OZONE OVERSEAS PVT. LTD.

PROCESS FLOW DIAGRAM

PFD Doc No. : PFD/WH/QC/F-01
PART NAME :- Digital Lock
ISSUE No. : 01
MATERIAL :- ……………. REV. : 00
CUSTOMER :- End Customer DATE : 7/14/2022
Storage Operation Movement Inspection & Testing
SYMBOLS:

Key No. /
Key No. / Process
Description SPL. CHR. Process Description SPL. CHR.
No.
No.

Picking of Locks for

10 Digital Locks Receipt &
M 90 Readiness at Final MN
Storage at Receipt area Inspection area

Final inspection (PDI)

20 10 Product Segregation as as per SOP
M 100
> Visual
C
Per Documents
> Functional

30 Filling of Check sheet

Products counting as per 110
20 M > Detailed QCS(WH) M
Documents > QC OK (With Lock)

Visual Inspection of Locks Sampling Inspection of

40 only Accessories & C 120 Ready to Dispatch M
Product Condition Locks

Functional Inspection along Handover Locks for

with detailed QC on Sampling C 13 Dispatch as per M
Basis Invoice
0
Re-inspection of
Packaging Box &
60 Fill-up of QC Report along Matching of No. of
with initial observations.
MN 140 M
Boxes as per invoice

Handover Products to
Document Preparation and Transporter for
share for inward in SAP Dispatch
70 (RR, Invoice & other
MN M
supporting Documents)

Storage of Locks at defined

80 location
MN

Note :

LEGEND :- C :- CRITICAL , M :- MAJOR & MN :- MINOR

PREPARED BY:- APPROVED BY:

 Digital Lock Handling Process (Receip
S.No. Process Description Department Transportation Inventory Motion
Digital Locks Receipt & Storage at
1 IQC 120 ---- 25
Receipt area
2 Product Segregation as Per Documents Store --- ---- 40

3 Products counting as per Documents IQC --- ---- ----

Visual Inspection of Locks only

4 IQC --- ---- ----
Accessories & Product Condition
Functional Inspection along with detailed QC
5 on Sampling Basis
Testing 5 ---- ----
Fill-up of QC Report along with initial
6 observations.
IQC --- ---- ----
Document Preparation and share for inward
7 in SAP (RR, Invoice & other supporting IQC --- ---- ----
Documents)

8 Storage of Locks at defined location Store --- 3~6 M 40

Picking of Locks for Readiness at Final
9 Inspection area
FQC --- ----
Final inspection (PDI) as per SOP
10 > Visual FQC --- ----
> Functional
Filling of Check sheet
11 > Detailed QCS(WH) FQC --- ----
> QC OK (With Lock)
Sampling Inspection of Ready to Dispatch
12 Locks
FQC --- ----
Handover Locks for Dispatch as per
13 FQC --- ----
Invoice
Re-inspection of Packaging Box & Matching
14 of No. of Boxes as per invoice Dispatch --- ----
Handover Products to Transporter for
15 Dispatch Dispatch --- ----
ocess (Receipt to Dispatch)
Waiting Over Production Over Processing Defects VA NNVA NVA

35 --- ---- ----

---- --- ---- ----

---- ---- ---- 0~2%

---- ---- ---- 0~2%

45 ---- ---- 0~1%

---- ---- ---- ----

15 ---- ---- ----

---- ---- ---- ----

---- ---- ---- 0~1%

---- ---- ---- 0~1%

---- ---- ---- 0~1%

---- ---- ---- 0~1%

---- ---- ---- ----

---- ---- ---- 0~1%

---- ---- ---- ----

 Process Capacity Sheet Model No. :

Offline/ Validity/
S.No. Process Process Discription Station No.
Online Assy

Mounting BKT &

1 MIG Welding-01
Reinforcement
Offline 01 2.0
2 MIG Welding-02 Base Plate & Ribs Offline 02 2.0
3 MIG Welding-03 Wheel arch & 3 nuts Offline 03 1.0
4 MIG Welding Wheel arch & 3 nuts Offline 03A 1.0
5 MIG +Spot Welding End Floor & 7 Nuts Offline 03B 2.0
6 MIG Welding-Tag-04 X-Member & 8 Nuts Offline 04 1.0
Long Mbr,7 Nuts, 3 Plates &
7 MIG Welding-05
1 Bracket
Online 05 2.0
8 Spot Welding-06 Stn-04 & Gusset Online 06 2.0
9 MIG Welding-07 Stn-06 & Reinforcement Online 07 1.0
Assy Reinforcement & 2
10 MIG Welding
Nuts
Offline 07A 1.0
11 MIG Welding-07.5 Stn-06.5 & Reinforcement Online 07.5 1.0
Assy Reinforcement & 2
12 MIG Welding
Nuts
Offline 07.5A 1.0
13 Trueing Gauging Trueing Online 08 2.0
14 Plug Welding-09 (Stn-07 & Stn-01) LH Online 09 1.0
15 Plug Welding-09.5 (Stn-07.5 & Stn-01)RH Online 09.5 1.0
Stn-09, Wheel arch &
16 MIG Welding-Rotary-LH-10
1 Bracket-LH
Online 10 1.0
Stn-09, Wheel arch &
17 MIG Welding-Rotary-RH-10.5
1 Bracket-RH
Online 10.5 1.0
Stn-10, Stn-10.5, Child Parts
18 Final MIG + Spot Welding-11
& End Floor
Online 11 1.0
New sub assy fixture Z plate sub assy Offline 11A 1.0
Stn-11/11.5 & 2 Assy
19 Final MIG Welding-Rotary-12
Reinforcement
Online 12 1.0
20 Chipping & Grinding-Top-13 Chipping & Grinding-Top Online 13 1.0
21 Chipping & Grinding-Bottom-14 Chipping & Grinding-Bottom Online 14 1.0
 Sub Structure Line
Basic Time (Sec) Cycle Time
Station
Loading Processing Unloading Additional Manual Completion Cycle Time
Cycle Time
Time Time Time Time Time Time Actual
Req

25 60 10 25 120 240 190 240

30 55 5 15 105 210 180 210
30 35 5 30 100 100
30 35 5 40 110 110 370 460
35 55 15 20 125 250
120 150 10 40 320 320 280 320
10 160 10 25 205 410 360 410
25 85 20 25 155 310 260 310
15 160 15 30 220 220
255 305
20 35 10 20 85 85
15 160 15 30 220 220
255 305
20 35 10 20 85 85
15 90 15 14 134 267 240 267
30 170 30 15 245 245 230 245
30 170 30 30 260 260 230 260
50 100 20 60 230 230 170 230
50 100 20 60 230 230 170 230
50 285 50 20 405 405 385 405
50 285 50 20 405 405 385 405
45 285 30 35 395 395 360 395
20 340 20 30 410 410 380 410
20 340 20 35 415 415 380 415
735 3190 415 4979
1150 23%