Question ID

1
2
3

Category
Sub Category
Facility
Open Area
Facility
Assembly Shop
Facility

Visual Displays

4
9
10
11
12
13
14
15
16
17

Facility
Reception
Financial Information

18

Production

19
20
21
22
23
24
25
26
27
28

Production
Production
Plant Engg
ME
ME
ME
ME
IE
IE
Tooling
SCM
MRB

Production
Production
Production
Production
Production
Production
Production

Question

Is there a safe assembly point?

Does the production areas have Diamond flooring of grade XXXX?
Are Information on EH&S hazards, as well as prevention and control methods, displayed in the work
area?
TATA logo of dimensions XXXX in blue

Remarks

physical things,
processes and
methods

Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13

Areas
Assembly
Programe Management
Facility & PED
Tooling
Safety & Security
ME
Quality & MRB
IT
SCM
IE
Admin (including housekeeping)
Finance
PPC

Sundeep
Sundeep
Jyoti
Sharanya J Sivaraman
Sharanya
Laxmi
Laxmi
Sundeep
Sharanya
Amey
Amey
Amey
Jyoti

Name
Sundeep
Jyoti
Sharanya
Amey
Laxmi

Areas
Assembly , Programe Management, IT
Facility, PED, PPC
Tooling, Safety & Security, SCM
IE, Admin (including housekeeping), Finance
ME, Quality, MRB

Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

Areas
Assembly
Assembly
Assembly
Assembly
Assembly
Assembly
Assembly
Assembly
Assembly
Assembly
Facility & PED
Tooling
Tooling
Tooling
Tooling
Safety & Security
ME
ME
ME
Quality & MRB
Quality & MRB
Quality & MRB
Quality & MRB
Quality & MRB
Quality & MRB
Quality & MRB
Quality & MRB
Quality & MRB
HR
HR
HR
HR
HR
PPC
PPC
PPC
PPC
PPC
PPC
PPC
IT
IT

SCM
IE
Admin (including housekeeping)
Finance
Programe Management

Checklist
Compliance to Skill Matrix as per SOP no SOP-XX-Y-ZZ
Compliance to Manpower Management as per SOP no SOP-XX-Y-ZZ
Compliance to Schedule Management as per SOP no SOP-XX-Y-ZZ
Compliance to Quality Compliance as per SOP no SOP-XX-Y-ZZ
Compliance to 6S as per SOP no SOP-XX-Y-ZZ
Compliance to Visual Factory as per OI no OI-XX-Y-ZZ/AA
Compliance to Shadow Boards as per OI no OI-XX-Y-ZZ/AA
Compliance to Total Productive Maintenance as per OI no OI-XX-Y-ZZ/AA
Compliance to Tool Control (Tool Chit) as per OI no OI-XX-Y-ZZ/AA
Compliance to Kanban / 2 Bin Systems as per OI no OI-XX-Y-ZZ/AA
Compliance to anenities & utilities as per SOP no SOP-XX-Y-ZZ
compliance to contractual requirements as per SOP no SOP-XX-Y-ZZ
Compliance to Configuration Management as per SOP no SOP-XX-Y-ZZ
Compliance to Tool Design,rework & Jig setting as per SOP no SOP-XX-Y-ZZ
Compliance to Tool calibration as per SOP no SOP-XX-Y-ZZ
Compliance to PPE Compliance as per SOP no SOP-XX-Y-ZZ
Compliance to Process Compliance as per SOP no SOP-XX-Y-ZZ
Compliance to Configuration Management as per SOP no SOP-XX-Y-ZZ
Compliance to contractual requirements as per SOP no SOP-XX-Y-ZZ
Compliance to In process quality as per SOP no SOP-XX-Y-ZZ
Compliance to Corrective Actions as per SOP no SOP-XX-Y-ZZ
Compliance to Supplier Quality Assurance as per SOP no SOP-XX-Y-ZZ
Compliance to Part Fit Check as per SOP no SOP-XX-Y-ZZ
Compliance to Quality Management System as per SOP no SOP-XX-Y-ZZ
Compliance to Material Review Board as per SOP no SOP-XX-Y-ZZ
Compliance to Receiving Inspection as per SOP no SOP-XX-Y-ZZ
Compliance to FOD requirements as per SOP no SOP-XX-Y-ZZ
Compliance to Consumable Maintenance as per SOP no SOP-XX-Y-ZZ
Compliance to Recruitment as per SOP no SOP-XX-Y-ZZ
Compliance to Leave Management as per SOP no SOP-XX-Y-ZZ
Compliance to Talent Development as per SOP no SOP-XX-Y-ZZ
Compliance to Employee Engagement as per SOP no SOP-XX-Y-ZZ
Compliance to Performance Management System as per SOP no SOP-XX-Y-ZZ
Compliance to Hardware Management as per SOP no SOP-XX-Y-ZZ
Consumable Management as per SOP no SOP-XX-Y-ZZ
Compliance to Material Handling & kitting as per SOP no SOP-XX-Y-ZZ
Compliance to Document Release as per SOP no SOP-XX-Y-ZZ
Compliance to Material Issue as per SOP no SOP-XX-Y-ZZ
Compliance to tracking of material consumption as per SOP no SOP-XX-Y-ZZ
Compliance to Swapping & reallocation as per SOP no SOP-XX-Y-ZZ
Compliance to software applications management as per SOP no SOP-XX-Y-ZZ
Compliance to server maintenance & security as per SOP no SOP-XX-Y-ZZ

Always

Often

Rating Scale
Sometimes

Rarely

Never

SIPOC

suppliers, inputs, process, outputs, and customers

1. Identify Business Needs / KPIs

2. Identify the stakeholders and their needs.
3. Map the needs of the business and process to specific KPIs defined by t
4. Plan who, how and when the KPIs should be captured and recorded?
5. Define Operating Mechanism
6. Define the tasks to be performed
7. Define the ownership and process of collecting data
8. Define how and through what mode the communication will be shared wi
9. Define Review and Feedback Mechanism
10. Define the review items, frequency for Meetings
11. Define the Process of CAPA and decision making on the basis of perfor
12. Identify the owners for action items and time line for process correction
How to pass the inputs of the lean manufacturing / 3P to the construction team
Program Tracking
Timelines for the activity for TPS

to specific KPIs defined by the organization.

captured and recorded?

munication will be shared with the stakeholders.

making on the basis of performance of metrics.

e line for process correction.
ruction team

Operating Rhythm can be defined as a set of pre-defined process of communication and int

of communication and interactions that should be present between different departments to ensure that the flow

ts to ensure that the flow of operations is not interrupted and is controlled as intended. It provides a structured

It provides a structured way of communication through which the stakeholders communicate to the project tea

unicate to the project team/operations and vice versa on items like roles, milestones, outcomes, targets and so o

utcomes, targets and so on that is aligned to the organizations vision.

Andon System in production areas. Significance assigned to different lights

Uni-directional flow
Value Stream Map exist and bottlenecks are clearly identified and prioritized
No Visual Blockages
Everything must be less than 1.5 meters (5 feet) in height
All utitily lines should be visible and properly colour coded.
All parts should be delivered within the forward or side reach of the assembler - literal poin
Use a water spider - the worker should never be required to walk to get parts
Use of Kanban / 2 Bin System for hardwares
Floor markings that identify the location of all essential items are in place
PM schedule for all plant equipments
Schedule for publishing updated BOM every month
Single day completion AOS
Visual Work instructions present

Ergonomics REBA score for the work

Quarterly evaluation of the work areas through Spaghetti Chart for optimum man-moveme

prioritized

e assembler - literal point of use

o get parts

optimum man-movement

Sl No.
Activity
1
Draft
SOP on
TPS
Contents
Operating
Instruction Manual
2
SOP - Implementation plan/ideas.
work instruction book that will be the home for all the detailed instructions
3
for implementing TSP. It will have multiple chapters and the chapters will
be
quite on
instructive.
believe
Srikanta
emailed use a template for this.
4
Training
writing anI OI
& Forms/
Checklist
Draft
the
list
of
chapters
and
the
subheadings
within them.
Preparation of individual OI
5
Checklist/Evaluation Form for new program
6
Checklist for each OI
1) Checklist used by new programs to know all the physical things,
7
processes and methods used to develop and implement a new operation
and
Ensuring all world best practices are included in the OI list
2)
The evaluation
usedthink
to evaluate
existing
ones.
inserting
everythingform
we can
of and then
simply
marking some as
8
future if they are not yet in use. This will create the inventory of practices
and guide us forward.
9
10
11
12

Syndication of Ois with key leaders

start routing this tool to key leaders in the three existing factories and
George to learn additions and perhaps organization ideas.
Reporting & Metrics for Prog Mgt
Roles & Responsibilities at each band
Deciding on the forum to review each level
Deciding on common metrics

Status
Accepted by John
Circulated

Responsibility

EDC
Remarks
Completed
30-Aug This activity can be effectively sta

Accepted by John

4th July

Completed on 14th July

10-Jul-14
21-Jul-14
30-Jul-14

Rejected

WIP

8-Aug-14

Praveen

Will be done post activity 5

14-Jul-14

30-Jul-14
21-Jul-14
Lakshmi

Is a parallel activity to the pt6 and

This may extend as it depends on

can be effectively started after the Ois are complete

activity to the pt6 and can be completed only after the OI checklist is done

end as it depends on the stakeholders

SCHEDULE FOR "OI" COMP

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36
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38
39
40

OI Description
3P
PRR(Production Readiness Review)
6S
Visual Factory
TPM(Total Productive Maintenance)
Tool Control
Kanban/2 Bin System
Self Sufficient Cell
Labour Accounting
Kaizen/Continous Improvement
TOP(Total Operational Performance)
FMEA(Failure Mode & Effective Analysis)
Consumable Management System
Oregon Productivity Matrix
Line Balancing
TBEM(TATA Business Excellence Model)
Skill Matrix
Performance Matrix
Operating Rhythm
Statistical Process Control(SPC)
RRCA(Reluntless Root Cause Analysis)
POKA YOKE
Spaghetti Study
Supermarket
Value Stream Map
19 Logistic Principles
20 Manufacturing Principles
Gemba & Genchi Genbutsu
Just In Time(JIT)
3M MANAGEMENT
Mandate Certifications of ISO & British standards EASA
Material Management
Risk Management
6 Sigma
Standardized Work Practices
Production Trouble & Action Book (PTAB)
QC Tools
SIPOC
PROCESS IMPACT ANALYSIS
PROCESS MATURITY ANALYSIS

SCHEDULE FOR "OI" COMPLETION

POC
Sundeep
Sharanya
Sundeep
Sharanya
Arin
Sundeep
Sundeep
Amey
Mani
Sundeep
Arin
Sharanya
Sundeep
Sundeep
Mani
Arin
Sharanya
Sharanya
vinaya
Mani
Amey
Amey
Sharanya
Amey
Mani
Mani
Mani
Sharanya
Sundeep
Amey

EDC
7/17/2014
7/16/2014
7/17/2014
7/18/2014
7/14/2014
7/17/2014
7/17/2014
7/18/2014
7/20/2014
7/11/2014
7/11/2014
7/16/2014
7/17/2014
7/18/2014
7/16/2014
7/18/2014

Sundeep
Amey
Amey
Arin
Mani
Mani
Mani
Mani
Mani
Mani

7/17/2014
7/19/2014
7/14/2014
7/14/2014
7/16/2014
7/15/2014
7/16/2014
7/16/2014
7/19/2014
7/19/2014

Draft
Prepared

AVAILABILITY
WITH CPD

YES
YES
YES

YES

YES
YES

7/16/2014
7/15/2014
7/16/2014
7/10/2014
7/16/2014
7/15/2014
7/18/2014
7/17/2014
7/19/2014
7/19/2014
7/16/2014
7/17/2014
7/16/2014

YES

YES

Already in CPD

YES

BASELINE
MATERIAL

Reviewed
jointly by
Team

YES

YES

YES

YES

YES
YES

YES
YES

YES

YES

Whether our understanding on the Checklist is correct?

Plan of action