T2VSA CLAUSE WISE STATUS REPORT: PRODUCTION PREPARAT

Clause
S.No. Clause Name Dcoument Name/Type : Record
No.
1 APQP Procedure

Scope

2 New Development Log Book

3 Special Product And Process Chracteristic

4 Past defect History/Lesson Learnt Sheet

5 Team Feasibility Commitment/Study

6 Quotation

APQP Matrix

7 APQP Timing Plan

8 New Prdocut Process Flow Diagram

Development
9 Control Plan

10 Tool Development Plan

11 Gauge Development Plan

1
12 MSA & SPC Plan

13 MSA & SPC Study

14 Measurement System Analysis-Attribute

15 Operator Training

16 APQP Signoff for Mass Production sheet

17 Performance Sheet

PPAP

TGW & TGR Sheet and analysis on TGW

18 MOM

19 PFMEA Procedure (PFMEA, Cutoff Criteria & Review)

20 List for PFMEA

21 S, O & D Ratings
PFMEA
22 PFMEA Review Plan
 PFMEA

23 PFMEA Review Record

24 Defect Matrix
T: PRODUCTION PREPARATION / NEW PRODUCT DEVELOPMENT

Status as on dated……02/09/22…………. Comments- 05.09.2022 Remarks

Available

Available

09.09.2022 - To be modified by
adding SOP details (IPC Stage
Available but not updated
and Product Handover to
production status)

Available

Available

Available

Available

Available

Available

Available

Available

Available

Available To be completed by
tomorrow
Available

Available

Not Available Document need to be shared.

Available

Available

Available

In-process

Available

Available

Available

Not Available 09.09.2022

Available

Available
Not Available 09.09.2022

Available
 T2VSA CLAUSE WISE STATUS REPORT: REGULATION
Clause No. S.No. Clause Name

6
7
Initial Production Control
2
(IPC)
8

10
11

12
T2VSA CLAUSE WISE STATUS REPORT: REGULATION OF INITIAL PRODUCTION CONTROL
Status as on dated……
Dcoument Name/Type : Record
02/09/22………….
IPC Procedure Available
Special Controls (Increased Inspection, Increased Frequency should
In-process
be at all stages)

Stricter Control for ISC Available

Handover sheet from Development to Mass Production Available

Information Flow to all the team/CFT members from ISC/IPC
requirements
In-process

ISC/IPC Tag Available

Intimation/Termination Check sheet Available

Defect Rate Not Available

Production Lotwise IPC Monitoring Sheet Not Available

Actual Record of ISC as per ISC Procedure Not Available

TGW/TGR Available

IPC Log Book Available but not Updated

ON CONTROL
Comments- 05.09.2022 Remarks

for 3 new developments of Mahle IPC

data is pending.

During MOM and Announcement

sheet.

To be updated in the procedure and

Defect monitoring sheet to be
prepared month wise for each New
Development part.

Monitoring sheet will be prepared and

will be updated for old
develeopments.

09.09.2022 to be updated for all old

product IPC stage.
 T2VSA CLAUSE WISE STATUS REPORT : CHANG
Clause No. S.No. Clause Name

5 Change Management

6
3 7

2
Initial Production Part
(IPP)
4 -- Part of NPD

5
 T2VSA CLAUSE WISE STATUS REPORT : CHANGING MANAGEMENT
Dcoument Name/Type : Record

4M Change Management Procedure shall be made with Annex.

4 M Change Summary Sheet

4M Change Inspection Record (Retro & Pro-active (Suspected))

4M Change Tag

4M Change Check record for retroactive and Suspected lot Check and
Traceability record

4M Change board and Abnormal condition display on shopfloor

4M Change Updation Board/ sheet

Awareness of change condition to operator and supervisor.

Initial Production Part Log Book

IPP Layout Inspection Report

IPP Tag, Lock & Key to keep IPP parts

IPP parts tracking record with traceability record

: CHANGING MANAGEMENT
Status as on dated……02/09/22…………. Remarks

Available

Available

Inprocess

Available

Inprocess

Available / display on shop floor is pending

Available

Available/ training plan for operator Available

Available but not updated

Available

Available

not Available
 T2VSA CLAUSE WISE STATUS REPORT: STA

Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 Document Control & Preparation Procedure
2 Document Issue Record
3 Document Change Record
4 Document Change Note

5 Obsolete Document Record

6 All Parts Control Plan Availability

7 Control Plan Review Plan

4 Standard Management
8 Control Plan Review Mechanism

9 Control Plan Review Record

10 Master List of Document, Procedure, Formats

11 Coherence Plan

12 Coherence Summary Sheet

13
E STATUS REPORT: STANDARD MANAGEMENT

Status as on dated……02/09/22………….
Available
Not Available
Not Available
Not Available

Not Available

Not Available Available for Mahle( other customer pending)

Available

Complete

Complete

Available

Available

Available
 Remarks

Available but records to be updated.

Available but records to be updated.
Available but records to be updated.

Available but records to be updated.

Records required

Records required
 T2VSA CLAUSE WISE STATUS REPORT: EDUCATION & TRAIN

Clause No. S.No. Clause Name Document Name/Type : Record

Education & Training Procedure

1 Master List of Employee (Staff & Casuals)

2 Induction System (Operator & Staff)

3 Induction training record

Skill Evaluation Criteria & Skill Identification

4
System

Minimum Skill level requirement to operate a

machine and backup

5 Level Wise Questionnaire

Skill Matrix of Operator & Competency Matrix
6
(Staff)
Training Need Identification (Operator & Staff)
7
and backup record
Annual Training Plan( Operator, Inspector, Store
8
& Staff)
Education and
5 9 Attendance and Effectiveness Sheet
Training

10 Skill Evaluation Plan (Operator)

11 Skill Evaluation Plan (Inspectors)

12 List of Critical Operators

14 Critical Operator training Plan

15 Operator Observance Plan

16 Operator Observance Audit Sheet & Record

17 Poison Test Plan

18 Poison Test Audit Sheet

Operator Obs. & Poison Test WI

S REPORT: EDUCATION & TRAINING

Status as on dated……02/09/22…………. Remarks

Available Completed

Available Completed

Available Completed

Not Available Completed

( Skill Assessment test paper available) First floor Pending

Available Completed

Available Completed

Available for operators only Completed

Available Completed

Available( for Staff need to be updated) Completed

Available Completed

Not Available Completed

Not Available Completed

Not Available Completed

Not Available

Available Completed

Available Completed

Not Available Completed

Available but record not available Completed

Not Available Completed

 T2VSA CLAUSE WISE STATUS REPORT : QUALITY AUDIT & PR
Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 Internal Audit, Product & Process Audit Procedure

Auditor Selection Criteria and Auditors list (Internal,

2
Product & Process Audit)

3 Internal Audit Plan

4 Internal Audit Check Sheet

Internal Audit Record ( All Shift)

5 Internal Audit Schedule/Notice

Internal Audit NC Raising and communicate to

6
concern sections with target date

7 Internal Audit NC Summary Report

8 Internal Audit NC Verification on target date

9 Last Audit NC Points Checked in Next Audit

Quality Audit &

Process Audit MRM Plan & Record

6 10 Process & Product Audit Plan

Process & Product Audit Record (All Shift)

Process and Product Audit with the help of Control

11
Plan

12 Product & Process Audit NC Summary Report

13 Product & Process NC Verification on target date

14 Last Audit NC Points Checked in Next Audit

Major Inhouse complaint and Customer complaint

15 effectiveness should be checked in Product &
Process audit
ORT : QUALITY AUDIT & PROCESS VERIFICATION
Status as on dated……02/09/22…………. Remarks

Available Updated

Auditor selection criteria has been deifned but

Not Available
auditor list to be prepared.

Not Available Ready

Available but IA need to be conducted for May

Not Available
2022
Not Available Not ready

Available but not updated Ready

Not Available Available

Not Available Available but Not updated

Not Available Available but Not updated

Not Available Not updated

Not Available MRM plan and circular updated

Not Available Available but Not updated

Not Available Available but Not updated

Not Available Available but Not updated

Not Available Available but Not updated

Not Available Available but Not updated

Not Audit NC were available but of having no

Not Available
Internal Audit plan.

Not Available Available but Not updated

15.09.2022

15.09.2022

16.09.2022

20.09.2022

NA

Meeting records are in process

15.09.2022

15.09.2022

20.09.2022

20.09.2022
 T2VSA CLAUSE WISE STATUS REPORT
Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 Supplier Selection Procedure and Criteria

2 Supplier approval record

3 Supplier Audit Plan & Audit Check Sheet

7 4 Supplier Control List of Approved Suppliers

Supplier Audit record, NC record, target
5
date, NC closure and effectiveness

6
E WISE STATUS REPORT
Status as on dated……02/09/22…………. Remarks

Available

Not Available

Available

Available

Available but no audit

Not Available
conducted -
1
 T2VSA CLAUSE WISE STATUS REPORT : HANDLING ABNORMALITY

Clause No. S.No. Clause Name Dcoument Name/Type : Record

Quality Abnormal Condition should be defined and

1
displayed on shopfloor

2 Awareness on Quality Abnormal Situations

Criteria to estimate suspected quantity produced

3
during abnormal situations and traceability record

4 Quality Abnormal Condition log book

Check record of parts produced during abnormal

5
situations

6 Customer Complaint Handling Procedure

7 Inhouse Complaint Handling Procedure

8 Supplier Complaint Handling Procedure

9 Rework Procedure

10 Customer Compliant Register

11 Internal Complaint Register

Handling Abnormility in
8
Quality

12 Supplier Complaint Register

13 Defect raising Criteria

14 Rejection analysis as per defect raising criteria

15 Countermeasure report against root cause analysis

Effectiveness monitoring, Standardization & HD

16
details should be available

17 OK Tag, Reject Tag, Hold & Rework Tag

Red Bin & Yellow Bin should be available on each

18
station
19 Red Bin Analysis and Display Board

20 Red Bin Analysis sheet

NDLING ABNORMALITY IN QUALITY
Status as on dated……
Remarks
02/09/22………….

Not Available Available

Completed
Available but less awareness - WI to be
Not Available
dipalyed at all shop floors in A3 sheet. 12.09.2022 Inprocess

Not Available Available

Criteria need to be defined.

Not Available Available

Not Available Available

Not Available Available

Not Available Available

Not Available Available

Not Available Available

Customer complaint Register to be

To be updated updated with brief details by adding 12.09.2022
corrective action and Preventive actions.

Inhouse Complaint record- Conatinment

Available but not updated action, Corrective and Preventive actions 12.09.2022
to be added.
Inhouse Complaint record- Conatinment
Availble but not updated action, Corrective and Preventive actions 12.09.2022
to be added.

Defect raising criteria defined for supplier

and inhouse both but the Supplier defect
Not Available 12.09.2022
rate will be finalized on the basis of their
current defect rejection trend.

Rejection Analysis to be conducted for

Not Available Supplier and Inhouse both of last 3 12.09.2022
months.

Not Available Available

Not Available Available

Not Available Available

Not Available Available

Not Available Available

Not Available
 1

eed to be defined.
 T2VSA CLAUSE WISE STATUS REPORT : 5S MANAG
Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 RM, BOP, WIP & FG and bin/trolley should be in covered area

Location of RM & BOP, WIP and FG should be defined and

2
material should be available on designated location

Max volume in a bin, Stacking height should be defined and

3
followed

Minimum Lux level should be defined at each station and weekly

4
checking record should be available
9 5S Management
No leakage of water, oil. Loose wiring & temporary connections
5
should not be available

6 Condition of tools, Jigs and storage

7 Daily Instrument Check Sheet, Instruments should be in box

PORT : 5S MANAGEMENT
Status as on dated……02/09/22…………. Remarks

Available

In-Process

In-Process

Lux level plan available

In-Process

In-Process

In-Process
 T2VSA CLAUSE WISE STATUS REPORT : EQUIPMENT / IN

Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 Daily Machine Check-sheet

2 Operator Awareness on Daily Machine Check-sheet
3 Breakdown Register
4 Breakdown Analysis
5 Equipment Breakdown Slip
6 Management List of critical Spares
7 List of Machines
8 Machine History Card
9 Machine Prevetive Checksheet & Record
10 Machine Preventive Maintenance Plan

1 Master List of Limit Samples

Inspection
2 Instrument/Gauge Calibration Plan & Record
Instruments
3 Limit Sample Tag (Expiry Date)
10 4 Gauge History Card
1 Master List of Poka-Yoke
2 Poka Yoke Pok-Yoke Monitoring Check Sheet
3 Poka-Yoke Repair Register
1 Tool History Card
2 Tool Life Standard
3 Tool Life Monitoring
Tool Maintenance
4 Tool Preventive Check Sheet
5 Tool Pereventive Maintenance Plan Vs Actual
Tool Breakdown, Analysis
1 Annual Calibration Plan should be available
2 Calibration record as per plan by NABL Lab
Calibration
3 Verification of calibration certificate

History Card.
S REPORT : EQUIPMENT / INSPECTION EQUIPMENT'S MANAGEMENT

Status as on dated……02/09/22………….

Available
In-process
Available
In-process
Available
Available but not updated
Available but not updated
Available but not updated
Available but not updated
Avialable for only mahle ( for other customers to be updated)

Not Available
plan Available, Gauge calibration records are in process
Not Available
Not Available

no poka yoke available

Available
Available
available
available
available
Available but analysis is in-process
available but not updated
available

Not Available

Not Available
NT'S MANAGEMENT

Remarks

Trainings is in plan

Records to be maintained

Master list of Limit Samples to be maintained and limit samples to

be displayed - 19.09.2022

Limit samples expiry date to be decided-19.09.2022

Gauge History Card - 19.09.2022

Records to be maintained
Calibration plan to be updated 19.09.2022

Criteria for Acceptance to be made for all Instruments -

19.09.2022
History Card - 19.09.2022
 T2VSA CLAUSE WISE STATUS REPORT : IMPLEMENTATION OF

Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 Visualizer/Alarm List

2 Visualizer/Alarm should be in working Condition

3 Visualizer/Alarm working monitoring record

SOP/WI on each & every station should be

4
Implementation of available in local language
11
Standards
5 Operator wise operator observance plan

6 Operator wise operator observance sheet & record

7 Judgement Criteria & Signature

EPORT : IMPLEMENTATION OF STANDARDS

Status as on dated……02/09/22…………. Remarks

Not Available

Not Available
List to be prepared for
Not Available Visualizer/ alarm on
machines.
Available
Plan to be made to check
their working condition
Available
Checking records to be
maintained.
Available
20.09.2022
Available
 T2VSA CLAUSE WISE STATUS REPORT : PRODUCTS MA

Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 FIFO should be available in RM & BOP, WIP and FG

2 FIFO WI and responsibility

3 Identification tag on RM & BOP, WIP and FG parts

4 Traceability with Batch/Production Lot/ Route Card

Similar part identification system should be defined and

5 displayed on shopfloor and shopfloor personnel should
be aware from similar part identification system

6 Identification of NG parts
12 Product Management
7 Red bin on each station

Red bin analysis attendance record, WI and record

8 Disposal Frequency and record

9 Rejection analysis record as per defect raising criteria

10 Identification of Hold parts

11 Yellow bin on each station

12 Rework record, Rework area, WI and Responsibility

PORT : PRODUCTS MANAGEMENT

Status as on dated……02/09/22…………. Remarks

in-process

Not Available

in-process

in-process

in-process

in-process

Available

Not Available

in-process

Not Available

in-process

Not Available

Available
 T2VSA CLAUSE WISE STATUS REPORT : HANDLING MANA

Clause No. S.No. Clause Name Dcoument Name/Type : Record

Customer Approved Packing Standard and

1
should be displayed on packing area

2 List of Bins and Trolleys

3 Handling Bin Cleaning Plan

13
Management
4 Bin Cleaning Check sheet and record

5 Trolley Maintenance Plan

6 Trolley Cleaning Check sheet

REPORT : HANDLING MANAGEMENT

Status as on dated……02/09/22…………. Remarks

Available
Bins and Trolleys ID
Not Available marking is still pending -
12.09.2022

Available List will be updated

accordingly-13.09.2022
Check sheet available but record not available
Area to be defined when
not in use for trolleys and
Not Available Bins - 13.09.2022

Available but record not available

 T2VSA CLAUSE WISE STATUS REPORT : CRITICAL PART MANAG

Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 List of MARU A Product

2 Maru A Product Man and Machine Matix

Identification of Maru A Check Points in WI at

Maru A station and in final inspection of Maru A
parts
Critical Part
14 Display of names & photographs of operators
Management
authorised to work at Maru A station and final
inspection of Maru A part

Rework record of Maru A parts and Traceability

of person doing rework and approving the
reworked parts
PORT : CRITICAL PART MANAGEMENT

Status as on dated……02/09/22…………. Remarks

not applicable
 T2VSA CLAUSE WISE STATUS REPORT : ADEQUATE TESTIN

Clause No. S.No. Clause Name Dcoument Name/Type : Record

1 List of Inspection Instruments

2 List of Testing Equipment

3 Annual Testing plan and MTC of RM

Adequate Testing
15 Inspection Instrument and Testing
4 Equipment
Instrument/Equipment handling Responsibility

Skill Matrix of Responsible person in Inspection

5
Instrument & Testing Instrument/Equipment

Training Record to handle Inspection Instrument

6
and Testing Instrument/Equipment
ORT : ADEQUATE TESTING FACILITY

Status as on dated……02/09/22…………. Remarks

Available but not updated 15.09.2022

Not Availble 15.09.2022

Avalable

Responsibility to be
Not Availble defined for handling -
15.09.2022

Skill Matrix to be
Not Availble updated and displayed
15.09.2022

Training Records wo be
Not Availble
maintained 15.09.2022
 T2VSA CLAUSE WISE STATUS REPORT : PROCESS AUDIT

Clause No. S.No. Clause Name Dcoument Name/Type : Record

Process Audit, NC record,

Countermeasure Sheet, Target date to
close NC's.
16 1 Process Audit

NC Closure record and Effectiveness

record.
WISE STATUS REPORT : PROCESS AUDIT

Status as on dated……02/09/22…………. Remarks

Process Audit will be

Not Availble conducted as per plan -
16.09.2022

Summary report and NC

Not Availble closure evidence to be
collected - 16.09.2022
 T2VSA CLAUSE WISE STATUS REPORT : SCALE & TOP MANAG

Clause
S.No.
No.

Management
1 Bandwidth &
Organization Structure

2 Scale and Top Review Mechanism

17 Management
bandwidth

3 Plant Sales Turnover*

4 PAT/Sales*
5 D/E Ratios*
6 ROCE*
SE WISE STATUS REPORT : SCALE & TOP MANAGEMENT BANDWIDTH

Status as on dated……
Dcoument Name/Type : Record
02/09/22………….

Do you have adequate organisation structure and defined

roles/ responsibilities for key areas such as Plant Head,
Quality, Production and Maintenance?

How frequently Top management visits the shop floor?

How frequently Top Management monitors key
performances (Performance at customer end, in-house
quality, productivity, maintenance, safety etc.)?

Plant Sales Turnover for the auditee plant.

Group Turnover
PAT/Sales
D/E ratio
ROCE
Remarks
 T2VSA CLAUSE WISE STATUS RE
Clause
S.No. Clause Name
No.

1 Working
Conditions

18 Safety

2 Human and
Machine Safety

3 Fire Safety*
 T2VSA CLAUSE WISE STATUS REPORT : SAFETY
Dcoument Name/Type : Record

Is shop floor temperature, noise level, air quality (fumes) ok?

Is layout and escape route on shop floor Ok ?
Is Rest Area/Toilets Available?
Is area/machine sufficient enough to allow easy movement of machines and tools.

Are Safety Standards made (as per process requirement) and taught to all
operators?
Are PPEs available as per the standards or not?

Machine Safety system (Door sensors etc. ) available or not?

Is Safety in material movement and tools ensured or not?

Are safety standards followed on shop floor as per the procedure?

Are usage of PPES adhered and monitored (by supervisor/senior) on shop floor ?
Accident reporting mechanism defined ?
Countermeasures against accidents taken and periodic verification being done ?

Audit Conducted by reputed 3rd party on MSIL defined check sheet?

AFETY
Status as on dated……
Remarks
02/09/22………….
 T2VSA CLAUSE WISE STATUS REPORT : LEGAL CO
Clause
S.No. Clause Name
No.

1 Consent to Operate

2 ESI & PF
Legal Compliance and
19
Environment

3 Hazardous Waste
Management
LAUSE WISE STATUS REPORT : LEGAL COMPLIANCE & ENVIRONMENT

Dcoument Name/Type : Record

Consent to operate (Valid as on date) available or not?

Are all operators enrolled for ESI and PF?

Management reviews the status of PF contributions /ESI payment?
If ESI& PF managed by Contractor, then does management
reviews and checks the ESI enrolment/ payments?

Are different type of wastes identified on shop floor and standards/

Procedures made?
Is Segregation done at source for different type of wastes?
Storage and disposal being done as per consent and periodic
confirmation at disposal stage?
& ENVIRONMENT
Status as on dated……
Remarks
02/09/22………….
Responsible Maruti VSA Audit clauses

Production preparation/ New Product development

Regluation of Initial Production Control
Standard Management
Education & Training
Amit
Quality Audit and Process Audit
Scale and Top Management
Safety

Supplier Control
Hanlding Abnormality in Quality
Equipment and Inspection Equipment Management
Sushant
Adequate Testing facility
Process Audit

Change Management
Implementation of standards

Aman 5S Management
Product Management
Hanlding Management