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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.

10

Uniform Dresses & Shoes for All Workers

11

A3 & A4 Transparent Leafs to be replaced with Acrylic

Boards

12

Performance Trend Charts to be Displayed in Key Area

13

Conference / Training Hall Layout to be Done

14

Utilities Such as Air & Water Lines are Properly Installed.

15

Unused Goods are removed & Kept far away from Work
Place

15

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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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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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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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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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
10

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

10

Finished Goods to be Stored Customerwise at Racks

11

Finished Goods Stock Report to be maintained.

12

Max. Level to be marked in FG Storage area

13

WIP-Standards has to be defined and implemented

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11

PSW/AOI & Revalidation Requirements

Customer Wise PPAP File Indexing while initial Submission

As per AOI/PSW, performing External Lab Testing

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Activity Description / Action Plan

Revalidation Plan

Revalidation Reports as per Customer Schedule

12

Responsibility

Target Date

Customer Satisfaction

Customer PPM Monitoring, Analysis & Action Plan

Customer Complaints' closure effectiveness

Positive Feedback Collection and Analysis for

Improvement

13

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

10

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

11

Colour Identification to be Introduced for Air & Water

Pipe Lines

12

Entire EB Panel Boards to be Fenced for Safety

13

Separate Area for Safe Assembly Point in case of

Emergencies

14

Safety Posters and Safety Guards in Equipments.

14

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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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.

16

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.

10

Supplier Complaint Register

11

Supplier Non-conformance Report & Counter Measures.

12

Supplier Complaint Closures - Review in MRM.

17

Production

Capacity Planning For Each Machine / Product / Men

Understanding the Present Capacity Utilization &

Upgrading for Increased Capacity

3
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1

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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