Training Topic Vs Name S.no Name of Person Designation 1 Ram oper 2 Shyam mgr 3 Ghanshyam supp.

4 Sonu oper 5 monu mgr 6 Bhavesh mgr 7 Pintu engg 8 Tinku engg 9 ratiram mgr 10 rajaram am 11 ratanlal am 12 joshi dm 13 pk dm 14 rajeev oper 15 mandal oper 16 miglani supp. 17 parveen supp. 18 jangra ae 19 vikasbh oper 20 vabhav engg 21 anil engg 22 ajit am 23 kky dm 24 ashok am 25 teeka oper

Level oper top middle oper top top middle middle top top top top top oper oper middle middle middle oper middle middle top top top oper

5s Y N Y Y Y N N Y Y Y Y N N N N N N N Y Y Y Y Y Y Y

TS N Y Y Y Y Y Y Y N N N Y Y Y Y Y N N N Y Y Y Y Y N

Positive attitite 7QC Tools Y Y Y Y Y Y N N N N N N N N N N N N Y Y Y Y Y Y N Y N N Y Y Y Y Y Y N Y Y Y N N Y N N Y Y Y N Y Y N

Kaizan Y N Y Y Y N N Y Y Y N N N N N N Y Y N N N Y Y Y

Work Instruction for Resposibility(APQP) Purpose : To define the rank of new product for development & activities & responsibilities for product deve process change of existing items. Scope : This WI is applicable for development of new product,Engg change and any Process change of ex Method : Description,Rank of Development and responsibility is defined as below Development Responsibility S.No Description Mkt AA A B C Engg Dev g

Reciept of drawing along with spec drg/ref.sample

O O O

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Pre-Feasibility Clarification from customer for incomplete info Technical feasibility. Cost Estimation Reciept of LOI from customer Preparation of PDF Preparation of Timing Chart Process Flow Chart BOM Passed History Study Component Drawing Drawing Review Review of Process Flow chart Listing of special Characteristics Evaluation of Regulatory/Statutory requirements, environmental Health & Safety Issues Process FMEA Productivity Goals Quality Goals Control Plan(Prototype) Tool Design/Drawing

O O O O O O O O O

O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O

O O O O

O O O O

O O O O O O O O O O O

16 17 18 19 20 21

O O O O O O

O O O O O O O O O O O O O O O O

O O

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Tool Manufacturing Gauge Testing Equipment Sourcing Raw Material/BOPs Sample Trial Run Follow-Up Results during Product Development Review with Customer Layout Plan Component Procurement Ppk Study Plan Operator Process Instruction Logistic Study Packaging Specifications Pre-Launch control Plan MSA Plan Production Trail Run,Pilot Lot Process Product Validation Process Capability Evaluation MSA study PPAP Customer Approval Feedback Analysis & Corrective Action Production control Plan Production Source Approval

O O O O O O O O O O O

O O O O O O O O O O O

O O O O O O O O O O O O O

O O O O O

O O

O O O O O

O O O O O O O O O O

O O O O O O O

O O O O O O O O O O

O O O O O

O O O

O O O O O O O O

O O

Development Rank: Rank Details AA Absolutely new component : no Experience of Production so far That the part happens to be similar to what had been produced so far but there happens to be large scale d A material,Machining Methodology,In the structure or in the function. A component similar to the component produced so far but there happens to be That whenever there happens to be changed in production site That whenever the place/country of development happens to be different from the place/country of product That whenever the Environment (Containing comtaminants like Metallic Chips,Dust) or else the degree of M and the safety contents B That Whenever there happens to be a Minor Deviation in the Component produced so far(To implement on C

That whenever there happens to be extremely minor change in details related to the component ,so much s becomes non mandatory(It becomes more of checks in regard to monitoring of the points of variation in reg

LEGENDS: For Development Rank Legend

Definition Point to be Implemented Review Required/Important from discussion point of view

(Blank) No Mark

Point which are not to be implemented but finally a plan is to produce which could verify as to why they a

For Responsibility Legend

Definition Prime Responsibility Co-Responsibility

00' Rev.No.

New Issue Description

QP) Document No. responsibilities for product development , Engg change and any

e and any Process change of existing items. below Responsibility Remarks QA Prod Matls

Document Reference

O O

O O O

O O O O O

O O O

O O O O O

O O

O O O O O O O O O O O O O O O O O

O O

here happens to be large scale difference in raw

to be

om the place/country of production ips,Dust) or else the degree of Moisture,Temperature,Pressure

roduced so far(To implement only for inspection of initial product)

ted to the component ,so much so that even the inspection ng of the points of variation in regard to 4M

n emented discussion point of view

ich could verify as to why they are not require to be implemented

New Issue Description

19/8/2004 Date

Advanced Product Quality Planning Status Report

Supplier Location Supplier Code Risk Assessment New: Site X
Other Risks Team Members Company/Title E-Mail

Date Review No.: Diamond Point:

Technology

Process

Program Model Year Lead Part No. Part Name Eng. Level User Plant(s)
Phone/Fax

Build Level

IPD Into Plant Date (MRD)

Status GYR Present History G G

Quantity

Concurred
No. SC's No. CC's

P.I.S.T. %

P.I.P.C. %

Risks: 1 = No Risk

3 = medium Risk (PSW part submission date can still be achieved - Special effort necessary)

5 = high (PSW part submission date endangered)

APQP Elements

GYR Status Present

Risk

Program Need Date

Supplier Timing Date

Closed Date

Resp. Initials

Remarks or

Evaluation

Engineer Assistance Required

History per Element

1 Customer Input Requirements 2 Agreed GQA 3 Product Feasibility 4 Sourcing Decision 5 Change Management 6 Environmental-Management/ IMDS/ ELV 7 Prototype Build Control Plan 8 Design Verification Plan 9* 10* 11* 12* 13 Facilities, Tools, Gauges Design FMEA DFMA @ Customer level Drawings and Specifications (Design Freeze) Information about Subcontractors

G G G G G G G G G R G G G G G G G G G G G G G G G G G G G G G G

G Y G G G G G G G R G G G G G G G G G G G G G G G G G G G G G G

1 3 2 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4/15/2005 4/15/2005 4/15/2005 4/15/2005 5/20/2005 6/3/2005 5/20/2005 4/29/2005 6/10/2005 5/13/2005 5/20/2005 5/20/2005 4/22/2005 4/29/2005 5/20/2005 5/13/2005 5/20/2005 5/20/2005 6/3/2005 6/3/2005 4/29/2005 6/10/2005 5/13/2005 5/10/2005 5/10/2005 5/13/2005 5/10/2005 6/17/2005 5/10/2005 5/10/2005 6/17/2005 6/24/2005

4/13/2005 4/13/2005 4/13/2005 4/13/2005 5/18/2005 6/1/2005 5/18/2005 4/27/2005 6/8/2005 5/11/2005 5/18/2005 5/18/2005 4/20/2005 4/27/2005 5/18/2005 5/11/2005 5/18/2005 5/18/2005 6/1/2005 6/1/2005 4/27/2005 6/8/2005 5/11/2005 6/8/2005 6/8/2005 5/11/2005 6/8/2005 6/15/2005 6/8/2005 6/8/2005 6/15/2005 6/22/2005

4/14/2005 OW TF 4/14/2005 AZ 4/14/2005 OW AZ 5/22/2005 TF 5/18/2005 TF 4/27/2005 AZ AZ AZ 5/18/2005 AZ 5/18/2005 AZ 4/20/2005 OW 4/28/2005 UE 5/2/2005 UE 5/11/2005 AZ 5/18/2005 AZ 5/18/2005 TF 6/1/2005 OW 6/1/2005 TF 4/27/2005 TF UE 5/11/2005 AZ 6/8/2005 AZ 6/8/2005 AZ 5/11/2005 TF 6/8/2005 TF 6/15/2005 AZ 6/8/2005 UE 6/8/2005 TF AZ AZ

In negociation Points to be cleared

1 Gauge may be unnecessary

see below

14* Logistic Concept 15* Packaging Specification (Serial & Spare Parts) 16* Design Validation @ Supplier Level 17* Design Validation @ Customer Level 18* Measurement Syst. Analysis/ Measuring Agreem. 19 Definition of Team for Serial Support 20 Definition of Quality Reporting 21 Prelaunch Control Plan 22 Safe launch concept incl. (SLC or EPC) 23* Manufacturing Process Flow Chart 24 Process FMEA 25 Working Instructions 26 Requalification/ Test Plan and Agreement 27 Preliminary Process Capability Study 28* 29* 30 31* Production Validation (PV) Testing Pre-production Run/ Run @ Rate Serial Control Plan Production Part Approval

32* PSW Part Delivery

APQP Elements mainly required for suppliers with design responsibility

COMMENTS

TGR / TGW (PDCA Format)

Part Name: Part Number
Defect / Problem Incharge Action Taken Target Date Implementati on date

Clause No.1.3

at)

Effectiveness of Checking 1st 2nd 3rd

Status Remarks OK/NG

INTIAL SUPPLY CONTROL

Part Name __________________________________ Part Number________________________________

Model

_______________

Station

__________________________

Customer _____________________________________________________

Start date of Initial Supply Control _________________________________________________________________________________ End Date of Initial Supply Control _________________________________________________________________________________ Remarks. ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________

Incharge ( Product Development) Extended upto (If required) ________________________________________________________________________________________

Reason for Extention _____________________________________________________________________________________________

Incharge ( Product Development)

Clause No.2.7

____________

____________

_____________

_____________

______________

______________

______________

_____________

_______________

CHECK SHEET FOR " INITIAL CONTROL PHASE"

1) NAME OF THE PRODUCT UNDER " Production Preparation Phase" --- WASHER ASSY. WINDSHIELD (YC-5) 2) NAME OF THE CUSTOMER :--- MARUTI SUZUKI INDIA LIMITED 3) PART NUMBER :- 38400M68K00/K10 4) DATE OF STARTING OF " ICP" :5) TERMINATION DATE OF " ICP" ( Period for Initial Control ) :6) PROJECT LEADER / CFT LEADER :-

S No
1 2 3 4

Points to be Implemented / Reviewed

Is the assembly line, stage under "ICP" is identified clearly --- "Under Initial Control Period" ? Are additional check points given in Supervisor check sheet for " ICP" ? Are additional check points given in Operator check sheet for " ICP" ? Are additional points in check sheet / WI for ICP clearly highlighted or is special identification of these additional points done ( Star mark etc) ? Are the Operators and respective Initial Flow Incharge aware of their / his responsibilities? Is the timing plan made detailing all the activities ?

Status
Implemented YES YES YES YES Not Implemented

5 6 7

YES YES

Is follow up of respective activities being done as per YES Timing Plan and is review status being updated in Timing Plan and are remarks for any delay or rescheduling recorded ? YES Is PDCA Approach followed for problem solving during ICP ? ( Rejection Analysis , rejection trend , To fillup the CM Sheet , to decide the actions and Is Process FMEA carried out ? Is cut off limit of RPN decided for taking actions on the basis of FMEA ? Is evaluation of Process capability done ? ( Once in 3 months) Is supplier audit planned and is carried out at decided frequency? Are operators being trained for the work they are performing ? ( training record / training plan / Skill matrix) Are Managers and Supervisors clear about their added responsibilities ? Is problem solving technique used for the faced problems ( inhouse , customer line rejection) ( See Counter Measure sheet , History of possible reasons , Action plan sheet , rejection trend , effectivemess of taken action) . Is " ICP" extended to supplier end also ? YES YES YES YES YES

9 10 11 12 13

14 15

YES YES

16

YES

17

18 19 20 21 22

Are identification tags used to identify initial products from the changed process and is the identification controlled through out the subsequent supplier process till despatch ? Is Initial product supplied to customer with necessary inspection reports and with FPP tag ? Are all the instruments calibrated ? Are all the fixtures validated ? ( Is Drawing available? ) Is MSA study carried out ? Are Breakdown trend maintained and is action plan made to reduce breakdown ? Signature of Initial Flow Incharge :YES

PHASE"

D (YC-5)

Responsibility / Remarks

CHECK SHEET FOR " TERMINATION OF INITIAL CONTROL PHASE

1) NAME OF THE PRODUCT UNDER " Production Preparation Phase" --2) NAME OF THE CUSTOMER :--3) PART NUMBER :4) DATE OF STARTING OF " ICP" :5) TERMINATION DATE OF " ICP" :6) PROJECT LEADER / CFT LEADER :-

S No
1

Points to be Implemented / Reviewed

Are all the problems occuring before SOP are resolved ans a recheck done to confirm that they remain solved ? Is any new problem arising in Initial Control Period resolved ? ( Verify the concerned records) Is cross verification of all the additional check points given in Supervisor check / Operator check sheet and Work Instructions sheet for " ICP" done ?Is there still a need for these additional points ? Are these documents revised before terminating the ICP? Is Cpk > 1.67 ( If not , is action decided to increase the Cpk value? ) ( Verify from the SPC records) Is ICP at supplier's end over. Are all the incoming parts related to ICP product OK ? Are Acceptance Standard revised ( Remove the extra check points -- if there is no quality issue during ICP ) Is History of all the problem faced during ICP maintained ( CM , rejection trends , History of possible reasons etc) Are Control Plan , FMEA rocess Flow Diagram , Work Instructions. Operator and Supervisor Check sheets have been updated ( Highlight the marks related to Customer Complaint , Customer Line rejection or related to Critical Process) Is the skill matrix of Operators and their Competency records updated ? Are the necessary Limit samples , Sketches available on all the required stages as per Control Plan Are all the jigs and fixtures suitable for their respective purpose ?

Status
Implemented

2 3

5 6

9 10

11

12 13 14 15 16 17 18 19

Are all the jigs and fixtures validated at regular interval ? Is History sheet of all the machines maintained ? Is time study carried out ? Are action taken for line balancing ? Is OEE carried out for this line ? Is the line capable of meeting Customers requirements ? Is MSA records updated as per Control Plan? Is there any repeated Breakdown ? Are all the machines suitable for their respective usage ? Are Production trial and Mass Production trial records available ? ( Verify the records) Signature of CFT Members :-

OF INITIAL CONTROL PHASE"

Status
Not Implemented

Responsibility / Remarks

INITIAL SUPPLY CONTROL SIGN OFF Part Number _____________________

Part Name ______________

Control duration : From ___________________ To _____________________ Extension (if any) _________________________________

Reason of extension _____________________________________________ Details of initial supply control : New component (Model) ___________________________ Design change (ECN number) ______________________ Process change : Process parameter change Tool/Die/Machine/Equipment change Layout change

Supplier change Operator change Relocated plant

S.No. 1 2 3 4

Control Item Customer complaints Inprocess rejection Incoming rejection Cpk Result of c'measure taken aginst problems during production preparation Result of c'measure taken aginst problems during initial supply control Any other

UOM numbers ppm ppm v alue current v s prev ious current v s prev ious

Specificat ion 0 30 30 1.67

Result at end of control duration

Effectiv e

6 7

Effectiv e

Result of Initial Supply Control Initial control checks can be terminated Initial supply control period extended by

NG NO days

OK YES

Approv ed by (Dev Distribution to CFT members : Head QA, Head Manf, Head Purchase, Head PE, Head Design

SIGN OFF

Name ____________________

_________________________

____

________________________

___

___

Supplier change Operator change Relocated plant

ficat n

Result at end of control duration

Remarks

tiv e

tiv e

OK YES days

Approv ed by (Dev p Incharge)

d Design

IPP Tags Initial Part Product Tag Part Name Part Number Reason of IPP Date of Production Inspected by Signature Clause No. 3.2

Clause No. 3.2

OBSERVANCE OF OPERATOR Operator Name

Section / Department

Rat

List of Activities performed by Operator Are the operator verification sheets completed daily by all shifts ? Are the tagging procedures being followed? Are the Non conforming rejection are located in the specified area. Procedure for carrying activities done as per the Operation standard

If Rating < 03, Operator counselling required, Training to be given to Operator

Clause No.11

ATOR
Rating Criteria 2 3 4 5

g to be given to Operator.

CUSTOME
PLAN

SI NO. OCCURRENCE

DATE OF

PART NAME

MODEL/ CUSTOMER

DEFECT

REPEAT NO

CUSTOMER COMPLAINTS VERIFICATION CHECKSHEET

DO
ACTUAL CLOSURE DATE

ROOT CAUSE ANALYSIS

ACTION TO BE TAKEN

TAR DATE

RESP.

SHEET
CHECK
FOLLOW UP / DATES 1 2 3 4 5 6 Horizontal Deployme nt

ACT

INSTITUTIONALISE THE PROBLEM WITH UPDATION OF FOLLO WORK CONTRO INSPECTI QUALITY INSTRUCTIO L PLAN ON STD ALERT NS

FMEA

WITH UPDATION OF FOLLOWINGS LESSON LEARNT

REMARKS

Process Precision Check

PART NAME:PART NO:Starting Point MODEL:DEFECT POSSIBILITIES 1 Missing 2 3 4 5
Sl.No

Team Menber

Date:-

End Point

6 Orientation 7 8 9 10
1 2 3

Operation Missing Reverse Double Wrong parts (different parts)

PROCESS STEPS

Proper Seating Damage Safety Identification

Defect Possibilities
OBSERVATIONS 4 5 6 7 8 9 10

Unloading of Raw Material

Loading of Finish Goods

ACTION

RESPONSIBILITY

TARGET DATE

STATUS

Clause No 13 MAKE A PLAN FOR PRECISION PRECISION

DAILY INSPECTION OF INSTRUMENT / EQUIPMENT / MACHINE

INSTRUMENT / EQUIPMENT / MACHINE NAME:CONTROL NO:S.NO PARAMETER TO CHECK 1 2 3 4 5 6 7 8

MONTH:9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 REMARKS

CHECKED BY VERIFIED BY LEGAND OK NG X OK AFTER CORRECTION APPROVED BY

QUALITY ALERT / FLASH NOTE

(Customer / In-house / Warranty / Supplier)
QA Date Time DEFECTS:Part Name Part No Model ACTION REQUIRED:Production Date Time

PHOTO/SKETCH:-

In Charge Prod. Note: Retension period :

In Charge QA

ANNUAL TRAINING PLAN Vs ACHIEVEMENT

Cat. Topic Duration Faculit No. of y Persons Facilities Department

YEAR Plan/ Actu al Apr. May Jun P A P A P A P A P A P A P A P A P A Total Date Sign.

Prepared By

Verified By

Approved By

Month Jul Aug Sep Oct Nov Dec Jan Feb

Operator level

Middle Mgt

Higher Mgt.

S.No

Topic

Date

Reasion for Delay

Next Date

Sign.

Approved By

Mar

DAILY STARTUP CHECK SHEET

(for Equipment/ Machine/ Instrument etc)
Name:No:Deptt./Section:Last Call/ Maint. Date:Month Call/ Maint. Due Date:Prepared By Resp.:Approved By

Parameter No 1 2 3 4 5 Parameter No 1 2 3 4 5 7 9 10 Opr. Sign. Sup. Sign. LEGAND Date 1 2

Parameter

Specification

Check Method

Freq.

Pr. No 6 7 8 9 10

Parameter

Specification

Check Method

Freq.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

OK Abnormality

NG

X Action Taken

OK AFTER CORRECTION Impl. Date Resp.

APPROVED BY Sketch (if any)

DAILY STARTUP CHECK SHEET

(for Equipment/ Machine/ Instrument etc)
Inst/Equi.Name:Control No:Deptt./Section:Resp.:-

S.No 1 2 3 4 5 7 9 10 Opr. Sign. Sup. Sign. LEGAND Date

Parameter to Check

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

OK Abnormality

NG

X Action Taken

OK AFTER CORRECTION Impl. Date Resp.

APPROVED BY Sketch (if any)

SKILL MATRIX
1 2 3 4 5 6 7 8 9 10 Revised on: Basic Knowledge only S.No EMP.NO PHOTO EMP.NAME Can work under supervision Plan Year Remarks September November February October January August March Minium no.of person req. for skill level June April May Minium no.of person req. for skill level Minium no.of person req. for skill level Minium no.of person req. for skill level July December Can handle independently Can train other Actual

A 4 7

NAME

TOPIC

DATE

REASION FOR DELAY

NEW DATE DATE

SIGN.