# Chapter 7: Shop Floor 18 Supplier Name Function Date

Open Prepared by Gaurav QMS - Incharge 21.09.2020

Close Approved by Mahesh Kumar C Plant Head 21.09.2020

Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date Actual Date Evidence Status

Rejection register to be prepared which includes Supplier name, Part detail, Rejection register for incoming rejection to be
7.1 11.06.21 No rejection register available for the parts stored in Quarantine area Dalbir 6/22/2021 23.06.21 Close
date of received, Qty, Target date for disposal & actual date of disposal, etc. prepared

Some key checkpoints are not defined and confirmed during daily start up check.
Add missing checkpoints in the start up checksheet and educate the concerned All key characteristics to be added in startup check
7.2 ASES report Ex. Checkpoint: Brake / clutch pressure 4~6 Surjeet, Aditya and Vinod 6/22/2021 23.06.21 Close
members. sheet
KG/CM2.

Conduct start up check according to the checksheet at 2nd shift start and record
7.2 ASES report Start up check is not performed during 2nd shift. (Followed at 1st shift only). Start up check to be ennsured in 2nd shift Surjeet, Aditya and Vinod 15/7/2021 Open
the results.

Quantity measurement items are not recorded with measured values, OK tick
Actual observation to be recorded for all process
7.2 ASES report mark only available. Ex. Checkpoint: Counter balance Record the actual measurement values for quantified measurement items. Surjeet, Aditya and Vinod 6/22/2021 09.07.21 Close
paramters
pressure 4~6 KG/CM2.

Product dimensions & process parameter not write the exact value. Product dimensions & process parameter to be verified & record Actual value to be written against the
7.2 11.06.21 Surjeet, Aditya and Vinod 6/22/2021 09.07.21 Close
Ex: Rivet Diameter the actual value. product dimensions

No specific place defined in the start up checksheet / production log to keep track
of corrective actions / deviations done for start up Create a provision in the start up checksheet / production log book to keep
Provision to be made for tracking correcitve action Gaurav, Surjeet, Aditya and
7.2 ASES report non conformity. track of corrective actions / deviation done for 6/22/2021 09.07.21 Close
for start up non conformity Vinod
No records available after corrective action taken for the defects during start up non conformity
production

Add the checkpoint in startup check sheet as "Confirm the removal of previous
During change over, removal of previous model input / output part, tooling, Gaurav, Surjeet, Aditya and 23.06.21/
7.2 ASES report model input / output parts, tooling, packing Check point to be added in startup check sheet 6/22/2021 Close
packing etc., is not checked and recorded. Vinod 09.07.21
from workstation and put them at specified area".

Some process parameters are not captured in work instruction or set up table and
not checked during model change over. Ex. Add missing process parameters in the work instruction and set up table.
Missing process parameters to be added in work Gaurav, Surjeet, Aditya and
7.3 ASES report Process: Progressive Stamping, Process parameter: Shut height 798+/-1 mm, Part: Verify the same during model change over and 6/22/2021 09.07.21 Close
instruction and setup table Vinod
Side door hinge Male, Machine: Press 600 ton record the results.
PLNP11.

Check point to be added in start up check sheet to

Check point to be added in start up check sheet to ensure the red bin is in empty Check point to be added in start up check sheet to ensure the red bin is in Gaurav, Surjeet, Aditya and
7.3 11.06.21 ensure the red bin is in empty condition before 6/22/2021 23.06.21 Close
condition before start of the shift. empty condition before start of the shift. Vinod
start of the shift.

Adjustment instruction not available in shop floor. Ex: Air pressure, Hydraulic Define the process adjustment instruction including skill level requirement.
pressure, Welding parameter, etc. Educate and evaluate the members for process Adjustment instructions to be prepared for process Gaurav, Surjeet, Aditya and 23.06.21/
7.3 ASES report 6/22/2021 Close
Process adjustment instruction is not defined. Ex. Projection welding process, adjustment condition. Display the qualified members list at respective work paramters Vinod 09.07.21
Defect: Thread shrinkage, Nut separation, Assy, etc., station

Restart up rule and evidence for restart up activity is not available. Ex. Restart up
condition: after trial production, after breakdown or Define the criteria for restart up along with reaction plan. Educate the Criteria for restartup with reaction plan to be Gaurav, Surjeet, Aditya and
7.3 ASES report 6/22/2021 23.06.21 Close
major disruption, Reaction plan: Start up, Set up, Poka yoke check and First part concerned members and follow the same defined Vinod
approval

Set up matrix to be prepared with respect to different models which Set up matrix to be prepared with respect to different models which
Gaurav, Surjeet, Aditya and
7.3 11.06.21 includes Die / tool/ Child parts details/ Process Parameter/ program includes Die / tool/ Child parts details/ Process Parameter/ program Set up matrix to be prepared Vinod
6/22/2021 23.06.21 Close
selection, etc. in Stamping & Welding process selection, etc. in Stamping & Welding process

Tea/Lunch break rule to to prepare and to be displayed In Gaurav, Surjeet, Aditya and
7.6 11.06.21 No rule displayed for tea / Lunch break- before leaving finish the part Rule to be displayed
Vinod
6/22/2021 23.06.21 Close
respective departments

Define the lighting level (lux) requirement at WIP / FG inspection station.

Lighting requirement (Lux level) is not defined and monitored at work in Gaurav, Surjeet, Aditya and
7.7 ASES report Monitor the same periodically and record the LUX level to be defined and monitored 6/22/2021 23.06.21 Close
progress and finished parts inspection area. Vinod
results.

Final inspection standard is not inline to control plan (some checkpoints are Gaurav, Surjeet, Aditya and
7.7 ASES report Revisit the final inspection standard according to control plan. Final inspection standard to revised 15/7/2021 Open
missing). Ex. Checkpoint: Forming crack, Bush crack, etc., Vinod

Final inspection standard is not in detail with inspection steps, photo, part Modify the final inspection standard to make in detail with clear inspection Gaurav, Surjeet, Aditya and
7.7 ASES report
positioning etc., steps, photos, part positioning etc.,
Detailed final inspection standard to be prepared
Vinod
6/22/2021 09.07.21 Close

# Confidential C
# Chapter 7: Shop Floor 18 Supplier Name Function Date

Open Prepared by Gaurav QMS - Incharge 21.09.2020

Close Approved by Mahesh Kumar C Plant Head 21.09.2020

Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date Actual Date Evidence Status

Some of the checkpoints are not checked during final inspection according to Educate the inspectors to follow the final inspection standard strictly. Ensure
Gaurav, Surjeet, Aditya and
7.7 ASES report control plan. Ex. Checkpoint: Forming crack, Bush their conformance to the standard through Final inspection to be inline with control plan
Vinod
7/1/2021 09.07.21 Close
crack etc., Inspector observation

Photo / sample with validity is not available for some defects. Ex. Defect - Add missing photos / samples with validity or defects and display at respective Photo/ limit sample to be developed for each Gaurav, Surjeet, Aditya and
7.7 ASES report
Forming crack. location defect Vinod
7/1/2021 09.07.21 Close

Some reaction rule like root cause analysis and actions incase of Inspection Gaurav, Surjeet, Aditya and
7.7 ASES report Reaction Rule to be defined incase of Inspection equipment is NOK. Reaction rules to be defined for not ok equipments 15/7/2021 Open
equipment is NOK is not defined Vinod

NC handling procedure is not displayed at Shopfloor.

Display the NC handling procedure at Shopfloor (easy access to Operators and NC handling procedure to be displayed on the Gaurav, Surjeet, Aditya and
7.10 ASES report which includes marking of defect location, put in the red bin, record in register 15/7/2021 Open
Inspectors). shopfloor. Vinod
immediately , end of the shift tally the rej qty with register

Feedback to cause process is not defined & followed incase of continuous Add feedback to cause process in the NC handling procedure with criteria. Gaurav, Surjeet, Aditya and
7.10 ASES report Feedback to cause process to be defined 16/7/2021 Open
rejection or major rejection Define and follow the feedback record. Vinod

Defect parts are not marked and not recorded immediately by category of defects.
Educate the Operators / Inspectors to mark the defective parts according to the
7.10 ASES report Ex. Process: Riveting, Part: Side Door Hinge Defect parts to be marked and recorded Surjeet, Aditya and Vinod 15/7/2021 Open
procedure.
Female, Defect: Plating dull, Quantity: 1 no

Disposal of defective parts from red box is not followed periodically. Cross Define the rejection parts disposal frequency and follow the same. Perform the
Disposal to defective part at the end of the shidt to
7.10 ASES report checking is not performed at end of the shift against cross checking at shift end for actual Surjeet, Aditya and Vinod 16/7/2021 Open
be ensured
actual quantity in red box and recorded quantity. quantity in red box against recorded quantity.

Rework decision matrix is not defined for process wise defects. Ex. Part: Door
hinge rear upper YP8, Process: Bush fitment Male + Modify the rework decision matrix for process wise defects according to Rework decision matrix ti be defined as per Gaurav, Surjeet, Aditya and
7.11 ASES report 16/7/2021 Open
Bush, Defect: Bush improper fitment, Gap between male & bush, loose after control plan control plan Vinod
fitment etc.,

Rework instruction is not defined for some reworkable defects. Ex. Ex. Part:
Door hinge rear upper YP8, Process: Bush fitment Male Rework instruction to be defined for all Gaurav, Surjeet, Aditya and
7.11 ASES report Prepare the rework instruction for missing reworkable defects 16/7/2021 Open
+ Bush, Defect: Bush improper fitment, Gap between male & bush, loose after reworkable defects Vinod
fitment etc.,

Rework record is not followed always for all kind of rework. Ex. Process: Bush Educate the concerned members to record the rework details when rework Rework record to be prepared for all kind of Gaurav, Surjeet, Aditya and
7.11 ASES report 7/1/2021 23.06.21 Close
fitment line, Rework: Bush improper fitment. performed reowrk Vinod

Some key informations are not captured in the rework record. Ex. Rework Gaurav, Surjeet, Aditya and
7.11 ASES report Modify the rework record to capture missing key information. Rework record to be updated 7/1/2021 23.06.21 Close
operator name, rework OK quantity etc., Vinod

Rule and record for reinspection of reworked parts is not available. Ex. Process: Define the rule for reinspection of reworked Gaurav, Surjeet, Aditya and
7.11 ASES report Define the rule for reinspection of reworked stamping parts 7/1/2021 23.06.21 Close
Stamping, Reworkable Defect: Burr. stamping parts Vinod

Gaurav, Surjeet, Aditya and

7.11 ASES report Rework part identification is not defined and followed. Define the reworked part identification rule and follow the same Rework part identification to be defined 7/1/2021 23.06.21 Close
Vinod

Rework records not available for the rework parts, which should includes the
7.11 09.07.21 16/7/2021 Open
reworkd Qty, Ok Qty, Rej Qty, Rework operaotr sign, QA signe, etc.

Skill matrix for rework operation is not exist. Ex. Process: Stamping, Rework: Gaurav, Surjeet, Aditya and
7.11 ASES report Prepare and display the skill matrix for rework operators. Skill matrix to be prepared for rework process 7/1/2021 09.06.21 Close
Burr. Vinod

Some unusual situations related to Equipment and Part is not defined. Ex.
Gaurav, Surjeet, Aditya and
7.12 ASES report Unknown defect, Defect in new location, Add missing unusual situation into the procedure with appropriate reaction rule Abnormality handling rules to be updated 16/7/2021 Open
Vinod
Spike rejections, etc.,

Unusual situation handling procedure is not known to concerned members at Gaurav, Surjeet, Aditya and
7.12 ASES report Educate the concerned members on unusual situation handling procedure Training to be provided 16/7/2021 Open
shopfloor. Vinod

Fallen parts check details and disposal status are not recorded. Ex. Part: Arm R00, Check details and disposal status to be recorded Gaurav, Surjeet, Aditya and
7.12 ASES report Record the fallen part quality check details and disposal status 16/7/2021 Open
Date: 15-07-2020, Qty 3 nos. for fallen parts Vinod

Unusual situations other than Fallen part is not recorded with retroactive, cause Follow the unusual situation handling procedure and record retroactive
7.12 ASES report Abnormal situation handling rules to be followed Surjeet, Aditya and Vinod 16/7/2021 Open
and action details confirmation details, analysis, actions and restart
# Confidential C
# Chapter 7: Shop Floor 18 Supplier Name Function Date

Open Prepared by Gaurav QMS - Incharge 21.09.2020

Close Approved by Mahesh Kumar C Plant Head 21.09.2020

Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date Actual Date Evidence Status

Poka Yoke failure retroactive confirmation to be defined in the

Poka Yoke failure retroactive confirmation not clearly defined in the Retroactive conformation to be clealy
7.12' 17.04.21 procedure. Ex: Checking of parts in next station, FG, If required Surjeet, Aditya and Vinod 16/7/2021 Open
abnormmal situation procedure defined for POKA YOKE failire
transit & Customer end,.

PM is not done as per plan for some machines. No deviation approval from QA Conduct the PM according to the plan. Incase of any delay, make reschedule
PM to be done as per plan, where schedule is
7.17 ASES report and reschedule plan is available for delayed PM. Ex. and follow additional check to avoid quality Ramesh Yadav 16/7/2021 Open
delayed deviation approval is required
Press PWM 26: Frequency is 6 months once, Due on: 06/20 - 2nd Week issues.

Define target for maintenance KPI's like MTBF, MTTR etc., based on past
7.17 ASES report No target for maintenance KPI is defined. Ex. MTBF, MTTR etc., data. Monitor the monthly results and initiate the KPI targets to be defined Ramesh Yadav 16/7/2021 Open
correction actions incase of non achievement of target.

Prepare general spare list with minimum stock level, reorder qty and lead time.
7.17 ASES report General spare list and its stock level monitoring is not available for Machines Monitor the spares IN and OUT to manage General spare list stock monitoring to be done Ramesh Yadav 16/7/2021 Open
the availability.

Life for consuming tools / spares is not defined and monitored. Ex. Die coating Prepare general spare list with minimum stock level, reorder qty and lead time.
7.17 ASES report life, Piercing punch life, Projection welding electrode Monitor the spares IN and OUT to manage Consumable tool life to be defined and monitored Surjeet, Aditya and Vinod 16/7/2021 Open
life etc.., the availability.

4M change display not available in shop floor. Ex: Assy, Stamping, Welding, 4M change display board to be displayed in shop floor. Ex: Assy, Stamping,
8.1 ASES report 4M change display to be made Surjeet, Aditya and Vinod 7/8/2021 09.07.21 Close
Assy etc. Welding, etc.

Open 19

Close 21

Total 40

% Action
53%
Implemented

# Confidential C