ISO 9001:2008

Management Review Meeting

Sep. 2014

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1
Agenda

1. Review of Quality Policy

2. Changes in QMS

3. Follow up action of last MOM

4. Review of Results of External Quality Audit
5. Review of results of internal quality audit
6. Review of Quality objectives

7. Voice of customer

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2
Agenda
8. Review of process performance
9. Summary of corrective and Preventive action
10. Summary of improvement actions
11. Review of training program and effectiveness
12. Review of Supplier / Subcontractors
13. Resource Requirements
14. Any other issues as raised by process owners
related to QMS, customer satisfaction

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3
Item 1 – Review of Quality Policy
QUALITY POLICY
Through team work , we seek organizational and employees growth
to meet expectation of customers, suppliers and stake holders by
continual improvement
Our key to success is ABC
Awareness, Belongingness & Commitment.
 
Date: 01/06/2012 N.Seshagiri Rao
Place: Pune Managing Director

Quality policy is reviewed and accepted as is.

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4
Item 2 – Change in QMS

No Change in existing QMS

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5
Item 3 – review of previous MRM actions

Reference - MOM of MRM conducted in August 2014

Action Items 12 No. Target Date Responsibility

Completed 12 No. NA -

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6
Item 2 – Review of Results of External Quality Audit
A. ISO 9001-2008 : Recertification Audit
Execution – Feb.2014,
 Total NC detected – 02 No. , Closed – 02 Nos.
Re-certification awarded with inclusion of Transformer division in audit scope
B. Customer Audit
Business Vertical – PMS Business Vertical – Transformer
Customer – Indus Customer – Emerson , ESAC
Execution - Mar.2014 Execution – Apr.2014
Total NC detected – 16 Nos. Total NC detected - 41
Total NC closed – 16 Nos. Total NC closed - 41
Audit Score - 84.14% Audit Score – 55 %

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7
Item 2 – Review of Results of External Quality Audit
B. Customer Audit
Business Vertical – Transformer
Customer – Emerson , Pune
Execution – Jun.2014
Total NC detected – 16 Nos.
Total NC closed – 16 Nos.
Audit Score – 67.75%

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8
Item 2 – Review of Results of Internal Quality Audit
Internal Quality Audit Cycle 1 ;
Scheduled /Execution : May-14/Jun-14
 Total NC detected - 30 Nos.
 Closed – 29 Nos.
 In-Process- 01 Nos.
 Categorization :
1. Lack of awareness –11 Nos.
3. System improvement – 10 Nos.
4. System defined but not followed – 09Nos.

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 Item 2 – Review of Results of Internal Quality Audit
Audit No. Department No. of NC.
1 IQC 1
2 QA-PMS 0
3 PRODUCTION-PMS 2
4 CARD-TESTING 3
5 CSC/FS-PMS 1
6 DND-PMS 1
7 MKT-PMS 0
8 QA-BALLAST 2
PRODUCTION-
9 BALLAST 0
10 CSC-BALLAST 3
11 DND-BALLAST 3
12 MKT-BALLAST 1
13 QA-TRX 2
14 PRODUCTION-TRX 3
15 DND-TRX 1
16 MKT/BD-TRX 0
17 PURCHASE 2
18 Store 2
19 HR 1
20 MAINTENACE 1
21 MR 1
Total 30

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10
 Item 5 – Quality Objectives
Target Apr May Jun- July Aug-14
Sl. Objectives Level -14
-14 -14 14
A Common Function
Lot
Acceptance
1 97% 99.39 99.72 99.24 99.82 99.25
Ratio at Incoming
Inspection.
B Ballast
APCB rejection 1000
1 1058 883 912 1127 977
PPM
Final lot
2 99% 98 99 100 99 99
Acceptance Ratio

Customer
3 complaint closure - 90% 92.0 92.0 89.0 96.0 99.8
within 7 days

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11
 Item 5 – Quality Objectives (PMS)
Sr. Measu’nt Target Mar Apr May Jun Jul Aug Trend
Objectives
No. Parameter Level -14 -14 -14 -14 -14 -14

In Process
1 Inspection Quality 1200 1054 1184 1074 1010 1133 1054
(DPMO)
Acceptance Ratio

Panel Testing
2 Quality 95 98.41 98.19 98.19 98.53 98.05 98.41
Acceptance Ratio

Final QA Testing Quality

3 Acceptance Ratio 97 98.00 99.91 99.92 99.92 99.94 98.00

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12
Item 5 – Quality Objectives (Transformer )

Sl. Objectives Measu’nt Target Apr May Jun Jul Aug Trend
Parameter Level -14 -14 -14 -14 -14

Electrical Testing
1 % 90 99.34 98.07 98.72 98.62 99.20
acceptance Ratio

Pre-Dispatch
2 Inspection % 95 99.69 99.61 99.77 99.54 99.79
Acceptance Ratio

Coil Inspection
3 Acceptance Ratio % 95 99.32 98.42 99.37 99.63 99.73

Review of new target lines and objectives

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13
Item 7 Voice of Customer – Ballast

Ballast CSI (%) Field Return PPM - Ballast

100 96.5 3000
2778
90 83.75
82.5 2000 2118
80
1468 1436
70
1000 1060
60
50 0
Q3:13-14 Q4:13-14 Q1-14-15 Mar-14 Apr-14 May-14 Jun-14 Jul-14

Analysis : Analysis :
Concerns Failures
GRE customer complaint handling 1x28W, PPFC, 30% ballast ,
2x36W, PPFC, 30% ballast,
2x54W, APFC ballast , Match box

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Late delivery % last 6 months

Item 7 Voice of Customer – Ballast

Defect Types
Delivery Performance
100
80 74 74 76 73
Others
60 14%
Site
40 Conditions
11%
20
Material
0 Quality Design
72%
Apr-14 May-14 Jun-14 Jul-14 2%

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15
Late delivery % last 6 months

Item 7 Voice of Customer – Ballast

Ballast Site Rej Qty Brand-wise Site Rej Qty
2500

2000

1500

Halonix
Surya
Thorn
CGL
Intelux
Bajaj Eetamax 6%1%1%1%
0%
1000 2058 7%
12% Wipro
71%
500

495
177 150 70 66
0 48 47 40 39

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 Field Complaints Status

Complaint Summary Jan - Jun 14

Total
Sr Complaint
Customer Name Brand Complain Model Name Defect Details Batch Code Defect Type Status
No Sites
ts
Bajaj Electricals
1 Bajaj 16 L24F28WS2P 1 Functional Failure / Flickering IG2 Design Closed
Ltd
L24F28WS2P 4 Functional Failure / Flickering IJ3, IK3 Design Closed

L24F36WS2P 9 Functional Failure / Flickering IF2, IK2, IL2 Design Closed

Wipro
2 Wipro 15 Site
Enterprises Ltd L24F54WS2A 1 Functional Failure NA Closed
Conditions

Site
S24CF18WS1PT 1 Functional Failure IL2, IK2 Closed
Conditions

Functional Failure; repeat Site

L24F36WS1P 1 IK1, IA4 Closed
failure in replacement; Conditions
Eetam
4 Prompt Services 2
ax
Flickering at supply voltages
SD28V0300PA 1 IE4 Design Closed
>240V upto 260V

Varun Pressings I/O Connector knob removal, Material

5 Wipro 2 S24CF18WS1PT 1 IB4 Open
Pvt Ltd ballast fitment difficulties Quality

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 Field Complaints Status

Complaint Summary Jan - Jun 14

Total
Sr Complai Batch
Customer Name Brand Complai Model Name Defect Details Defect Type Status
No nt Sites Code
nts

Evergreen Engg. Co. Pvt I/O Connector knob removal, Material

6 CGL 1 LD27V1100PA 1 IF4 closed
Ltd ballast fitment difficulies Quality

7 Techno Light Intelux 1 L24F28WS2P 1 Lamp Striking IA4 NA Closed

Non-working; loose Site

8 Thermax Ltd Intelux 1 L24F36WS2P 1 IB4 Closed
connections Conditions

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18
 Item 7 -Loss and Gain of the customer -
Ballast
Turnover in Cr
Turnover in Loss/
Brand Cr (feb-July- Gain in Remarks
(feb-July-13)
14) Cr
Bajaj Loss 2x28 PPFC 30% & 1x28 PPFC 30% Fulham & LED
3.71 3.3 0.41 driver
Wipro
2.5 1.58 0.92 2x54w BAG , 2x28 PPFC 30% & 1x28 PPFC 30% Fullham
Intelux
1.6 1.55 0.05 Dispatch issues as pressure from OEM
CGL Got break through in LED driver business of
1.57 1.56 0.01 Rs.43 Lac
Surya
0.6 0 0.6 Stop business due to quality issues
GE
0.34 0.12 0.22 Shifted to LED business & 2x54 APFC business loss
Eetamax
0.21 0.15 0.06 Stable & converting to LED business slowly
Other 0.39 0.35 0.04 LED driver & small OEM support
  10.92 8.61 2.31  

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19
 Item 7 Voice of Customer – PMS
PARTNERS PERFORMANCE MANAGEMENT SCORE CARD (PPMSC)  - Mar'14
Suppl Rank within
Field Deliv Audit ier Total product Overall Rank
SQA Feb'1
Produ Partner Perform ery Improve Conc PDI- Mar'1 Classific
Audit 4
ct Name Score ance Ratin ment ern LAR 4 ation Score Mar- Tren Feb- Mar Tren Feb-
Score g Score Room Score 14 d 14 -14 d 14
Score
Intelux
PMS Electroni 84 0 37 70 100 100 56.35 Bronze 60.40 1   1 20   18
cs Pvt.
Ltd.

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Item 7 Voice of Customer – PMS

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Item 7 Voice of Customer – PMS

Field Failure Rate

25

20 19.9 20.7
17
15 14.7

10

0
41730 41760 41791 41821

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Item 7 Voice of Customer – TRX

Delivery Performance -TRX

100

80
69 67.5
60

40

20

0
Q1 Q2

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 Item 7 Concession, NCR, Customer Complaints
NCR Against
TOTAL
NCR WORKMAN
STATUS
Category Wise NCR Category wise
PROCESS
SHIP
DESIGN MATERIAL
percent concession Percent
9-CLOSED
13 5 6 2 0
4-Open Material Process Design
Man Process Design
Design
Design Material
Man 27%
Concession Raised 15% 47%
TOTAL 46%
concess
ion Design Purchase IQC Production Process
38% Process
27%
15 4 6 1 4

Customer
PROBLEM RELATED
MONTH TOTAL Customer STATUS
Complain Category
PROCESS WORKMAN
SHIP DESIGN MATERIAL
70 wise & its Percent
60
50
April-14 1 0 1 0 CLOSED 40
30 60
May-14 Intelux 1 0 1 0 Process related 20 40
5
Concession Open
10
June-14 0 0 1 0 CLOSED 0
Process Design

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Item 7 Cost of Poor Quality- Ballast

Sl Cost Account Apr- May Jun

14 -14 -14 COPQ - Ballast (Rs)

1 APCB  Fault finding and 1415 729 525 250000
rework
200000
2 Cabin ting 6625 5025 1958

3 Ballast Rework 18750 0 1687 150000

4 Screen Printing Rework 313 125 0
100000
5 CSC 64333 78774 196682
50000
  Total cost of Poor Quality 91436 84653 200852
(Rs)
0

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Item 6 – Review of Process Performance: R&D , PMS
In time
Total no of In
Parameter Hold Completed Intime completion
projects process
%
Projects 22 11 4 7 4 57.14
Software
10 0 1 9 7 77.78
development
Improvement
12 5 1 7 6 85.71
projects

On time project completion

Improvement projects 86

Software development 78

Complete project 57

0 25 50 75 100

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26
Item 6 – Review of Process Performance: R&D ballast
Sr. Aug-
Description Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14
No. 14

1 No of models released 0 0 14 1 0 0 0 6

2 No of models developed 5 5 12 4 4 6 8 6

3 Component Approval
3 2 2 11 4 3 7 2

4 Design Improvement 5 12 10 1 1 0 6 1

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27
Forecast V/s Dispatch YEAR-2014-15 - Ballast Division

MONTH Forcast Dispatch Variance 250,000

Jan-14 234,800 130,686 104,114

200,000

Feb-14 177,000 124,503 52,497

150,000
Mar-14 152,000 133,664 18,336
100,000
Apr-14 69,900 69,787 113
50,000
May-14 68,540 64,367 4,173
-
Jun-14 67,000 68,972 -1,972 JAN FEB MAR APR MAY JUN

Jul-14 101,700 87,906 13,794

Dispatch
Forecast

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 BALLAST Productivity for Year 2014-15:

Month Qty 250 228 234

207
JANUARY14 228 200 186

FEBRUARY-14 207 152

150 144
127
MARCH 14 234
100
APRIL 14 144

MAY 14 152 50

JUNE 14 186 0
Jan-14 Feb- Mar- Apr-14 May- Jun-14 JULY
JULY 14 127 14 14 14 14

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Fall Out Rate- Transformer Division
FOR PPM Data

Quarter
FOR Noise Hardware
Month fixing HV fail
PPM contribution mistakes

Jan-14 142700 72400 19500 2200

Q4
2013- Feb-14 79600 32900 15100 2700
14

Mar-14 39800 18200 1700 0

Apr-14 45300 24400 3500 0

Q1
2014- May-14 115000 53100 0 26500
15

Jun-14 56000 2500 15300 10200

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 Plan Production Vs Actual Production- Transformer Division

Plan vs achievment
Productivity per person
100
20
80 76
61 15
60 12
60 50 10
10 9
40
4
5
20
0
0 Apr-14 May-14 Jun-14 Jul-14
Apr-14 May-14 Jun-14 Jul-14

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31
 Item 8. CAPA Summary
Statergic Corrective Complete %
Sl. Business unit / Kaizen
action req. d Pending completion
process
1 Ballast 0 29 25 4 86.60

2 PMS 26 33 30 3 90.90

3 Transformer 26 13 11 9 85

Transformer 85

PMS 91

Ballast 87

50 75 100

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32
 Product /process non compliance Summery
Sl Area / Scope of Non NCR NCR NCR Status of Pending NCR
compliance raised closed pending
1 In process 1.Transformer winding Primary to secondary short
(RT/EE2506/VT/ST.PIN/CR.WDG/1.32MH,30UH)
1.Material 11 09 02 2.(RT/EE2506/VT/ST.PIN/ST.WDG/1.7MH,30UH)
2.Design 6 6 0 3.Actual design requirement for the Model S24UV39IS2AL is of DT/ 1,15,15.but
as per BOM DT/1,15. BOM not change.
2 FQA
1.Production 1 0 1 1.L24CF18WS2PCE -Rejected for the High Wattage.
1.1.Label Problem/production 3 3 0 (Required Wattage 33W to 39w but observed wattage 45 W to 49W).
3.Design 7 7 0
3 Customer Complaint 1 00 01 1.S24CF18WS1PT–M/S Varun Pressing ,Input/output connector knob removal.
Total 29 25 4

Material 11 Dept .wise Non-Conformance %

Design 13
Material
Production 4
14%
Customer Complaint 1 39% Design

Production
46%

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33
 FOR Analysis report :Cabinet Apr- Jun 14
% cumulative Apr - 14 % cumulative May -14
100.0
98 99 100 100 98.3 99.5 99.8 100.0
93 96 96.1
87 90 89.4 93.4
80 80 79.3 80.0
72
62 60 60.0
55.3
34 40 40.0
34 28
20 20.0
10 8 7 4 3 3 2 1 1 0 0 0 0 0 0 0 0 0 0 0.0
0
0 0.0 0.0
CP BP CD CIPC BD BEHOS BLM CLS BIPC CLM BLS CP BP CD CIPC BD BEHOS BLM CLS BIPC CLM BLS

Sl Problem June May April Total

% cumulative June -14
100
1 CP 70 329 213 612
100 96 99 100 2 BP 20 60 175 255
90 95
80 82 80 3 BD 19 143 41 203
72
4 CD 15 24 59 98
60 60 60
46 5 BEHOS 12 7 22 41
40 40 6 CLM 7 16 9 32
20 20 7 BLM 2 13 18 33
0 0 0 0 0 0 0 0 0 0 0 8 BIPC 4 2 11 17
0 0 0 0
CP BP CD CIPC BD BEHOS BLM CLS BIPC CLM BLS 9 CIPC 2 16 51 69
10 BLS 0 1 6 7
  Rej Qty 151 611 605 1367

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34
 Corrective Action
Problem Qty Proceed Qty Rej % Rej FOR % Rejection Apr- June 14

Damage 159685 301 0.2

0.2 Damage
Fabrication 159685 199 0.1 Fabrication
0.5 0.1
Powder Coating 159685 867 0.5 Powder
Coating
Total Rej Qty 159685 1367 0.9

Vendor % Rejection reason causes Corrective Action

Rej
Prathamesh 0.5 1.damaged cover, 1. No inspection prior 1. In process inspection started after immediate powder
Powder Coating 2. bubbles in to dispatch coating [ before curing].
paint, stain 2.Reuses of 2. Norms decided for reuse of powder.
mark / residue, 3. Powder. 3. 3. Automation of conveyer instead of manual previous
Scratch 4. Bur in Handling issue. Manual handling. 4. Mold modified for hole diameter
hanging hole. [ PP].

R&S powder 0.2 Bottom/cover Material Handling . 1. Major issue: R&S powder coating has been stopped.
Coating/Vidya Damage. 2. Handling proposed through BIN by shunny shree from
powder Coating existing.

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35
 APCB PPM Analysis/corrective action
% Cumulative Shree Jee (Apr- June) % Cumulative Alfa (Apr- June)
100 Cumulative % Alfa Apr-14
97 100
100 100 100 100 100
90 80 80
80 80 70
73 60 60
57
60 57 60
40 40
40 40
17 20 20
20 16 20
7 4 0 0 0 0 0
0 0 Jump Wrong Polarity Other Dry point Missing Wrong Insertion
Jump Wrong Polarity Other Dry point MissingWrong Insertion

Sl Non-Achievement of Analysis Corrective Action Implementation Target Responsibility

Target date
A Components Jump- Hole to Caution point at vendor process/ inspection stage. Immediate: Shree jee/
L24F36WS1&2P/PTI: lead ratio Assemblon/ALFA/ VDL.
CN1 and CN2. C5, C6, more.
D1,D5,D18,D19,D20 Under action with PCB manufacturer by Engg. June 14. VDL/ Engg./ Epitome.
Workmans
Wrong polarity hip issue. 1. Training to operator at vendor end for Co-Maker
B. L24F36WS1&2P/PTI, Component Polarity., caution point added.
C3, C4, D1-D4,D6,D7 Immediate.

2. 100% VI Inspection & report from the Co-maker. Immediate. ShreeJee

3.Test zig & wattmeter to be provided to Co-Maker. 31st July 2014 QA/ENG/VDL/PROD

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36
 Product /process non compliance Summery
Sl Area / Scope of Non NCR NCR NCR Status of Pending NCR
compliance raised closed pending
1 In process 1.Transformer winding Primary to secondary short
(RT/EE2506/VT/ST.PIN/CR.WDG/1.32MH,30UH)
1.Material 11 09 02 2.(RT/EE2506/VT/ST.PIN/ST.WDG/1.7MH,30UH)
2.Design 6 6 0 3.Actual design requirement for the Model S24UV39IS2AL is of DT/ 1,15,15.but
as per BOM DT/1,15. BOM not change.
2 FQA
1.Production 1 0 1 1.L24CF18WS2PCE -Rejected for the High Wattage.
1.1.Label Problem/production 3 3 0 (Required Wattage 33W to 39w but observed wattage 45 W to 49W).
3.Design 7 7 0
3 Customer Complaint 1 00 01 1.S24CF18WS1PT–M/S Varun Pressing ,Input/output connector knob removal.
Total 29 25 4

Material 11 Dept .wise Non-Conformance %

Design 13
Material
Production 4
14%
Customer Complaint 1 39% Design

Production
46%

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37
 Item 10 - Supplier Performance

8000 100

5970 89
6000 75

4616 66
65
62
4000 5058
3065
45
1848
20001287 1657
1342 1460 25
903
878
0 0
Mar-14 Apr-14 May-14 Jun-14 Jul-14 Wk 32 Wk 33 Wk 34
Alfa Shreeji Alfa Shree ji

Co maker Quality performance Co maker – Delivery Performance

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38
 Item 10 Vendor Development Highlights

100

90

80 73.8 73.6 74.8 74.8

68.6
70 63.9

60

50

40
Jan'14 Feb'14 Mar'14 Apr'14 May'14 Jun'14 Jul'14
Sri Sai Creative Pranav

Magnetic vendor - JSRV Acceptance Ratio Vendor Rating Score

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39
 Item 11.Training program and effectiveness
100% 16
13
78.80% 14
73 % 12 13
75% 70% 69% 12
11
10
50% 8
6
25% 4
2
0% 0
A M Ju Ju A M Ju Ju
pr ay n- l-1 pr ay n- l-1
-1 -1 14 4 -1 -1 14 4
4 4 4 4

Training effectiveness Percentage Number of training conducted

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40
Item 12 Resource requirement

Transformer :
Insulation Tester
Clamp on meter - Fluke
Transformer testing panel
Watt loss Measurement Equipment

PMS:
R&D – Measuring equipments and manpower
Ballast:
Nil

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41
RESOURCE REQUIREMENT – TRANSFORMER UNIT

RESOURCE REQUIRED
SR.NO Required location Remark
(Immediately)

1 Insulation tester Testing Current Meter has become

faulty

At present we are not having

2 Fluke Clamp-On Meter Testing
good accuracy meter.

We can test Trx’s up-to 40 KVA

3 New Test Panel Testing
on available test panel.

4 Safety Shoes & Separator stand Testing Basic requirement.

Watt Loss Measurement Requirement specified by

5 Inward Testing
Equipment Emerson customer.

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42
RESOURCE REQUIREMENT – TRANSFORMER UNIT

SR.NO RESOURCE REQUIRED Required location

1 Heavy duty racks for Raw material stacking Production

2 Fiber pallets for raw material, semi finish Production

and finish good

Fork lift (battery operated) for Raw material movement

3 Production
and stacking

4 Winder for foil winding machine Production

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43
Item 13 Other relevant issues

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44