defined place Sale to scrapper
5 DEFINITION
QC Quality control CL Customer Line
Activity responsible department WR Warranty Return.
CFT Cross functional team IN-HO In-House.
QA Quality assurance
FMEA Failure mode effect analysis
OCI Operation control instruction
CP Control plan
6 Effectiveness & Efficiency Indicators /Performance Indicators

Performance indicators Relavent To Q/E Detail of Performance Indicators Responsibility Frequency Reference Documents
No.of fool proofing done in the process Respective Monthly Summary of poka-yoke
Effectiveness Q
No.of preventive actions taken incharge Monthly DICR reports
Q-Quality Management System Requirement , E-EMS Requirement

7 REFERENCES
----------
------------
8 AMENDMENT RECORD
Amendment Date Amd No Amd Details Reason For Amd Amd By Approved By
04.01.10 03 Nill Periodical Review Bhupendar MR
10.04.12 04 Nill M & M Requirement Bhupendar MR
Prepared By Checked By Approved By Format Rev. 01

4. PFMEA Procedure (Refer Ex 21)
PFMEA PROCEDURE SOP
PROCESS APPROACH FOR PFMEA MAKING Date

Page
TS CLAUSE NO. 7.3.1.1 /7.3.3.2 ISO 14001 CLAUSE NO.
Rev. No.
Activity/ WHAT Output/Format &
Sl.n Responsibility CONTROL
INPUT QA Pur Engg Prod PPC MR CFT All HOW WHERE WHEN WHY Reference
o (WHO) /CRITERIA
1 2 3 4 5 18 19 20 Instruction
GuideLine for skill

Formulate the CFT Based on Skill Requirement such as
New Products built, Existing Whenever formulate newly requirement.
Head members. Hard skill , soft skill and Technical
1 product(or) process Project Room (or) added/deleted the To form the CFT F1-7101B ……………….
Engineering skills in cause & Effect analysis,
modification stage. members list. F10-7101B
Ranking stages.
F09-7101B
19
F01-7101B
Master schedule ,PFMEA F06-7101B
1.Past Trouble Data base with guide
input check sheet , CFT F06A-7101B
Start to prepare line of update & Diploy the horizantal
members list, simillar process At the time of making fresh F03-7101C
2 CFT diployment ,2. Drawing, 3.Similar part Project Room To make PFMEA ……………….
PFMEA, List of poke yoke , PFMEA. F02A-WI/SOP-
comparision,(Detection & prevention
lesson learnt and past trouble 7101B/01
mechanisim,
data base F07-7101B
WI/SOP-7101B/02
19
Operation Name /
3 CFT Process flow diagram. Using process flow chart. New project -PFMEA PFMEA./ Revised the To make PFMEA F20-7101 ……………….
Number.
existing PMEA.
Customer (or) internal 19

Identify the At the time of making fresh Every product
Customer (or) internal drawings /
4 CFT drawings / Simillar part Process/Function New project -PFMEA PFMEA./ Revised the characteristics fialure ………………. ……………….
Simillar part PMEA
PMEA requirement. existing PMEA. modes to be analysed.
19
F01-7101B
To prevent the F06-7101B
past trouble datas , simillar CFT inputs / Past trouble datas At the time of making fresh
Identify the Potential re-occurrence,warranty F06A-7101B
5 CFT part pfmea,List of poke yoke, simillar part pfmea,List of poke yoke, New project -PFMEA PFMEA./ Revised the ……………….
failures,customer F03-7101C
lesson learnt lesson learnt existing PMEA.
complaints. F02A-WI/SOP-
7101B/01
F07 7101B
19

Simillar part PMEA ,Customer To identify the potential F06-7101B
6 CFT Potential effects Based on product knowledge New project -PFMEA PFMEA./ Revised the ……………….
feedback,Field informations risk. F06A-7101B
of failure existing PMEA.
19
Based on product functions failure with
Identify the Sev respect to next process , assembly line
At the time of making fresh
Simillar part PMEA ,Customer Rating (S). ,Customer line and enduser .Ranking To identify the severity
7 CFT AIAG -latest manual. PFMEA./ Revised the F03-7101B ……………….
feedback,Field informations should be given for all effects of effects
existing PMEA.
failures and highest ranking should be
taken as severity ranking
19
Identify and mentioned At the time of making fresh To identify the safety &
Customer (or) internal
8 CFT the Class. Customer (or) internal drawing New project -PFMEA PFMEA./ Revised the regulatory and to decide ……………….
drawing
existing PMEA. on Sev rating
19
F01-7101B
Identify the potential To prenvent the re- F06-7101B
past trouble datas , simillar Cause(s)/Mechanism(s) At the time of making fresh
past trouble datas , simillar part pfmea, occurrence .To identify F03-7101C
9 CFT part pfmea, list of poke yoke of Failure and implement New project -PFMEA PFMEA./ Revised the ……………….
list of poke yoke and lesson learnt. the process control F02A-WI/SOP-
and lesson learnt. existing PMEA.
the same in new project methos using 4M 7101B/01
F07-7101B
19 Collect and summarize the last 6

Identify the months internal rejections data for
Project past trouble datas , simillar occurrence each defect wise or Cause wise from At the time of making fresh To know the prodcut
Rating (O) F02-7101B
10 Development In- part PMEA, occurrence the simillar product (or) mother plant AIAG -latest manual. PFMEA./ Revised the chracter rejection rate in ……………….
F04-7101B
charge /CFT backup sheet. .Based on that datas, existing PMEA. past timings.
A Identify the occurrence rating by using
Occurence Ranking Guide.
19
A F01-7101B
F06-7101B
past trouble datas , simillar Identify the Current F06A-7101B
past trouble datas , simillar part pfmea, At the time of making fresh To define the process
11 CFT part pfmea, list of poke yoke Prevention method New project -PFMEA F03-7101C ……………….
list of poke yoke and lesson learnt. PFMEA. control method
and lesson learnt. and deploy the same F02A-WI/SOP-
in the new projects if 7101B/01
applicable F07-7101B
19
F01-7101B
Identify the Current F06-7101B
past trouble datas , simillar Detection method & past trouble datas , simillar part F06A-7101B
deploy the same in At the time of making fresh To define the process
12 CFT part pfmea,CFT inputs,list of pfmea,CFT inputs,list of poke yoke New project -PFMEA F03-7101C ……………….
new projects if PFMEA. detection method
poke yoke and lesson learnt. and lesson learnt. F02A-WI/SOP-
applicable 7101B/01
F07-7101B
19
Detection Rating Based on detection

Similar PFMEA./ Past At the time of making fresh
13 CFT -D Guideline Detection AIAG -latest manual. ranking ,identify the best F05-7101B ……………….
Trouble datas. PFMEA.
Modify the current detection method.
control prevetion
and detection
19 method
Severity ,occurrence ,detection Calculate RPN if feasible
value Severity ,occurrence ,detection ranking At the time of making fresh To know about the RPN
14 CFT ranking for every product New project -PFMEA F07-7101B ……………….
(SXO for every product characteristics PFMEA. value based on SOD
characteristics XD)
19
If RPN value and Based on below criteria

other critria 1.Highest RPN. At the time of making fresh To bring the threshold
15 CFT RPN value & Severity value exceeds,Actions New project -PFMEA F07-7101B ……………….
2.Severity = > 9 & 10, PFMEA. value with in the target
to be initiated 3.Severity x Occurance > 36
If RPN value and

other critria To Control the internal
with in the the At the time of making fresh
16 CFT RPN value & Severity value Based On SOD Prioritization New project -PFMEA PPM ,Customer PPM and F07-7101B ……………….
limits, Actions to PFMEA.
Warranty PPM
be initiated for top
3 thershold limit.
19
After verification
Regualr updation,change
of corrective
Upadate the amendment record of At the time of making fresh in process,product and
16 CFT updation of Past trouble data action results New project -PFMEA F08-7101B ……………….
PFMEA. PFMEA. customer complaints
,update the closing.
PFMEA
PFMEA should be verified

before approval
(1.Severity /Occurrence /
1.Verified the contents
Detection Ranking inline with ( Severity /Occurrence /
guide line (or) Not. Severity , Occurrence , Detection Ranking ) all
2. Verify the RPN & Severity Based On PFMEA input check sheet & Detection Ranking are inline with AIAG
17 CFT Prepared draft PFMEA doc. Value under the defined Before releasing the PFMEA F11-7101B ……………….
Applicability matrix and RPN for each guide line (Or) Not.
target (or) Not ) every failuremodes 2.Recommented actions
are initiated for target
exceed contents.
If OK Approved If NOT OK
the PFMEA Correct the
and Release PFMEA .
1.During developmnet stage

change update the
2.Customer complaint action PFMEA in a Regualr updation,change
Pro active: Once in six month
closing / Change in process / regular interval. Based On PFMEA input check sheet & in process,product and
18 CFT Existing all -PFMEA. Reactive : As per the F08-7101B ……………….
Change in Product / In- Applicability matrix customer complaints
condition defined in INPUT.
House corrective action taken closing.
/ Against Warranty failure
corrective action.

5. Control Plan Procedure (Refer Ex 24)
Doc. No.
ISSUE
PRODUCTION CONTROL PLAN REV No
DATE
1. PURPOSE
The purpose of this procedure is to define a structured approach for
• Identifying the control parameter required for controlling the quality of product at
specified production rate.
• Specifying the controlling method for parameter depending upon the criticality of product
• Specifying the reaction method in case of non-conformity.
2. SCOPE
This procedure will apply to Prototype, Prelaunch & Rampup and Production control plan
3. CROSS REFERENCE:
• ISO/ TS 16949: 2009: Clause No. 7.5.1
• Advanced product quality planning (APQP) manual.
• Failure mode and effect analysis (FMEA) manual.
4. TERMS & DEFINITIONS:
FMEA: FAILURE MODE AND EFFECT ANALYSIS: A formal, structured procedure used to
analyses failure mode data from both current and prior processes to prevent
occurrence of those failure modes in the future. When this technique is carried out
in product design development then called as Design Failure Mode and effect
Analysis (DFMEA), and when used in process development then called as
Process Failure Mode and Effect Analysis (PFMEA). PFMEA should be a living
document
SPECIAL PROCESS CHARACTERISTIC: A special process characteristic (e.g., critical,

key, major, significant) is a process characteristic for which variation must be
controlled to some target value to ensure that variation in a process or a special
product characteristic is maintained to its target value during manufacturing and
assembly
SPECIAL PRODUCT CHARACTERISTIC: A special product characteristic (e.g., critical,

key, major, significant) is a product characteristic for which reasonably anticipated
variation could significantly affect a product’s safety or compliance with
governmental standards or regulations, or is likely to significantly affect customer
satisfaction with a product.
PROCESS FLOW CHART: The Process Flow Chart is a schematic representation

of the current or proposed process flow.
Sl.
Item Process Flow
No
START
For New
Control Plan
1. New Product
2. Engineering Changes
1 Triggers For Revision of
existing Control
Plan
CHANGES 1. Results of Corrective Actions

Change in Location 2. Results of Continuous Improvement
Change in Machine / Tooling 3. Customer Audits and Feedback
Change in Process Parameters 4. Customer Complaints
Change in Process Sequence / methods
5. Warranty Issues
1 6. Inputs from Internal Audits
7. VA / VE 8. FMEA Revision
1. DFMEA 8. Special Prod./Process Charecteristics

1 2. PFMEA 9. Guages and Testing Equipments
3. Engineering Drawing 10. Packaging standards & Specifications
2 Inputs 4. Engineering Specification 11. Process Flow Chart
5. Material Specification 12. Floor Plan Layout
6. Drawings an Spec. changes 13. Charecteristics matrix
7. Eqpts, Tooling & Facilities 14. Lessons Learned from Similar parts
R&D
Form Cross Functional Team with
representations from Manufacturing, QA, PE,
3 Team R&D, Maintenance, Tool Room, Purchase,
Marketing, Packing & Despatch
4 Type of Control Plan Identify Control Plan as
Used in case of With Stringent controls. With Normal controls.

1 Prototype Mfg only Used till Ramp up exit Used for regular production
Pre launch &

Prototype Production
Ramp up
CFT
Enter Unique Code / Number identifying Sl No. of the Control Plan.
5 Control Plan Number
Identify Page No also.
CFT
6 Part No. / Identify the Part No as per the Engineering Drawing and the revision level in
Change level the Control Plan. Identify the Date.
CFT
7 Part Name /
Identify the Part Name as per the Engineering Drawing
Description
CFT
8 Organisation / Enter the name of the organisation, location and department preparing the
Plant Control Plan
CFT
9 Organisational Code Enter the Identification Supplier Code given by the Customer
CFT
Enter the name of the person in CFT who is preparing the
10 Key Contact info. Control Plan, also his/her phone No.& e mail id .
QUALIFICATION CRITERIA :- 1
1. Edu.: Degree / Dip. In Engineering
2. Exp: Min 2 yrs
3. Product & Process Exp.: Min 6 Months CFT
11 Core Team info. Enter the Names, Tel nos. & e mail id`s of the CFT members.
CFT
12 Organisation / Plant
Enter Plant approval date by the Customer
approval date.
CFT
13 Date (Origin) Enter the date the original Control Plan was compiled
CFT
Enter the Revision status ands date the Control Plan is
14 Date (Revision) revised.
CFT
15 Customer Engineering Enter the Customer Engieering approved date in the Conrol
approval date. Plan
CFT
16 Customer Quality Enter the Customer Quality approved date in the Conrol
approval date. Plan
CFT
17 Other Approval / date Enter any other agreed approved date in the Control Plan
CFT
Enter the Process Nos. f or all the processes f rom the
18 Process No. Process Flow Chart
CFT
19 Process Name / Enter the process / Operation Name as per the Process
Operation Description Flow Chart f or the process being addressed
CFT
1. For each Operation, identif y the Machine No., Fixture

20 Machine, Device, no.,
Jigs & Tooling for Mfg. Tool No. f or the Model being produced.
2. Enter the Work Instruction No., Process Flow No.,
CFT
Enter Serial No. f or each Product / Process Charecteristics
21 Charecteristics No. being Measured
CFT
1. Enter the Product Charecteristics being measured f or

the
22 Product particular Process addressed.
Charecteristics 2. Include Special Charecteristics as per the classif ication
f rom FMEA.
Spl. Charecteristics classified as:
a. Safety, b. Regulatory, c. Critical, d. Major.
Eg. Weld Shear Strength, Penetration
CFT
Enter all the Process Charecteristics being measured f or
23 Process
the
Charecteristics particular Process addressed.
CFT
Enter the default SSWL symbol for identifying Special
24 Special Charecteristics
Charecteristics and also Customer designated Special
Classification Charecteristics symbol if any. Safety Regulatory Critical Major
S R C M
CFT
25 Poduct/ Process Enter the Product / Process Specification as per Engineering

Spec. Tolerance Drawing, DOE Results, as per Simulations, Material
Standards, Internal Manufacturing / Assembly requirements
CFT
Enter Tolerances (Unilateral / bilateral) for all the Product /
Process Specifications
CFT
26 Evaluation / Measurement Enter the Instrument, Guage, Testing Equipment being

Techniques measured / tested with IMTE No.
CFT
Enter Tolerances (Unilateral / bilateral) for all the Product /
Process Specifications
Ensure R & R should be less than 30% Ensure L C of instrument is 1/10 th of
for standard charecteristics and less tolerance being measured
than 10% for Special Charecteristics
for variable data. For Sp.Ch. of attribute data 100 %
Inspection is recommended
CFT
27 Sample size / Enter Sample size for each Charecteristic being measured and
Frequency the frequency of samples being collected.
eg. Based on Production Quantity, Time, Shift etc.
Titre Sample size & Frequency will be Sample size & Frequency should
used during Prototype, Prelaunch & seperately address for First off, Last
Ramp up. (Refer F/QA/302) off, Setup, if applicable.
Method for Sampling Plan

CFT
28 Control Method Enter the Control Method like Stage Inspection, Pre Control
Charts, Poka Yoke, SPC, Visual Controls, 100% inspection, for
Take inputs from FMEA. (Link controls
from FMEA for the process being
addressed
CFT
1. Identify the Reactions to Conditions of Non Conformances

related to Process, Product and any other Abnormal
29 Reaction Plan
Situations.
2. Give Referance to Control of N C Products and Abnormal
Condition Handling Flow Charts.
CFT
Enter the Poke Yoke / Checklist number if available for the
30 Poka Yoke particular Process
CFT
Prepare the Control Plan
QA CFT
Review the Control Plan using Control Plan

Input / Review Checkist ( F/QA/292)
METHOD FOR CALCULATING THE SAMPLING PLAN

For a likely failure rate of 0.00333 or 1 part per 300 pcs.
(I part per 300 pcs as mentioned in the Stage Insp. Format) R&D
Defect Rate=1/300 = 0.00333 = 0.00167(divided by 2 for out -of-
specifications high or low) Approve the Control Plan
Using a Z-table the associated Z-value is 2.94 for a tail value of
0.00167
Ppk = 2.94/3 = 0.98
Hence before going into mass production, Ppk must be achieved
greater than 0.98, only then present control of sampling CFT
inspection (1 part per 300 parts) mentioned in Stage Inspection
will be valid.
CFT Sign Off
Note: if the above criteria is not achieved, then

on the basis of observed Ppk, sampling
frequency will be decided. R&D
Release the Control PLan
R&D QA Mfg
Observe & Validate the Process as

per the Control Plan
R&D
Review the Control Plan once in Three months and change
the Control Methods / Specifications if necessary
Use Checklist ( F/QA/292)
STOP
ANNEXURE -I
Control Methods by Gravity
1
Measurement
Sl No Charecteristics Symbol Control Methods
Equipment/ Technique
1. P Y Checksheet
1. P Y Checksheet
S
1 Safety 3. SPC X- R chart

1. P Y Checksheet
1. P Y Checksheet
2 Regulatory R 3. SPC X- R chart

1. P Y Checksheet
1. P Y Checksheet
3. SPC X- R chart
C
3 Critical

6. Set Up Verification and Set Up Verification and
Stage Inspection S I Format
1. P Y Checksheet
1. P Y Checksheet
3. SPC X- R chart
4 Major M

6. Set Up Verification and Set Up Verification and
Stage Inspection S I Format
1. SPC X- R chart
Set up verification
5 Others 2. Set up verification
Checklist
Stage Inspection
3. Periodical Inspection
sheet
ANNEXURE - II
CONTROL METHOD CHANGE STANDARD
CURRENT PROCESS CONTROL METHOD NEW CONTROL METHOD

EXIT CRITERIA
Sl No Control Methods Immediate Permanent
1
Check & implement No complaint for
100% Visual - 100% Visual & marking Product or process continuous 3 months, Poka
pokayoke yoke introduction
2
Check & implement No complaint for
Additional 100% Visual
100% Visual & marking - Product or process continuous 3 months, Poka
& marking (Detection)
pokayoke yoke introduction
3
No complaint for
100% check & marking,
Use of fixture/gauge Fixture/gauge Check & improve over continuous 3 months,
Do fixture/gauge
(Detection) validation fixture / gauge usage improvement in
validation
Fixture/gauge usage
4
No complaint for
Fixture control 100% check & marking, Check & improve over continuous 3 months,
Fixture validation
(Prevention) Do fixture validation fixture usage improvement in Fixture
usage
5
No complaint for
100% check & marking,
100% testing with Daily poka yoke check Check & improve over continuous 3 months,
Do poka yoke &
machine & machine validation poka yoke sustainance improvement in Poka yoke
machine validation
sustainance
6
No complaint for
SPC Study - 100% check & marking -
continuous 3 months
7
No complaint for
Process pokayoke 100% check & marking, Check & improve over continuous 3 months,
Daily poka yoke check
(detection) Do poka yoke validation poka yoke sustainance improvement in Poka yoke
sustainance
8
No complaint for
Process pokayoke 100% check & marking, Check & improve over continuous 3 months,
Daily poka yoke check
(prevention) Do poka yoke validation poka yoke sustainance improvement in Poka yoke
sustainance
9 No complaint for
Product pokayoke Check & improve over continuous 3 months,
- 100% check & marking
(detection) poka yoke sustainance improvement in Poka yoke
sustainance
10 No complaint for
Product pokayoke Check & improve over continuous 3 months,
- 100% check & marking
(prevention) poka yoke sustainance improvement in Poka yoke
sustainance
Issued By Prepared By Reviewed and approved By

6. Poka Yoke Procedure (Refer Ex 28)
7. Procedure for Process Change Management (Refer Ex 34)
ISSUE
CHANGE MANAGEMENT SYSTEM REV No
DATE
1. PURPOSE: -
To ensure that any change in standards/processes/procedures / tool design :
(i) Implemented only after Detailed investigation of its feasibility.
(ii) To reduce the undesirable impact of the change .
(iii) Information to customer and Customer approval (if required).
(iv) To avoid any undesirable changes in future .
2. SCOPE: -
Any Internal / External permanent/provisional change in the design of a tool,
manufacturing process; inspection process, supplier; procedure or any other document
with in the scope of quality management system / environmental management system
3. CROSS REFERENCE:
a. ISO /TS 16949:2009: CLAUSE NO. 4.2.3
b. PRODUCTION PART APPROVAL PROCESS (PPAP) MANUAL.
c. SUPPLIER MANUAL/ VENDOR MANUAL (if applicable)
4. TERMS AND DEFENITION:
INITIAL PART PRODUCTION (IPP): the first production lot part / batch /lot made after
approval of production part approval process. The lot must be made with the conditions
approved by the customer in part submission warrant
CHANGE APPROVAL NUMBER : the controlled number allotted to a change to design

records, specifications, or materials for production product/part number(s).(Submission
is required on any change to production product/part design records, specifications
or materials).
PRODUCTION PART APPROVAL PROCESS (ppap): PPAP defines the generic requirements
for production part approval. The purpose of PPAP is to determine if all customer
engineering design record and specification requirements are properly understood by
the supplier and that the process has the potential to produce product consistently
meeting these requirements during an actual production run at the quoted
production rate
PROCESS CAPABILITY: Capability is the total range of inherent variation in a stable

process. It is determined using data from control charts. The control charts shall
indicate stability before capability calculations can be made. Histograms are to be
used to examine the distribution pattern of individual value and verify a normal
distribution. When analysis indicates a stable process and a normal distribution, the
indices Cp and Cpk can be calculated. If analysis indicates a non-normal distribution,
advanced statistical tools, such as PPM analysis, will be required to determine capability.
If control charts show the process to be non-stable, the index Cpk can be calculated
PART SUBMISSION WARRANT (PSW): PSW is a standard document required for all newly
tooled or revised product in which the supplier confirms that inspections and test done
on production part shows conformance to SSWL requirements. This also verifies that
the supplier process has potential to produce to these requirements, where applicable
during an actual production run
START
1. Customer Complaints- Zero Km / Warranty

2. Delivery failure
3. Kaizen Sheets
4. Internal Quality problems ( Rejection / Rework)
Triggers 5. Result of FMEA
6. Product/ Process / System audit
7. Supplier issues
8. Any changes to 4M conditions
Engineering Changes System Changes

Types
Design / Product /
Tooling Changes Process Changes
Change in 1. Results of Audits

1. Change in product 1. Man/ Material/ Method 2. IMS Document Changes
dimension 2. Plant Location / layout 3. Kaizens
Reasons 2. Change in design 3. Sub supplier 4. Other issues
3. Change in VA/VE 4. Inspection & Test method
4. Change in Raw Material 5. New / Modified tooling
6. New Technology / Machine
7. Upgradation or Reassignment
1 of existing tooling
8. Change of sub supplier parts
9. Spl process parameters
Customer
Internally
Initiated
0 Day
Receive the nature of Receive the nature of
Changes Changes
Head R&D
Ref. Annexure I for
4M conditions
Trigger Progress
Review the Changes Review the Changes
Tracking sheet 5 Days
Head R&D Head R&D
Prepare Action Plan for
High Risk changes
Format No. CFT
Conduct Risk assessment
/ Feasibility
Progress To be Reviewed 3 Days
Once in two weeks
GM
Inform to NO NO Inform to
Customer Feasible Deptt.
YES See 1
Guidelines
Below In case any specific
Head R&D
1
Inform to customer and
obtain approval 1 Day
 requirement by
customer is there,
same should be
followed
Head R&D
Process Change Approval
Raise Design Change Note Raise Engg Change Note
Request
(DCN) (ECN)
1 2 Days 1
Review with Checklist 2 Days

Head R&D
Approval of Change Note Approval by MR

Head R&D 2 Days
Update List of
Changes - MR/R&D
Start New Design

ISP 20
Follow APQP Procedure
CFT 2 Days
Prepare Timing Chart
Head R&D 1 Day

No Partial
Prepare Process Flow Modification of
Tooling/Guages &
existing stock is
Head R&D 10 Days
allowed
Modify existing / Make
New Tooling & Guages
Head TR
Convert all Toolings/Guages including
spares to the new design.
Review existing stock to the old design

and take actions.
Head R&D
Conduct Production Trials

Head Mfg 4 Days
Verify
NO Head R&D
Re Start & Validate
design
Head QA
YES
Head R&D
Submit to Customer Prepare Final Engg.
if required Drawing
2 Days
CFT Compare following results with
Prepare Pre Launch existing and modified design
Control Plan a. Cpk results
b. CFT life
2 Days c. RFT life
d. Weld Shear Strength.
Complete Production Trial e. paint test
Run
10 Days Head Mfg Head QA
Head R&D
Submit to Customer
Complete PPAP
if required
2 Days
Head R&D
Submit to
Prepare PSW
Customer
1 Day
Use Initial Part Production Lot

Information Format
PSW Approval by F/QA/300
Customer
GUIDELINES FOR
CUSTOMER PSW APPROVAL

1. Design Change Training
2. Complete New Toolings Plan
3. Raw Material Change
Head R&D 4 Days
4. Plant Relocation
5. Sub supplier Change Impart Training to
6. Special Process Change Concerned people
Head HR
Implement Change
Head R&D
1
INTERNAL PSW APPROVAL ( QA Head) Ensure all documents
1. Minor Change in tool have been changed
2. Change in Inspection method
3. Machine relocation within the plant
4. Process change other than special process
1 Day
Start Production
Head Mfg
Conditions for Ramp Up:-
1. Production increases > 30%
Head R&D 2. Design Change
3. New Manufacturing Location
Is Ramp
4. Complete tooling Changes
Up required
5. Raw material Change
YES ?
6. Total Process Change
Follow Ramp Up NO
Procedure
CFT
Analysis of Changes
Identify Changes Deptt
wise, product wise and
subject wise
7 Days Internal System
Audits to check analysis
CFT of changes
Identify avoidable and
unavoidable changes
5 Days
CFT
Take actions for un
avoidable changes
15 Days
STOP
ANNEXURE - I
CHANGE POINT AND ITS CONTROL FOR PLANNED CONDITIONS
TYPE CHANGE POINT STANDARD KEY CHANGE CONTROL POINT
New operator
Existing operator on
Training and additional check of his work
new job / changed job
MAN
Skill matrix
Personnel Rejoined
after long time
Manpower change
Information to customer .
(qty=>10%)
Operation , inspection , Operation standard , inspection
rework , packaging standard , rework standard ,
method change packaging standard
Transportation standard and
Transportation and
packaging standard approved
packaging mode change
by customer
* Internal approval for raising change
Change other than
specified in PQCT / PQCT / control plan
* Sending change request to customer
control plan . * Approval from customer and implementing
change
Approved Product drawing /
Product / process / tool * PPAP approval ( if required )
process flow chart / Tool
METHOD
Design change
Drawing * Update PQCT / Production control plan /
New location / new Concerned documents
Specified location * Training and information to all concerned
factory
* Quality alert
Process order change Process flow chart
* IPP lot
Approved procedures , format , * Ramp up (if required)
Change in documented work instruction , operation * Mass production of changed part .
system standard ,
Inspection frequency
change Inspection standard
Outsourcing the process Process flow chart

Machine/ dies/ Jigs/
Approved process flow diagram
Fixture (inspection/
, dies/Jigs/Fixture * Internal approval for raising change .
production) change * Sending change request to customer.
*
MACHINE
Machine specification Approval from customer and implementing

Machine specification change .
change
* PPAP approval ( if required )
Machine design change Machine design * Update PQCT / Production control plan /
Concerned documents
Automation in present
design
Machine design * Training and information to all concerned
* Quality alert
Source change Approved source * IPP lot
MATERIAL
* Ramp up (if required)

Specification change
(raw material , die * Mass production of changed part
Approved material specification
material , packaging
material )
ANNEXURE - II
CHANGE POINT AND ITS CONTROL FOR UNPLANNED CONDITIONS
TYPE CHANGE POINT STANDARD KEY CHANGE CONTROL POINT
Outflow of un inspected
part / rejected / Reaction plan * Stop the line immediately
reworkable part *
METHOD
Calculate the suspected lot / part quantity at raw

material store ,work in progress , finished good stock
yard ,Godown , customer end .
Change in process Parameter as per PQCT / * Information to the customer (if it looks that part
parameter production control plan has out flowed to customer )
* Identify the batch separately with hold tag and
store in separate area .
* Quarantine the entire batch
MATERIAL
* Verification of the product w.r.t customer

Material standard as per PQCT / requirement
Material mixing
production control plan
* Check feasibility of NG part for deviation.
* If deviation allowed , notify the customer in
advance about the plan to dispatch the deviated part
to customer
* Send the deviated production part .
MACHINE
Change in machine Parameter as per PQCT /

* Inform to customer in advance about the plan to
parameter . production control plan resume normal production
8. Supplier Selection Evaluation Standard (Refer Ex 81B)
9. Sub-Supplier Audit Checksheet (Refer Ex 83)
9. Sub-Supplier Audit Checksheet (Refer Ex 83)

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L I E R E VA LUAT

ACCEPTING ALTERNATIVE DRIVING POSITIVE

Rise by daring to disturb Rise with your Rise by shaping

First Edition, May 2012

4. Chapter 1 Quality Policy & Quality Assurance System.......................................................... 07

6. Chapter 3 Quality Assurance at the Process Development Stage......................................... 41

7. Chapter 4 Quality Assurance at the Pre-Production Stage................................................... 53

8. Chapter 5 Quality Assurance at the Production Stage......................................................... 61

9. Chapter 6 Control of Sub Suppliers..................................................................................... 148

This ensures readiness of supplier in terms of quality & delivery requirements

This Manual is only for Reference.

This is a guideline based approach where each and every requirement is

3 Implement somehow Chapter Evaluation Criteria Weightage %

B. Final Rank and Total Score:

Total Score of Process Indicators = Total Score – Demerit Score

Quality Policy & Quality Assurance System

Example 1 - Audit Check sheet

AUDIT SCHEDULE NO: REPORT NO: DATE:

Sl. No of Audit findings for which NC was sighted: Sign of AUDITEE

Attribution to ISO-TS 16949 / ISO 140001 / OHSAS 18001: Sign of AUDITOR

NON CONFORMANCE / NEGATIVE OBSERVATION

(use space overleaf if required)

VERIFICATION OF EFFECTIVENESS OF IMPLEMENTATION (Write Evidence )

Date Auditor Sign

NCR Status VERIFIED BY MANAGEMENT REPRESENTATIVE

1.2 Quality Objectives

1 INTERNAL QUALITY PPM 100 120 80 90 60 50 0 50

5 YIELD % 83.07% 86.61% 85.58% 85.38% 86.87% 88.00% 86.08% 0.8658175

LINE 1 3.39% 2.70% 0.86% 0.77% 1.14% 1.32% 0.71% 0.00985

LINE 2 4.64% 0.74% 0.78% 0.54% 0.16% 0.52% 0.61% 0.004575

PAINTING 0.00% 0.00% 0.01% 0.00% 0.02% 0.00% 0.05% 0.000175

LINE 1 10.26% 6.47% 4.83% 4.79% 10.65% 4.46% 1.80% 0.05425

LINE 2 22.15% 2.48% 7.00% 4.61% 1.84% 5.92% 3.31% 0.0392

PAINTING 6.54% 3.10% 3.56% 6.50% 4.27% 3.58% 4.98% 0.048325

10 PARTS / MANDAY 4.2 6.6 6.5 6.9 5.8 12 10 8.675

11 TRAINING HOURS 68 272 160 0 496 800 224 380

1.3 QA System & Organization

ORGANISATION LAYOUT CHART FOR QUALITY ASSURANCE DEPARTMENT

Overall responsible for QA

Analysis of the Quality Concerns for the Current Products

WARRANTY/FIELD COMPLAINT REGISTER

Date of Chasis Month of Defect Claim Phenomena Before After

Date: Reviewed By: Approved By:

V1 Refer BMS for current revision level Page 1 of 1

Example 6 - Monthly Monitoring Trend, Pareto Chart

TARGET - ASSEMBLY (REJECTION) BREAK DOWN OF TARGET

0.5 0.475 Oct 09 Material pitting 0.01 0 0

Weld shift 0.1

100 REJECTION = 0.47% 0.06

Trial (MIG weld)

rej. Due rework

after unloading. 0.025

3 QD/11/03 Weld crack 05.01.11 New - NA NA NA NA Under progress P 05.01.11

Example 9A - Warranty Information Analysis Procedure

Input What Where Output When Who How

Attend the Warranty

Conduct the data analysis and the preliminary joint analysis (

Claim accept -a) The part in which defect is confirmed is sent to

Responsibility : Customer Representative/Marketing/PD

A Forward to QA, Operation, Production, ME &

Forward to QA, Operation, Production, ME &

Below the Alarm control Action to be NO Beyond

. Project Manager /Engg..