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VENKATESWARAA INSULATION

ACHIEVE 100PPM / SQ MARK - CHECK LIST


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Activity Description / Action Plan

1)

Visual Control & Disciplinary Activities

Shop Floor Cleanliness

Responsibility

Target Date

Free From Mud, Oil, Dust, Scrap, etc.,


2

Wall Painting & Floor Painting

Clear Gangway & Pathway

Process Flow(I/P-Process-O/P)- Layout For Entire Factory


with Optimum Distance Between Each Process.

No Back & Forth Movement of Goods Against Process


Flow Layout

Process Location Identiification

Working Tables Should be Clean & No Rust

Working Height to be Maintained between 750-850mm.

"ACHIEVE SQ MARK / 100 PPM" Display in Key Areas.

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Uniform Dresses & Shoes for All Workers

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A3 & A4 Transparent Leafs to be replaced with Acrylic


Boards

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Performance Trend Charts to be Displayed in Key Area

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Conference / Training Hall Layout to be Done

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Utilities Such as Air & Water Lines are Properly Installed.

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Unused Goods are removed & Kept far away from Work
Place

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Organization's Performance with Product Display Case

Testing Facilities

Universal Testing Machine (UTM)

Shore 00 Hardness Durometer

Density/GSM Tester

Compression Set Apparatus

Temperature Sensor Gun

Colour Matching Cabinet

3)

Rejection Control

In-Coming, In-Process & Customer Rejection Data


Collection

Rejection Analysis, Action Plan with Effectiveness


Monitoring and linkage with Improvement.
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VENKATESWARAA INSULATION
ACHIEVE 100PPM / SQ MARK - CHECK LIST
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Activity Description / Action Plan

Separate area for Receipt materials inspection

Quarantine Area for incoming, In-process & Final

Responsibility

Target Date

Inspection
5

Rejected materials identification with Red Tag

Separate Area for Rework and Rejection Storage &


Separate Table Allocation for Rework

History of NC Part Occurrence incoming/In-Process/Final


Inspection

Scrap Yard to be Created with Defined Frequency


Disposal.

Scrap Register to be Maintained

4)

Machine Maintenance

Daily, Weekly, Monthly, Quarterly, Half-Yearly and


Annual Preventive Maintenance Plan.

Machine History Card

Critical Spares Stock Register / Display Board

Critical Spares Stock Storage Rack

Machine History Card

5)

Tool/Die Maintenance

List of Punching Dies

Tool/Die Validation in Fixed Frequecy

Tool History Card (No of Shots)

Punching Die Identification in sequence with respective


material Selection

Tool/Die Storage Layout to be made

Tools/Dies will be stored customer wise.

Sufficient Racks to be made for Tools./Dies Storage

6)

Display Board With Table On Each Machines

Display Board Quote Receipt & Order Finalization

My Machine

Machine Specifications

Work Instructions - English & Tamil (With Photos)

Annual Preventive Maintenance check List


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VENKATESWARAA INSULATION
ACHIEVE 100PPM / SQ MARK - CHECK LIST
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Activity Description / Action Plan

Daily/Weekly/Quarterly/Half-yearly M/c Check Sheet

Job Card

First-Off & Last-Off Samples Display

Responsibility

Target Date

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VENKATESWARAA INSULATION
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Activity Description / Action Plan

7)

First-Off&Last-Off Samples Identification & Storage Rack

First-Off & Last-Off Samples Storage at Racks

(With 1 Weeks Retention) with batch Identification

8)

QA Laboratory

Master Samples Storage with Identification in Racks

Master Accepted & Rejected Samples to be Stored in

Responsibility

Target Date

QA Lab with Lock & Key.


3

QA Lab Layout with Identification

Inspection Standards
a) Incoming Inspection
b) In-Process Inspection
c) Final Inspection

Customer Complaints' Status Board (Red Colour) to be


displayed at Factory To monitor the Effective Closure.

Appropriate Selection, Master List, and Calibration of


Monitoring & Measuring Equipments.

Part Identification Tag for Identification & Traceability


Purpose which reveals RM Lot, Work Order, Operator,
Mfg Date & Part Details.

Manufacturing / Work Standard (With Important Control


Points)
a) Pre-Production / Sheet Cutting
b) Semi-Automatic Adhesive Coating Machine
c) Die Punching Machine I,II & III.
d) Slicing Machine
e) Slitting Machine
f) Pouch Sealing Machine I, II & III.
g) Simultaneous Sealing & Cutting Machine
h) Lamination Machine
i) Packing
j) Raw Material Inventory Control
k) Finished Goods Inventory Control

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VENKATESWARAA INSULATION
ACHIEVE 100PPM / SQ MARK - CHECK LIST
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Activity Description / Action Plan

9)

Training

Skill Matrix & Job Responsibility to be Displayed in

Responsibility

Target Date

each process
a) Pre-Production / Sheet Cutting
b) Semi-Automatic Adhesive Coating Machine
c) Die Punching Machine I,II & III.
d) Slicing Machine
e) Slitting Machine
f) Pouch Sealing Machine I, II & III.
g) Simultaneous Sealing & Cutting Machine
h) Lamination Machine
i) Incoming / In-process & Final Inspection
j) Packing
k) Raw material Storage FIFO Control
l) Finished Goods Storage FIFO Control
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RM, WIP & FG Storage & Control

Raw Material GRN Identification

RM Storage as per material/Weight/Colour/Thickness

Raw Material Stock Staus Board with FIFO Control

Raw Material Storage Rack Identification

Raw material Stores Layout

Stores Stock Report - Review Meeting

Stores Issue / Receipt Register

Max. Level to be marked in RM Storage area

Material Lifting & Movementof weight between


20-500 Kgs Fork Lift to be Purchased

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Finished Goods to be Stored Customerwise at Racks

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Finished Goods Stock Report to be maintained.

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Max. Level to be marked in FG Storage area

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WIP-Standards has to be defined and implemented

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PSW/AOI & Revalidation Requirements

Customer Wise PPAP File Indexing while initial Submission

As per AOI/PSW, performing External Lab Testing


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VENKATESWARAA INSULATION
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Activity Description / Action Plan

Revalidation Plan

Revalidation Reports as per Customer Schedule

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Responsibility

Target Date

Customer Satisfaction

Customer PPM Monitoring, Analysis & Action Plan

Customer Complaints' closure effectiveness

Positive Feedback Collection and Analysis for


Improvement

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Health & Safety Measures

List of Personnel Protective Equipments (PPE)

PPEs at each machines For Operators


Gloves, Shoes etc.,

Shelf Life of Receipt Chemicals & Adhesives

Pressure Vessel to be calibrated

Entire Electrical wirings to be properly routed.

No Electrical outlets near Material Storage area.

Necessary Fire Extinguishers in Place

No Oil Spillage near Hydraulic Units

Min & Max to be Marked in all Pressure Gauges

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In/Out Identification to be Marked in All Pipe Lines.

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Colour Identification to be Introduced for Air & Water


Pipe Lines

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Entire EB Panel Boards to be Fenced for Safety

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Separate Area for Safe Assembly Point in case of


Emergencies

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Safety Posters and Safety Guards in Equipments.

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Improvement

Task Force Team For Improvement Activities

Cost Saving Projects Without Affecting Quality

Poka-Yoke implementation to Avoid Manual Errors.

Document Back Up Procedure to be implemented

Rewritable DVDs/External Hard Disk Procurement

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VENKATESWARAA INSULATION
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Activity Description / Action Plan

Responsibility

Target Date

Inspection & Packing Tables

Final Inspection Table with sufficient lights to be made.

Final Inspection Layout to be created with sufficient


Inspection Lines.

Skill Matrix for Inspectors to be Displayed at Final


Inspection Area
Packing Standard with Photos to be Displayed at
Final Inspection & Packing Table.

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Supplier Control

Supplier PPAP/ISAR/PSW Collection

Supplier RM Master/Limit Samples

Incoming Inspection Register

Incoming Rejection Analysis

Test Certificate for Incoming Materials

Supplier Quality Assurance-Procedure to be Documented.

Supplier Audit Check List / Auditing in Certain Frequency.

Supplier Parts Revalidation as required.

Identification & Traceability of Supplier Materials.

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Supplier Complaint Register

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Supplier Non-conformance Report & Counter Measures.

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Supplier Complaint Closures - Review in MRM.

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Production

Capacity Planning For Each Machine / Product / Men

Understanding the Present Capacity Utilization &


Upgrading for Increased Capacity

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Job Card For Each Process / Machines


Management Systems Implementation
ISO/TS 16949:2009 Quality Management Systems for
Particular to Automotive Requirements

ISO 14000:2004 Environmental Management Systems

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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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ENKATESWARAA INSULATION

E 100PPM / SQ MARK - CHECK LIST


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