IMaRQ 2023 TSA

The Southern Associates
Good Morning!!
Hearty Welcome
To
Mr. J.Peter-Manager-QA
TAFE
SUPPLIER QUALITY SYSTEM SURVEY
13th iMaRQ AUDIT
Venue :THE SOUTHERN ASSOCIATES

Date :22.02.2023
Wednesday
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QUALITY POLICY / MISSION & VISION
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The Southern Associates INTRODUCTION
Mr.N. P. Chandrathan
Our founder and guiding light, Mr. NPC started had executive experience
in the forging industry as the Senior Production Manager in India Forge.
His drive for business led him to start The Southern Associates in the year
1990. With his industry expertise, strength of establishing relationships
and desire to make a mark in the industry and society, he has built the
company to its present state.
Mr.C. Ravi
Now the proprietor of TSA's sister concern AF, Mr. Ravi joined his
father in business at its inception. He oversees activities such customer
relationship management, finance and operations of both concerns. His
firm hand and keen eyes are the core of our organization.
Mr.C. Raju
After completion of his BSc, Mr. Raju too joined his father in the
business at its inception. He duals as our Director of Operations and
Director of Accounts and Administration. He makes sure to share his fire
with the rest of the organisation and it often remains are key motivating
factor
Ms. Raashmi
Mr.R. Siddharth
Has joined our organization after completion of her
Has joined our organization after completion of his
Bachelor's in Commerce. Currently working with
MSc in Advanced Manufacturing in Australia. His eye
our Accounts team, goal is to systematise all
for technology and aim to fasten processes are already
processes in the organisation and enable efficient
beginning to yield results and is what will lead to the
administration and management of all departments.
expansion and growth of our organization.
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Our Core Competency
In Technology:
Hot forging, Trimming, Coining, Cold forging, Cold coining, Normalizing, Shearing, Shot
blasting, CNC turning, CNC Turn milling, VMC milling, Hard turning, Broaching, Welding,
Primer Coating, Conventional drilling & Riveting
IN DESIGN :
Well experienced, in-house design and development team for forging dies and tools to fulfil our
customer requirements. Our fully integrated Solid works package links product and die design to
high-speed die sinking & Our Del cam simulation software ensures we get it right the first time,
every time by disciplined approach to the forging and die design.
IN SUPPLY OF :
Steel Forgings, ferrous and non-ferrous components for automotive, pneumatics, oil field
components, valves, defense, mining and other such industries. We are in supply of products like
Shaft, Rod eye, Stems, Ball Pins, Chain Links, Track Link Pins, Crank Shafts, Connecting Rods,
Conveyor Assemblies, Gear Blanks, Pinions, Axle Shafts, Valve Bodies, Flanges and Nozzles
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 2 Plants in Chennai, Tamil Nadu, INDIA.

Our Plants  1 Plant – Hot Forging
 1 Plant – Machining & Cold Forging
THE SOUTHERN ASSOCIATES ARIHANTH FORGINGS
Machine Shop Hot Forgings Cold Forgings
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Customers
Customers

 CNC Turning Machines (CNC) -08 Nos
 Mazak - 1 No
 Mazak- 1 No (CNC Turn Mill)
 Doosan - 1 No
 Super Jobber -1 No
Manufacturing
Equipments
Production  Jyothi (DX150) -1 No
Customers  Jyothi (DX200) -1 No

 Jyothi(DX200-5A) -1 No
 ACE - 1 No
 Vertical Machining Center (VMC) -07 Nos

 Hass – 1 No
 Hart Ford -2 Nos
 Acer (AMS)-3 No
 AMS MCV-450-1 No  Special Process -02 Nos
 PANASONIC MIC WELDING -1 No
 Hydraulic Press -02 Nos
 INDUCTION HARDENING ( 200 KW)-1 No
 600 Ton Press – 1 No
 10 Ton Press – 1No
 Conventional Machines -04 Nos

 EIFCO -2 Nos
 ITCO-1 No
 SIDHA PURA-1 No
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 CNC Turning
Inhouse
Facility  CNC Turn Mill
Manufacturing  VMC Milling, Drilling & Chamfering
 Hard Turning
 Broaching
 Conventional Drilling & Chamfering
 Cold Forging
 Primer Coating
 Welding
 Revitting
 Induction Hardening-Under Trail
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DOOSAN – 200 to 500 mm CNC
MAZAK -200 to 560mm CNC
Machining
Facility
JYOTHI -250 (CNC) SUPPER JOBBER-200 to

JYOTHI-150 (CNC)
JYOTHI-200 (CNC) 500mm- (CNC)
AMS-VMC
AMS ACER -400 to 600mmVMC HARD FORD-630 to 1200mm VMC
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K2 CRANE -5 TON
Cold Forging
Facility
PRESS FORM COLD FORGING-600 TON
INDEF –CHAIN BLOCK PULLEY-1 TON ELGI-20HP –AIR COMPRESSOR
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REVITTING M/C
ENCRAVING M/C
Conventional
& Other
Facility
EIFCO-38MM
DRILLING M/C
EIFCO-38MM
PRESS-10 TON. DRILLING M/C
BROACHING M/C
PANASONIC MIG WELDING

M/C-YD 400 RX1
SIDHA PURA -25 MM

DRILLING M/C
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Vendor  Cylindrical Grinding  Heat treatment

Facility
 Center less Grinding  Hardening & Tempering
 Surface Grinding  Induction Hardening
 Polygon Turning  Case Hardening
 Key Way Milling  Hot Chrome Plating
 Key Way Slitting  Nitro Carburizing
 Honing  Aging
 Thread Rolling  Blackening
 Welding
 Sand blasting
 Plating
 Zinc Plating
 Magnetic Phosphating
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OPTIHITE 2D HEIGHT GAUGE - 450 SIZE CONTROL AIR MITITOYO SURFACE
GAUGE (DQMS) ROUGHNESS TESTER
Inspection
Facility
PROFILE PROJECTOR
DIGITAL BEVAL
PROTRACTOR
BEVAL PROTRACTOR
HEIGHT GAUGE-UPTO
300 MM
LUZ METER
MAGNIFER -10X
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POLISHING MACHINE ROUGH GRINDER CUTTING MACHINE
MICRO SCOPE
Metallurgy
Lab Facility
PLATING THICKNESS GAUGE
HOT MOULDING PRESS VICKERS HARDNESS TESTER
BRINELL HARDNESS TESTER
ROCKWELL HARDNESS TESTER MPI INSPECTION MACHINE
PORTABLE HARDNESS TESTER
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DIGITAL VERNIER CALIPER
Internal INTERNAL CALIBRATION SCOPE:
INSIZE SLIP GAUGE -4110-
calibration 2112
1.PLUG GAUGES
Facility
2.SNAP GAUGES
3.KEY WAY WIDTH GAUGES
DIGITAL MICROMETER
COMPARATOR STAND
DIGITAL THERMOMETER
DIGITAL PLUNGER PLUNGER DIAL-0.001MM

GAUGE LEVER DIAL-0.01MM
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VMC-AMA-450
Implemented
Under PRESS-10 TON.
new machines BROACHING M/C
Installation
this year-2022
INDUCTION HARDNENING (200 KW)

UNDER TRAIL RUN
PANASONIC MIG WELDING VACCUM CLEANER FOR BUR

M/C-YD 400 RX1 CLEANING
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 Metallurgy Lab & Standards Room was established

 Quality Assurance Cabin was established
Quality Assurance Department -Cabin

Metallurgy Lab & Standards Room
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Tafe Domestic Parts
Production
Products
Customers
Shaft Lower Link –LH & RH Delivery Pipe Knod Diff Lock Plug Filler Pressure Plate LH & RH
Selector 1R SM Arm Spindle-LH

Lever Assembly Pedal Cover Bottom
Clutch Pedal Assembly

Arm Spindle-RH
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iMaRQ Audit Result Trend

Target for i2MaRQ : Above 85 %
90 85
80 77.72
73.85 74.03 72.92 74.22
71.38 71.75
70 67.75 67.45
60 56.43
53.35
50
45.23
40
30
20
10
0
Result in %
2009 2011 2012 2013 2014 2015 2016 2017 2018 2019 2021 2022 2023
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Customer’s & External Audit Score Trend for the year of 2021 to 2022
Customer Audit Score Trend
100 98.24 100 100
100
90
85.33
83
80 77.72
74.22
70
60
50
40
30
20
10
0
2021 iMaRQ 2021-SHL 2021-ISO 2022 iMaRQ 2022 Tafe Process 2022-SHL 2022-ZED Audit 2022-ISO
9001:2015 Audit (MSME) 9001:2015
Zero NC Zero NC Zero NC
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ISO 9001 : 2015 Audit Result for the Year of 2022-2023 “ 0” Non Conformance
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ZED (Zero Defect Zero Effect) Audit Result for the Year of 2022-2023 “ 0” Non Conformance in Bronze Level
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KPI FOR THE YEAR 2022-2023
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THE SOUTHERN ASSOCIATES Process Measure and Objectives Monitoring Record Ref.No.: TSA/R-02
Rev.No. 00, Dt.02.04.2018
Year of 2022 - 2023

Average /
Sl.No Process Measure UOM Target
Apr-22 May-22 Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Nov-22 Dec-22 Jan-23 Feb-23 Mar-23 Total
Enquiry Received No.s - 4 4 2 2 2 2 6 8 4 6 40
1 Order Received No.s - 1 0 0 0 0 1 1 0 0 2 5
Enq Vs Order Conversion % 30 25 0 0 0 0 50 17 0 0 33 12.50
2 Delivery Performance % 100 79 77 78 76 76 69 79 88 90 76 78.80
3 Supplier Performance % 95 95 96 95 95 96 97 97 94 96 96 95.70
4 Sub Contractor Performance % 90 95.5 85 88 96.3 98 96.3 97.2 98 98 97 94.95
5 Production Plan Vs Achieved % 100 81 86 91 91 92 93 93 94 95 94 91.00
6 Customer Satisfaction % 90 3 feedback = 93.31% 93.31
7 Customer Complaint No.s 0 4 4 7 2 6 1 5 5 4 3 41
8 In House Rejection PPM 2500 1131 2002 1860 2663 2986 1625 1810 3183.0 2199 1242 2070.10
9 Customer End Rejection PPM 100 91 1310.00 3211 37.00 16752 203 20957 5172 8729 49367 10582.90
10 Machine Break Down Hrs/Month 126 35 18.0 71 10.00 168 18.5 44.5 54 251.0 223.0 89.30
Nos /
11 No of Trainings 1 1 1 1 2 2 1 1 1 2 2 14
Month
12 No of Suggestions No.s / Year 30 14 2 8 6 5 14 6 38 2 6 101
13 No of Continual Improvements No.s / Year 15 1 1 1 1 3 4 6 7 4 3 31
14 New Product Development No.s / Year 10 1 0 0 0 0 1 1 0 0 2 5
15 In House Rework PPM 1500 935 337 764 555 995 1683 1149 1071 1015 1433 993.70
16 Cost of poor quality % <1 0.77 0.81 1.86 1.7 2.27 1.010 1.1 2.17 0.64 2.85 1.52
17 Machine Utilization % 70 72 52 78 82 79 65 75 71 71 72 71.70

Incoming Rejection
18 PPM 2500 815 1097 892 676 582 327 794 3910 301 32864 4225.80
(Sub Contractor)
Safety Nos /
19 0 0 0.00 0 0.00 0 0 0 0 0 0 0
(No of Accidents) Month
Metric
20 Waste disposal of Oil soaked Gloves and Cotton Waste Ton / 0.07 0 0 0 0.143 0.180 0 0 0.284 0 0 0.06
Month
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Inhouse Machining Rejection Trend

4,000
3183
2986 Target : < 2500 ppm
3,000 2663
1,762 1860 1625 1810

Rej PPM
2,000
2199
2002
1,000
1131 1242
0
2021-2022 Apr'22 May'22 Jun'22 Jul'22 Aug'22 Sep'22 Oct'22 Nov'22 Dec'22 Jan'23 Feb'23 Mar'23
Production Plan Vs Actual

120 Target :100%
100
89 91 91 92 93 93 94 95 94
86
81
80
Production %
G
60 O
O
40 D
20
0
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Clutch Pedal-
Primer Peel off-
Qty: 234 nos
Clutch Pedal- Cover Bottom-Drill MSPTO Lever-16

Welding Tapper- Hole Missing-Qty- nos -NPD Stage
Qty: 6 nos 24 nos
26 of
48
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Complaint-1: Clutch Pedal-Primer Peel off Qty :234 nos

Action : Primer Coating Process was standardized and got sign off
from customer
Complaint-2-Cover bottom –Drill Missing-Qty-24 nos Complaint-3-Clutch Pedal Welding Tapper-Qty-6 nos
Action : Poka Yoke trays have been implemented Action : Welding Fixture design was changed
Before
After
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Washer-Lot
rejection –
Customer
Complaint-SPT
28 of
48
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Target :100%
Delivery Performance
120
100 88 90
78 79 77 78 76 76 79 76
80 69 G
Delivery %
60 O
O
40 D
20
0
100 94 OEE & Machine Availability 89

86.09 89 86 89 86
90 81 83
82 75 78
80 78 79
75
70 74
72 71 71 72
65
60
52 Total OEE Target
50
40 G
30 O
O
20
Target : >70% D
10 29 of
0
48
02
1
r'2
2
y'2
2
n '22 l'2
2
g'2
2
p'2
2
t'2
2
v'2
2
c'2
2
n '23 b'2
3
r' 23
20-2 Ap Ma Ju Ju Au Se Oc No De Ja Fe Ma
20
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IMPROVEMENTS & ACHIEVEMENTS FOR THE

YEAR 2022 -2023
Production
Customers

We have Won the Tafe QCC Competition in Jan’22
TSA
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We had Implemented TPM system to Monitor ERP has been implemented

Production Performance in our Machine Shop
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Successful Accomplishments (Quality Month Celebration has been done )-26.11.2022
33
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Successful Accomplishments (Quality Month Celebration has been done )-26.11.2022
34
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Successful Accomplishments (Quality Month Celebration has been done )-Nov’22
35
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PROPOSAL-
END OF
FEB’23
Geedeeweeler-Uniturn 400 HD TM
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 New Forging plant at Kakallur
Proposal  Induction Billet Heater Kakallur Plant

 Plant Extension in TSA
Plant Extension in TSA
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KAIZENS FOR THE YEAR 2022 -2023
Production
Customers

G
O
O
D
39 of 48
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Primer Coating Process has been improved

Fixture Storage method has been improved
Vacuum Cleaner has been introduced for Bur Cleaning Safety equipment have been improved Currently we have
7 nos of Fire extinguisher and 1 no of Fire Bucket Stand
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Packing Container design has been changed

Luz and Digital Beval protractor have been introduced
Packing Work Instructions have been displayed Safety Story has been displayed
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Designation Pocket Pouch with Quality Policy and Calibration Card (Annual Plan was displayed)
Mission Vision introduced
TSA Policies have been displayed EMS has been improved
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1.Turn Mill Center has been implemented . (Mazak 150 MSG)-15.11.2021

Capabilities:
1. All 12 holders are suitable

for live tooling.
2. Operations like turning,
facing, milling, boring
shoulder milling, polygon
turning, gear hobbing ,
gear skiving and
Broaching can be done in
this machine.
12 TURRET STATION 3. Extremely versatile and
150 MSG MAZAK WITH LIVE TOOL productive as it has
MACHINE HOLDERS turning, milling and
hobbing capabilities.
Before -4 Operations in Delivery Part After-1 Opeartion in single machine setup
10-CNC 1 20-CNC 2
10,20,30 & 40-
(Turning) (Turning)
Turn mill (Turning,
polygon turning,
40-VMC-1 30-Polygon drilling)
(Drilling) turnING (OS)
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2.MCV 450 with 4th axis cradle setup has been implemented (10.10.2022)
AMS MCV 450 VMC Capabilities:
MACHINE
1. Different Parts can be packed
both on top face and bottom
face of the fixture. This
increase door to door time
which free’s operator (simple
automation), this also
ARMSPINDLE LH
Improves flexibility and
FIXTURE
productivity.
2. Through cooloant spindle

improves chip evacuvation
in drilling op which
increases productivity and
hole quality.
3. Parts like forks and spindles

ARMSPINDLE RH can be done in one setup.
FIXTURE Increases productivity and
quality
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2.Before-VMC Machine only Available Before-Process flow -5 operations (4 th axis cradle
implementation)
Proposal
Op 10 Op 20 Op 30
Broaching Out
Source
Op 50 Op 40
After-Broaching machine added After-Process flow -3 operations (Cradle setup
and broaching Machine)
Op 20
Op 10
Op 30
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2.Benefits of 4th axis cradle setup Implementation

Before-Conventional 5 stage setting
Proposal After-4th Axis Craddle Setup
Batch processing (Batch Qty 200 nos): Arm spindle One piece flow (Batch qty 200) : Combined 4 th axis
LH will be processed 1st , setting will be changed Arm Craddle setup process gives 1 no of Arm Spindle LH
spindle RH will be processed next and then sent to and 1 no of Arm spindle RH for each machining cycle.
Out source for Broaching. Broaching machine has been added to the cell.
1. Material Lead time:- 12 days for 1st set. 1. Material Lead time :- 1 hour for 1st set.
2. Quality feedback- Late (Shrinkages after slitting 2. Quality feedback- Immediate ( Shrinkages after
op (200 nos*3 operations= 600 operations) might slitting can be compensated from the 1 st part= 1 no* 2
vary for few heat treatment batches , this will operations= 2 operations- since it is one piece flow).
cause unnecessary rework)
3. Touch time- 5 times/ part. 3. Touch time- 3 times/ part.
4. Cycle time for one set- 31 mins. 4. Cycle time for one set – 28 mins(same machining
parametes) 10 % increase in productivity.
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3.Group Technology implementation (Cellular Manufacturing Layout)-20.05.2022
Before-Functional Layout Before –Part Routing
Proposal
After-Cellular Layout After-Part Routing
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3.Immediate Benefits attained after switching to Cellular layout :

Proposal
Functional layout (Before) Cellular layout (After)
1. Product routing cannot be standardised for HMLV parts 1. Routing can easily standardised, and this standardisation
(System reliability is less) promotes lean practices such and done in one machine and one
piece flow concepts. (System reliability is more)
2. Parts are difficult to trace as the parts move a lot of distance 2. Cells arranged in such a way that the parts move within 2m
beyond 2m between operations. Easily traceable.
3. Rejections were high because feedback is late (Batch 3. Rejections are less as feeback is immediate(done in one or
processing- some times weeks ). There are chances for whole one piece flow- 15 mins ) processing.
batch to get rejected.
4. Unnecessary movement of material creates waste. Also 4. Movement of material is restriced to cell. Reduces operator
creates operator fatigue. fatigue and waste this improves productivity.
5. Bottleneck operation are difficult to be identified as routing 5. Bottleneck operation can be easily identified and can be
keeps changing. acted upon to improve productivity.
6. No of material handling bins required and WIP are higher in 6. One piece flow and done in one concept reduces the number
functional layout when compared to Cellular layout of bins required and thereby WIP.
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Future scope of work
Turnmill with machine

tending robot & Pallet Twin Spindle
changer
S.No What Who When How Why

1 Automate machine tending TSA- Feb-2023 Add suitable parts to run Will increase
for Turnmill center.(Level QCC Machine 24/7 . Add Robot productivity by
3 automation) Team for Machine tending 20%.
2 Develop parts and add TSA- March- 2023 Parts similar to forks and Will increase
Twin spindle with pallet QCC- spindles to be added. Add productivity by
changer Machine.(Level 3 Team 4th axis vmc Machine with 50- 60%.
automation) pallet changer.
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Carbon Foot Print to be implemented- End of Dec’2023
 Recycle more.
 Make a pledge to recycle our waste and take advantage of our
local recycling facilities. ...
 Cut out plastic. ...
 Minimise food waste. ...
 Save water. ...
 Use eco-friendly products. ...
 Fertilise our garden. ...
 Reduce electricity usage.
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The Southern Associates TRAINING
Fire Drill was conducted in TSA Eye Test Medical Camp was conducted in TSA
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We have been Conducting Training as per our Training Schedule – Target – min 6 Training
Annually Per Person
EMS-On The Job Training-2022
Sharpening Axe (Training)
Safety –Fire Drill Training-2023

SPC- Class Room Training-2022
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We have formed 3 nos of QCC Teams for

15 no of 5S Zones were identified in TSA
Continual Improvements and
and
6 nos of Projects have been completed
17 nos of 5S kaizens were implemented
Production
Customers
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TPM Competition was held and winners were awrded
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TSA all employees visited Arihanth Forgings to observe their improvements on 03.01.2022
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Inprocess QMS SystemProductionWe have KPI Communication System
Products for all Employees
Forged
Document Display Board
1.SOP
2.WI
Production
3.Inspection Report
4.Production Report
Customers
Instrument & Gauges
Storage Stand
Input Material Storage

Stand
Rework Parts Storage

Stand
Rejected Parts (NC)

Storage Box ( Lock & Key
System)
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NC Parts Storage Room (Controlled by QA Team)
Products
Forged
Production
Customers
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The Southern Associates STORES
We have separate storage area for raw material and
consumables.
FIFO for Daily Raw
Material & Stock Status
Production
Production
Customers
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The Southern AssociatesFINISHED GOODS STORAGE AREA
We have separate storage area for Production

finished FIFO for Daily Finished Goods
goods parts & Stock Status
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The Southern Associates VISUAL DISPLAY SYSTEMS
Production
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ENVIRONMENTAL MANAGEMENT SYSTEM
We have Implemented EMS and safety Policy and Improved our waste Disposal Method
Production
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Complaint Details:
Primer peel off, Uncoverage & rust issues in 1446A00602-
Clutch Pedal Sub Assembly at Customer end on
03.01.2023
Invoice No: GST/22-23/1779 dt 31.12.2022
Qty: 144 nos
Root Causes: In Sufficient hanging capacity Ineffective Air curing process- Part dispatched condition
Primer Bath 10 nos only Part placed on floor
1. Ineffective Primer coating process (due to non-standardized process)

a. Before primer coating, Viscosity of Primer & Thinner mixture was not measured
b. Non-standardized primer bath was used. Bath was designed by TSA (Plastic Container)
c. Frequent cleaning of bath was not done.
d. Dipped time was not standardized
e. Part curing method was not effective. Part hanging time maintained 15 to 20 mins and then parts were placed on the floor by using
polythene cover or metal stand (Air dry cleaning by min 6 Hrs). Insufficient hanging capacity – at a time only 10 nos. could be
hanged.
f. After dipping excess paint was not removed properly.
2. After primer coating DFT thickness was not measured.
3. Tape test/Cross hatch test was not conducted for all lots. Test was conducted once in 3 months only for one part.
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4. Shot blasting process for 18 mm rod done for batch qty (on an average 1500 to 2000 parts). The lead time from Welding to Primer
coating took more than 4 to 5 days and due to this, rust was formed on the stem. This rust was cleared by emery sheet manually
before primer coating.
5. Shot blasting process was outsourced due to the breakdown of our shot blasting machine. This became a practice for TSA.
6. Bright bar condition was used instead of black bar, because quality issues were there on black bars (More variations observed on OD
due to this part assembly problem at TSA)
7. The rod for one lot was procured from unapproved Trader (Sarada Alloy steels) due to unavailability of materials.
Corrective Actions:
Coating thickness
1.B4 Cup, 3M Tape & Hatch test tool purchased Gauge
2.Primer and thinner mixing ratio is standardized for 4: 1 ratio
3.Viscosity is measured and maintained at mixture: 25±2 Secs
4.Part dipping time is standardized by Dipping time : 10 - 20 secs (move the part up & down, left & right).
5. Primer bath design to be changed by Conical type metal container (which is being used for oil packing)
6.Primer bath cleaning frequency to be defined once in a week Hatch Test
3M Tape
7.Primer changing frequency to be defined once in month Tool
8.Curing time and method were changed
a. Hang the part by increasing the number of hooks (100 nos per day)
b. Ensure there is no metal to metal contact to prevent primer layer. B4 Cup
c. Curing air dry for 1 night (min 8 hrs)
9.After dipping, the excess primer to be removed by brush
10.After Curing, DFT to be measured by Coating thickness gauge and maintained
at 25 to 35 microns
11.Before dispatch one sample per lot to be inspected for Tape test/Cross hatch test.
12.During packing, all parts to be covered by polythene cover to avoid part touch.
13.Lead time taken from shot blasting to primer coating to be reduced. Only required parts to be
shot blasted instead of batch quantity, welded and primary coated immediately.
14.Rod to be procured only from approved sources
15.Work instruction to be made for bath cleaning & Mixture preparation
16.SOP to be made for Primer coating process
17.After the completion of above mentioned actions, Primer coating process approval to be obtained from TAFE
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Immediate Actions taken to avoid line stoppage (on 10-01-23):
1.Primer removed manually in the available parts (40 nos) at TSA. Re shot blasting and re primer coating were carried out as per the
standardized primer process. Boss area was covered by polythene cover to avoid surface damage on machining area.
2.Primer and thinner was mixed for 4: 1 ratio.
3.Mixture viscosity was measured and observed as 23.65 seconds.
Excess primer
4.Part hanging capacity was increased from 10 nos to 50 nos
Part hanging cleared by Brush
5.Qty : 50 nos primer dipping process was completed. Now parts are under curing
Capacity increased
process
by 10 nos to 50 nos
6.DFT and tape test will be carried out on 11.01.2023.
Part loaded in shot After Shot blasting

blasting (Boss (No rust on part)
covered by cover)
Viscosity
observed-
23.65 sec
Primer- QD
Casting sealer Primer & Thiner mixing Ratio-4:1
Charcoal
Grey Primer - 4 ltr Thiner -1 litre
Thinner-
Faber make -
Thinner 2009
ACHIEVE ZERO PPM

Actions Taken on 11.01.2023
Separate Location has been implemented for Primer Coating Process
Cap provided Lux Achieved-342
ACHIEVE ZERO PPM

1.Primer Coating Thickness achieved 26 microns.

Result
2.Flim Adhesion test is good and no peel off.
3.SOP updated for Primer coating process and displayed
4.Work instruction prepared for primer coating process
and displayed
5.Work instruction for Bath cleaning activity and displayed
6.Check sheet for bath cleaning activity prepared ,updated
and displayed
7.Authorized persons for primer coating process prepared
and displayed
8.Control plan updated for primer coating process and
displayed
9.Daily primer process and inspection report updated
ACHIEVE ZERO PPM

The Southern Associates AWARDS
ACHIEVE ZERO PPM

Thank THANK YOU !!

You
Customers and hoping for a WIN-WIN Relationship with Tafe & The
Southern Associates
We thank every team member of Tafe for their unrelenting

support to The Southern Associates
The Glory of Success is not in never falling,

but in rising every time you fall
ACHIEVE ZERO PPM

IMaRQ 2023 TSA

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Copyright:

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IMaRQ 2023 TSA

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The Southern Associates

Venue :THE SOUTHERN ASSOCIATES

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM 2 of 40

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM

 2 Plants in Chennai, Tamil Nadu, INDIA.

THE SOUTHERN ASSOCIATES ARIHANTH FORGINGS

Machine Shop Hot Forgings Cold Forgings

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM 6 of 40

Customers  Jyothi (DX200) -1 No

 Vertical Machining Center (VMC) -07 Nos

 Conventional Machines -04 Nos

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM

JYOTHI -250 (CNC) SUPPER JOBBER-200 to

ACHIEVE ZERO PPM

PRESS FORM COLD FORGING-600 TON

INDEF –CHAIN BLOCK PULLEY-1 TON ELGI-20HP –AIR COMPRESSOR

ACHIEVE ZERO PPM

PANASONIC MIG WELDING

SIDHA PURA -25 MM

ACHIEVE ZERO PPM

Vendor  Cylindrical Grinding  Heat treatment

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM

PLATING THICKNESS GAUGE

HOT MOULDING PRESS VICKERS HARDNESS TESTER

BRINELL HARDNESS TESTER

ROCKWELL HARDNESS TESTER MPI INSPECTION MACHINE

PORTABLE HARDNESS TESTER

ACHIEVE ZERO PPM

DIGITAL PLUNGER PLUNGER DIAL-0.001MM

ACHIEVE ZERO PPM

INDUCTION HARDNENING (200 KW)

PANASONIC MIG WELDING VACCUM CLEANER FOR BUR

ACHIEVE ZERO PPM

 Metallurgy Lab & Standards Room was established

Quality Assurance Department -Cabin

ACHIEVE ZERO PPM

Tafe Domestic Parts

Selector 1R SM Arm Spindle-LH

Clutch Pedal Assembly

ACHIEVE ZERO PPM

iMaRQ Audit Result Trend

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM

ACHIEVE ZERO PPM

KPI FOR THE YEAR 2022-2023

ACHIEVE ZERO PPM

Year of 2022 - 2023

1 Order Received No.s - 1 0 0 0 0 1 1 0 0 2 5

Enq Vs Order Conversion % 30 25 0 0 0 0 50 17 0 0 33 12.50

2 Delivery Performance % 100 79 77 78 76 76 69 79 88 90 76 78.80

3 Supplier Performance % 95 95 96 95 95 96 97 97 94 96 96 95.70

4 Sub Contractor Performance % 90 95.5 85 88 96.3 98 96.3 97.2 98 98 97 94.95

5 Production Plan Vs Achieved % 100 81 86 91 91 92 93 93 94 95 94 91.00

6 Customer Satisfaction % 90 3 feedback = 93.31% 93.31

7 Customer Complaint No.s 0 4 4 7 2 6 1 5 5 4 3 41

13 No of Continual Improvements No.s / Year 15 1 1 1 1 3 4 6 7 4 3 31

14 New Product Development No.s / Year 10 1 0 0 0 0 1 1 0 0 2 5