Escolar Documentos
Profissional Documentos
Cultura Documentos
Supplier
Controlling Co.
HKMC Mgmt. Team
Assessor
Supporter
Eval. Date
ed Rubber)
Ver 1.0
Controlling Co.
Supplier Code
HMC :
%, KMC :
%, Other :
Mgmt. Representative
Tel. No.
Address
Rubber Compound
No. of Employees
ISO/TS16949 Certification
Major Customers
Equipment Status
Test Equipment
(Measuring Instruments)
RPA, MDR-2000, MV-2000, Disper tester 3000, Densimeter, Satra Ozone chamber, Zwick UTM, Ageing Oven
2. Evaluation Result
.Common Requirements
Initial Certification Date and Score
29.0
pts
.Industry Requirements
pts (
(Sign)
(Sign)
37.0
pts
Total
pts
66.0
pts
pts
Supporter
HKMC :
(Sign)
12.
00
No
Evaluation Category
2
3
1.0
2.0
1.5
2-1 Standards (Control Plan, Inspection Standard, Work Standard) Preparation and Revision History Implementation Status
4-1 1st Tier Supplier Inspection Agreement and Periodic Inspection/Test Status
3
3
6
2
4
3
3
4
2.0
1.5
3.0
1.0
2.0
1.0
1.5
3.5
4-2 Measuring Equipment Preparation/Control Status, Verification/Calibration Status (Including Gauge R&R)
3.5
5-1 Organizational Status for Establishing / Maintaining Quality Management System and Job Assignment Control Status
1.0
5-2 New/Transferred Team Member and Management Training (Including Special Characteristics Process and Foreign Operator
1.0
5-3 Control Status of Vulnerable Time Period for Quality Control (Late Night, Before and After Shift Changes, etc.)
1.5
5-4 Process / Customer Defect Correction and Countermeasure, Effectiveness Evaluation (Including Quality Target/Result)
2.0
50
29.0
6-1 Are stock inspection of raw materials and stock procedures being complied after standard?
2.0
6-2 Are FIFO procedure for raw materials and validity period established and being complied after standard?
2.0
3.5
4.5
7-3 Is the distinguishing management for mix prevention after weighting/mixing performed after standard?
4.0
8-1 Situation of condition management for mixed equipment (temperature, water, chamber temperature, gas etc.)
4.0
8-2 Standardization of mixing order and situation of compliance (insert order, time)
4.0
4.5
9-1 Are aged facilities and management for rubber (CMB,FMB) appropriate?
4.5
9-2 Are setting of maturation period by material classes and management standards being complied?
4.0
50
100
37
66
1-1 Status of Outsourced Part / Raw Material Inspection Agreement and Suitability Control of Inspection Standard
.Common Requirements
Outsourcing
Part Control
1-2 Receiving & Periodic Inspection Implementation Status for Outsourced Part / Raw Material
Outsourced Part / Raw Material Storage Condition (Contamination of Foreign Objects, Damage Prevention, FIFO, Inventory
2-2 Container Load Standard per Part and Handling Status, Part Container Control Status, Process 3C5S
Process
Control
2-3 Lot Traceability Control (Raw Material~Completed Part, Completed Part Shipping, etc.)
2-4 Key Process Quality Status Display Preparation/Display and Control Status
2-5 Design and 4M change history management
Equipment
Control
Testing
Quality
Management
Sub Total
.Industry Requirements
Raw Materia
Mix weighting
Kneading
Ripening
Pt.
Result
Alloted
Sub Total
Grand Total
Supplier :
Evaluation Opinion
Item 1-1
Item 1-2
Item 1-3
Item 2-1
Item 2-2
Evaluation Disqualification for score under 4.5 pts
Item 2-4
Item 2-5
Item 3-1
Item 3-2
Item 4-1
Item 4-2
Item 5-1
Item 5-2
Item 5-3
Item 5-4
Item 6-1
Item 6-2
Item 7-1
Evaluation Disqualification for score under 4.5 pts
Item 7-3
Item 8-1
Item 8-2
Evaluation Disqualification for score under 4.5 pts
Evaluation Disqualification for score under 4.5 pts
Item 9-2
Questions
1-1
Requirements
Item
Status of Outsourced Part / Raw Material Inspection Agreement and Suitability Control of Inspection Standard
Status of Outsourced Part / Raw Material Inspection Agreement
- Receive / Maintain a copy of 1st tier supplier inspection agreement for the customer supplied parts.
- Substitute inspection agreement with inspection standard when difficult to implement inspection agreement (Example: Raw material supplied by
large corporations, plating industry, etc.)
Suitability of Inspection Standard of Outsourced Part / Raw Material (Inspection Item, Inspection and Measurement Period, Mesurement Method,
etc.)
- Establishemt and implementation of inspection standard for the customer supplied parts
- Mill Sheet receiving status and periodic material property inspection status
Control plan implementation status for inspection items within the inspection agreement (including customer supplied items)
1) Outsourced Part / Raw Material Inspection Agreement and Inspection Standard not established
Criteria
2) Outsource Part / Raw Material Inspection Agreement / Standard implemented, but some key items omitted causing quality issues
Requirements
Item
Criteria
1-2
3) Outsourced Part / Raw Material Inspection Agreement / Standard implemented, but some items do not correspond with control plans and other
standards.
Requirements
0
0.5
1
1.5
5) Inspection Agreement has been implemented, and all details of Inspection standards and other related standards are satisfactory. Excellent
revision control implemented.
Receiving & Periodic Inspection Implementation Status for Outsourced Part / Raw Material
Receiving Inspection Log List Control Status
Daily Inspection, Periodic Inspection Standard / Procedure Preparation and Compliance Status
Pre / Post Inspection Identification and FIFO Control
Inspection Master (Master Sample) Control Status, Packaging Condition of Packaged Parts
Measuring Instrument / Inspection Equipment Retention and Utilization Status
Outsourced Part Inspection Result Control (Daily, Periodic, Reliability Inspection) and Assurance of Inspection Capability
Non-conforming Part Handling Procedure and the Countermeasure Preparation Status (Non-conforming Part Containment Control)
Raw Material receiving inspection and periodic inspection management(Millsheet receiving/check, self-verification, 3rd party test)
1) Outsourced Part / Raw Material receiving inspection standard and procedure not implemented, and any inspection is not being carried out for all
parts
2) Outsourced Part / Raw Material receiving inspection and periodic inspection requirements are insufficient, and inspection is not being carried out for
some of the parts
3) Outsourced Part / Raw Material receiving inspection and periodic inspection requirements are satisfactory, but some of the inspection have been
omitted
5) Receiving Inspection and Periodic Inspection requirements are satisfactory. Excellent countermeasure preparation and its effectiveness verification
1-3
4) Outsourced Part / Raw Material Inspection Agreement has been implemented. Inspection Standard and other related standards have been
prepared and the details are satisfactory
4) Outsourced Part / Raw Material receiving inspection and periodic inspection requirements are satisfactory
Item
Pts
2.5
3
Outsourced Part / Raw Material Storage Condition (Contamination of Foreign Objects, Damage Prevention, FIFO,
Inventory Control, etc.)
Warehouse Layout Status Map, FIFO Structure (Structural System, Receiving / Issuing Process Display)
Outsourced Part / Raw Material Management Condition (Damage, Corrosion, etc.)
Outsourced Part / Raw Material Identification Control (Inspection Status, Material Grade, Material of Long-term disuse, etc.)
Outsourced Part / Raw Material Storage Condition (Contamination of Foreign Object, packae damage, Use of packaging material from the raw
material manufacturer)
Residual quantity control status after a process input (Storage condition / Identification Indication / expiration date, etc.)
Questions
Criteria
1-3
Pts
1) Outsourced Part / Raw Material Control / Identification / Storage Standard, etc. procedure not established
2) Outsourced Part / Raw Material Control / Identification / Storage Standard have been established, but not properly controlled due to incompliance of
standards
3) Outsourced Part / Raw Material Control / Identification / Storage Standard have been established, but some modifications to requirements are
necessary
1.5
4) Outsourced Part / Raw Material Control / Identification / Storage Standard satisfy requirements
2.5
5) Outsourced Part / Raw Material Control / Identification / Storage Standard satisfy requirements, and controlled in conjunction with computer system
Issues / Observation
Item 1-1
Item 1-2
Verified arbon black - N765, MRN No - 8416; supplier Hi tech - lot qty 2000kg,
Lot no - RK80013294-002, lot no traceability not available in system, FIFO
not ensured, Supplier inspection report verified as per inspection standard ash content not specified in supplier report & found ok, Calibration status of
OZONE test cabinet verified, DOC - 26.04.16, certificate no - VITH/VIPL/F16F17/1
Item 1-3
Physical identification of left over carbon black N765 - 150 kg not available &
in system no traceability is there for left over batch, bin qty is being shown in
Issues / Observation
Physical identification of left over carbon black N765 - 150 kg not available &
in system no traceability is there for left over batch, bin qty is being shown in
system; linage with lot no in system required
Questions
Criteria
2-1
Requirements
Item
Standards (Control Plan, Inspection Standard, Work Standard) Preparation and Revision History Implementation Status
Document Control Condition such as Control Plan / Work Standard Preparation and Revision Control
- Condition Control / Self Inspection Item, Specification, Period, Control Assignment, Record Control, Non-Conformance Handling
(Including Verification of Key Requirement/Necessity Item Omission Status)
Conformity and Connection Status between Work Standards, Control Plans and Inspection Standards
Process FMEA Preparation and Verify in connection with Quality Document Details (Recommandation)
1) Standards such as Control Plan, Work Standard, Inspection Standard, etc. not prepared
2) Control Plan, Work Standard, Inspection Standard have been prepared, but key inspection items / standards haven been ommitted
3) Control Plan, Work Standard, Inspection Standard have been prepared / displayed, but not corresponding with the actual control conditions
4) Control Plan, Work Standard, Inspection Standard, Process FMEA, etc. satisfy requirements
5) Control Plan, Work Standard, Inspection Standard, Process FMES, etc. satisfy requirements. Excellent document revision history control
2.5
3
Container Load Standard per Part and Handling Status, Part Container Control Status, Process 3C5S
Suitability of Display and Identification of Part Identification Tag / Process Transfer Tag for Prevention of Part Mixing
- Lot Control Status such as the Identification of Inspection Status of Completed Part, etc.
Standardization of Completed Part Container per Part and Customer Approval Control (Load Quantity / Weight)
- Industries that are, realistically, hard to standardize and approve container shall establish own control standard (Verify control status)
(Verify Container Control and Handling Condition, ex: Surface Treatment, Heat Treatment, Same Container for Receiving / Shipping from
Suppliers)
- Container Selection considering the characteristics of Part (Prevention of Inflow of Foreign Object, Contamination Prevention Cover, etc.)
- Multi-Level Loading and Plant Floor Storage Condition (Paper Box, Plastic Box, Designated Container, etc.)
Periodic Inspection of Illumination Level in the work areas / inspection areas
- Illumination Level Control Standard Preparation / Implementation Status (Measuring area: Illuminatino Level of each Key Processes)
Periodic 3C5S checks to Improve Plant Floor
- Objective Evaluation through Utilization of Check Sheet and Point System (Recommendation)
1) Standardization of Part Handling, Part Identification and Customer Approval Control not implemented
2) Standardization of Part Handling, Part Identification and Customer Approval control implemented but not complied appropriately
Criteria
2-2
Requirements
Item
Pts
0
1
Questions
Criteria
NO
3) Some of the requirements for standardization of part handling, part identification, customer approval control, illumination level control, etc. are not
satisfactory
1.5
4) The requirements for standardization of part handling, part identification, customer approval control, illumination level control, etc. are satisfactory
2.5
5) All above requirements are satisfactory, and implemented excellent periodic checks and improvement activities for 3C5S
Requirements
Item
Pts
Lot Traceability Control (Raw Material~Completed Part, Completed Part Shipping, etc.)
Preparation, Control and Record Condition for Lot Traceability of Outsourced Part / Raw Material, Subsidiary Part and Completed Part
- Suitability of Process Transfer Tag Utilization / Control and Record Condition
- Part / Press Die Lot No. Control Status, Part Container Identification Status, Long-Term In-Process Part, etc.
- Prevention of Residual Part Inflow and FIFO
- FIFO plan preparation and compliance status when Bar-Code system is Implemented
For Security / Safety Part, Security / Safety Process shall be indicated to be identified on the Part (Lot Mark, Identification Mark, etc.)
2-3
1) Lot Traceability Control Standard not prepared, and Record Control not implemented
Criteria
2) Lot Traceability Control Standard prepared, but Record Control not implemented
3) Lot Traceability Control prepared and implemented, but traceability not verified due to partially omitted record control
4) Requirements for Lot Traceability Control Standard and Security / Safety Part are satisfactory
5) Requirements for Lot Traceability Control Standard and Security / Safety Part are satisfactory, and controlled in conjunction with computer system
such as the barcode system
Requirements
Item
2-4
1.5
3
4.5
6
Key Process Quality Status Board Preparation Details and Display Locations
- Details : IQS Improvement, Field Claims, Advance Verification Part, Non-conforming Part found at Customer/HKMC location
- Location : Display in Relevant Process
(Example: Receiving Inspection Process, Relevant Process of Quality Issue Occurrence, Completed Part Inspection Process)
Prepare / Update the most updated quality status board with most recent quality issues
(Verify update status: minimum 1 / month)
Display Key Process Quality Status Board. Verify the information understanding level of team members and managers for the relevant process
Identification of Critical Process and Key Control Process in Work standard, Inspection Standard
1) Critical Process and Key Control Process not identified, nor displayed, in Work Standard or Inspection Standard
2) Critical Process and Key Control Process identified, but Quality Status Board not prepared / displayed
Criteria
3) Requirements for quality status preparation / display satisfactory, but not complied by the team members / managers due to lack of understanding
for the requirements
4) Requirements for quality status preparation / display and the understanding of details by the team members are satisfactory
0
0.5
1
1.5
Criteria
NO
Questions
5) Requirements for qualtity status preparation / display and the understanding of details by the team members are satisfactory. The information is
updated periodically and well controlled.
Pts
2
Issues / Observation
Item 2-1
Item 2-2
Issues / Observation
Item 2-4
Moulding return batches data displayed on shop floor, verified for the
month of May-16, most recent issues being discussed in daily production
meeting, board of daily production meeting not displayed, Q-triangle to be
implemented with information of most recent issues daywise.
Issues / Observation
Questions
Requirements
Item
Pts
Criteria
3-1
1) Equipment daily inspection control standard not established and the daily inspection not performed
2) Equipment daily inspection control standard established and the inspection being performed, but some inspection items omitted
3) Equipment daily inspection and gauge verification / calibration being performed, but some of the requirements are not satisfactory
1.5
4) Equipment daily inspection and gauge verification / calibration requirements are satisfactory
2.5
5) Equipment daily inspection and gauge verification / calibration requirements are satisfactory. Excellent improvement activities
Criteria
3-2
Requirements
Item
Periodic Inspection for Equipment Preventive Maintenance Activities and Spare Part Control Status
2) Equipment Periodic Inspection Plan established, but for some equipment, the plan not yet established for some equipment
3) Equipment Periodic Inspection being implemented as planned,m but maintenance / repair required for some equipment
1.5
4) Equipment Periodic Inspection and Spare Part Control requirements are satisfactory
2.5
5) Equipment Periodic Inspection and Spare Part Control requirements are satisfactory. Improvement activities to prevent reoccurrence
are continually performed
Issues / Observation
Item 3-1
Item 3-2
Questions
Requirements
Item
Criteria
4-1
Requirements
Item
Pts
1) Inspection standard not prepared and implemented because the Inspection Agreement, per part, has not been concluded
2) Insufficient inspection standard preparation and implementation because the inspection agreement has not been concluded for some parts
3) Inspection agreement has been concluded, but some of the requirements for the completed part inspection standard and the periodic
inspection are omitted
4) Inspection agreement has been concluded and the requirements for the completed part inspection standard and the periodic inspection
are satisfactory
3.5
5) Inspection agreement has been concluded and the requirements for the completed part inspection standard and the periodic inspection
are satisfactory. Excellent revision history control
Mesuring Equipment and Inspection Fixture Reliability Assurance Status (Verification/Calibration Period Set, Calibration Condition)
Mesuring Equipment Verification/Calibration Schedule vs. Result Control Status (Measuring Equipment Verification/Calibration Report, Tag
Attachement Status, etc.)
Periodic Gauge R&R Performance Status
For High-Priced Measuring Equipment, Certification from the 1st Tier Supplier or Approved Testing Institution Required (Example: CMM,
Chemical Component Analyzer, etc.)
Criteria
4-2
1) Necessary measuring equipment not prepared and verification/calibration not performed (including externally performed
verification/calibration)
2) Some necessary measuring equipments available, but verification/calibration not performed for the equipments
3) Necessary measuring equipments available and verification/calibration performed for the equipment, but the gauge R&R not performed.
4) Necessary measuring equipments available, and the verification/calibration performance condition is satisfactory. Gauge R&R performed
5) Necessary measuring equipments available. Excellent verification/calibration and gauge R&R performance status (Good PostCountermeasure and Countermeasure Implementation History)
3.5
4
Issues / Observation
Item 4-1
Item 4-2
Calibration plan v/s actual verified for the month of May-16; calibration of zwick
testing m/c - Z020 verified - DOC - 10.04.15 - as per date it is expired but
machine is installed in Sep-15, masters not available for testing equipments
R & R plan available verified for thickness gauge - LAB/INS/28
Questions
5-1
Requirements
Item
Organizational Status for Establishing / Maintaining Quality Management System and Job Assignment Control
Status
Internal Quality Management System Establishement and Implementation Status
- Quality Manual/Procedure/Instruction Availability and Implementation Status
- Team Organization Status for Set-Up / Stablization
- Detailed Job Assignment Preparation Status
Basis for Quality Management System Implementation Target and Improvement Activities to Achieve the Target (Post-measure)
Criteria
2) Team / Department for setting-up / implement QMS organized, but the job assignment not prepared
Requirements
5-2
4) Team organized for maintaining QMS and job assignment prepared. The target / result control is satisfactory
1.5
Criteria
New/Transferred Team Member and Management Training (Including Special Characteristics Process and Foreign
Operator
1) No training performed because of no documentation of training procedure nor training plan establishment
3) Annual internal/external training plan established, but the training plan is insufficient and some trainings are not performed
4) Annual internal/external training performed as planned, and the qualification certification control status is satisfactory
5) Excellent annual training performance, and the qualification certification control for the key process operators and inspectors is satisfactory
Item
0.5
3) Team organized for maintaining QMS and job assignment prepared, but the QMS target set only in formality
5) Works are processed in accordance with the organization set-up / job assignment. Excellent improvement activities for achieving targets
Item
Pts
0
0.5
1
1.5
2
Control Status of Vulnerable Time Period for Quality Control (Late Night, Before and After Shift Changes, etc.)
5-3
NO
5-3
Criteria
2) Control Standard established, but the standards are insufficient and not well controlled
3) Control Standard is satisfactory, but countermeasures not implemented and insufficiently controlled when non-conformance occurs
4) Control Standard and Control Status satisfactory
5) Control Standard and Control Status satisfactory. Excellnet analysis / improvement measure performed when problems occur
Requirements
Criteria
5-4
1) Control Standard not established for Quality Control during vulnerable time period
Item
Pts
0
0.5
1
1.5
2
Process / Customer Defect Correction and Countermeasure, Effectiveness Evaluation (Including Quality
Target/Result)
Establishment of Quality Targets and Detailed Implementation Plan. Notification of Daily Quality Result and Monthly Comprehensive Result
to 1st Tier Supplier
- Result Control in comparison with the Targets from Previous Year (Input into VAATZ system lead by 1st Tier Supplier)
Process Defect (Production Quantity, Defect Quantity, PPM), Customer Defect (Delivery Quantity, Defect Quantity, PPM), Outsourcing
Defect (Receiving Quantity, Defect Quantity, PPM)
- Establish Improvement Measure and Continual Result Control for Target Shortfalls
Periodic Process/Customer Defect Cause Analysis/Corrective Action/Effectiveness Verification/Horizontal Deployment Implementation Status
2) Process/Customer/Outsourcing Defect Status is controlled, but the basis for target setting is insufficient. Some result control have been
omitted.
3) Process/Customer/Outsourcing defect Status is being summarized, but the quality issue improvement activity is insufficient
4) Process/Customer/Outsourcing Defect Status summarization and Improvement activity satisfy requirements
5) Process/Customer/Outsourcing Defect summarization and Improvement activity satisfy requirements, and horizontal deployment activity to
other car models is excellent
2
3.5
4
Issues / Observation
Item 5-1
Item 5-2
Item 5-3
Issues / Observation
Ispection standards available, same are being verified during night shift, log book also
available for communication during shift change, verified testing records of 20.06.16 NR3055, batch no - 622-625, For maintenance activities supervisor is not available in C
shift need to be call from home in case of urgencies.
Item 5-4
Nc batch target is less than 0.2%, Moulding returned batch 0.25% - target v/s actual verified
- under target
NC management procedure is there.
2 complaints raised to supplier in the month of June-16: 16.06.16
1. Foreign material in raw rubber - PVR 1220 - supplier - Reliance industries - report is
awaited from supplier
2. ISNR-5 raw rubber - used in rubber compound & Ts2 observed out of spec - date 13.06.16, lot no - 12B38, MRN no - 8186 - response still awaited from supplier no actions
taken by supplier - KL rading company (Travancore rubber & Tea comapny)
. Evaluation
Industry Requirements (Raw Material)
NO
Questions
Criteria
6-1
Requirements
Item
Are stock inspection of raw materials and stock procedures being complied after standard?
Requirements
Criteria
6-2
1) There is no supervision standard for setting standard of procedure, inspection and storage for material
0.0
2) The standard of procedure, inspection and storage for material has been established but is not observed.
1.0
3) The standard of procedure, inspection and storage for material has been established but some observation is missed
2.0
4) The standard of procedure, inspection and storage for material has been established and it is good but it needs to compensate the present
condition
3.5
5) The standard of procedure, inspection and storage for material has been established and it is good and the present condition is excellent
Item
Pts
4.0
Are FIFO procedure for raw materials and validity period established and being complied after standard?
State of FIFO procedure and observation
Management of distinguishment and putting other substance before and after inspection
Management state of posting status board of raw material and setting expiration date for each material
[Computerization] Computerization of raw material FIFO and aging (Bar code system)
- Prevention of raw material mixing, First In First Out, Raw material aging
- Raw rubber sheet : 6 Months from production
- Aditives : no longer than 1 year with not opened condition
0.0
1.0
3) It does not manage posting status board and expiration date but FIFO procedure is observated
2.0
4) It needs to compensate to manage expiration date but FIFO procedure and posting status board is managed
3.5
5) Quality management which is FIFO, posting status board, management of expiraton date and so on of stocked parts is excellent
4.0
Issues / Observation
Item 6-1
Operation standards for raw material are defined - verified for zinc oxide; Raw
material identified in case of storage requirements in controlled tempreature; list
available - OS/Lab/09 - chemicals verified as per list lying in AC room; Vulkalent
EC, tempreature & humidity monitoring is there alarm system to be
implemented.
Moisture content & mooney is being verified in raw rubber & for compounding
chemicals are being verified for moisture content - verified for SVR CV 60 raw
rubber lot no- 1871-1897 & for IPPD (Antioxidant) lot no - 20160121
Item 6-2
FIFO is defined, Verified for carbon black N765 lot no 8416, shelf dife defined
for all raw materials in raw material operation standard, verified fro IPPD - shelf
life 2 years, same is displayed on barcode
Pick me first stickers also displayed to maintain FIFO
Raw rubber shelf life defined is min 1 year & max 3 yrs against requirement of 6
months
Additives - min 6 months & max - 3 yrs against requirement of 1 year
. Evaluation
Industry Requirements (Mix weighting)
NO
Questions
Criteria
7-1
Requirements
Item
Criteria
7-2
Requirements
Item
Item
Pts
0.0
1.0
2.0
4) Formulation standard for material classes is established and being complied, but the record management is lacking
3.5
5) Formulation standard for material classes is established and being complied, and the record management is clear
4.0
0.0
1.5
3) weighting standard is established and being complied, but result values are not being recorded
3.0
4) Computional system of weighting standard and record management is established, but prevention of lacking weighting F/Proof is not possible
4.5
5) weighting results and transfer documents are utilized and F/Proof is excellent due to establishment of computional system
6.0
Is the distinguishing management for mix prevention after weighting/mixing performed after standard?
7-3
Questions
Require
ments
NO
Criteria
7-3
Pts
5
0.0
2.0
3) Missing identification management of process transfer document/label etc. for mix-prevention after weighting/mixing
2.5
4) Satisfying identification management of process transfer document/label etc. for mix-prevention after weighting/mixing
4.0
5) Computerization of production planning for manufacturing processes,management for performance and lot record are being complied and
are matching with the products
5.0
Issues / Observation
Item 7-1
Automatic weighing system implemented by rice lake is implemented,
Weighing formulae fixed operator is doing loading as per standard formulaeverified for current chemical weighing for NR4550, traceability is from final
rubber compound report, WIP identification & traceability is missing
Item 7-3
Issues / Observation
Automatic system of weighing is there, only that bin will open which is required
as per ongoing formulae, barcodes are being generated for every process
transfer & same are being scanned, final rubber compound traceability & FIFO
is good but being managed manual
. Evaluation
Industry Requirements (Kneading)
NO
Questions
8-1
Requirements
Item
Situation of condition management for mixed equipment (temperature, water, chamber temperature, gas etc.)
State of verifying routine inspection of equipment and establishment of standard for equipment conditions
Verifying establishment of plans for regular equipment inspections and state of conduction
Situation of equipment condition management and standard for record management
- Standard setting and routine inspection of coolant temperature, chamber temperature, roll temperature
[F/P] Automatic control of process parameter, temperature, time and wattage at mixing process
- Mixing rubber temperature real time monitoring device
- Automatic coolant control device
3) Lacking management condition of mixing equipment and hand regulation management of cooling water
2.5
4) Satisfying management of mixing equipment and management for temperature adjustment of cooling water, but no F/Proof
5) Excellent management of mixing equipment and temperature adjustment of cooling water due to F/Proof
Criteria
Requirements
0.0
2) Standardization of mixing order is done, but corresponding process was not published and lacks in compliance
2.0
3) Mixing order is standardized and corresponding process is published but lacking in compliance
2.5
4) Mixing order is standardized and published, compliance is satisfying, but of mixing condition records are partly missing
4.0
5) Mixing order is standardized and published, excellent compliance of mixing condition and record management
5.0
teria
8-3
0
1.5
Item
Item
Requirement
s
Criteria
1) Mixing equipment is old, maintainence is not possible and cooling water is not circulating
8-2
Pts
0.0
8-3
Questions
Criteria
NO
Pts
1.5
3) Inspection standard is established and is being conducted after standard, but customer-requested content is missing
3.0
3) Inspection standard is established, is being conducted after standard and record is satisfying, but supplement of analysis management is
required
4.5
5) Conduction after inspection standard, record keeping of inspection result data and history management are excellent
6.0
Issues / Observation
Item 8-1
Routine equipment inspection is being done, verified daily check sheet - for
K2A intermixer
Dumping criteria defined - based upon Temp, time & energy
Mixing rubber tempreature specification defined in OPI - for automatic mixing &
thermocouple is there in mixer for monitoring, display is there on machine
Chiller is there for maintaining tempreature- alarm is there for tempreature out
of spec for controlling chiller temp
Testing defined in case of premature dumping
Item 8-2
Mixing order is defined - OPI to be corrected for chemical addition - validation
of programme to be done (programme to be corrected as per defined
commands)
Identification sticker is there - lab tested ok & batch expiry date is also
mentioned
Analysis of hold batch is there improvement required, verified for rubber batch
no 648, compound code - NR4548
06.05.16, incoming testing reports for
Issuesdated
/ Observation
raw material used in rubber compound also verified
. Evaluation
Industry Requirements (Ripening)
NO
Questions
Criteria
9-1
Requirements
Item
0.0
2) Holding of storage room, but room narrowness and thermostat,hygrostat are not established
1.5
3) Holding of storage room, but physical property of rubber CMB, FMB is changed due to missing installation of thermostat, hygrostat
3.0
4) Holding of storage room, satisfying management of thermostat and hygrostat installed, but no alarm system in case of abnormal occurrence
4.5
Requirements
6.0
Are setting of maturation period by material classes and management standards being complied?
Criteria
9-2
5) Holding of storage room, management is excellent for thermostat and hygrostat, and F/Proof is managed by installing an external alarm
system in case of abnormal occurrence
Item
Pts
2) Storage time of each material is set but it does not managed posting current state and record
1.5
3) Setting storage time for each material is observated but record of expiration date on some material is missed
2.5
4) Posting standard of storage time for each material, management of coming into and out are excellent but expiration date and management of
other substance need to compensate
5) Posting standard of storage time for each material, management of coming into and out, expiration date and management of other substance
are excellent
Issues / Observation
Evaluation Disqualification for score under 4.5 pts
Batches stored in controlled temp conditions, temp & humidity monitoring is
there; Alarm system for final rubber compound store in case of temp & humidity
control is not there, reaction plan for abnormal situation (like temp out of spec,
humidity out of control to be made); variation in temp & humidity records
observed.
Calibration report of tempreature & humidity indicator verified - certificate no
AACPL/TH/TIHI/160105.3.2 - doc - 05.01.16 , cdd - 05.01.17
Master calibration certificate not matching - certificate no mismatch
Item 9-2
FIFO of final rubber compound is being controlled manually - shelf life defined
- 21 days, barcode stickers for each rubber compound are being generated but one barcode for one batch & there are 4 spools in one batch identification
on each spool is by mentioning rubber compound no on individual spool where
expiry/shelf life is not mentioned - verified for rubber batch no 602 - rubber
compound 60NR98
Frequency of measuring moisture content of final rubber compound in case of
hyundai will be done, spec will be reviewed - 0.5% & below current spec is 1.0
%
2 black
3 in ricelake system
Improvement Measure
Evaluation Date: 2
Due
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
7 required
25.06.16
25.06.16
25.06.16
black.
Cleaning procedure for bin cleaning of chemical weighing is
11 required .
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
OPI.
15 is required.
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
25.06.16
15.
26 humidity in lab.
25.06.16
25.06.16
25.06.16
(Sign).
(Sign).
2nd Tier
25.06.16
(Sign).
Mr. Guriya
Mr. Guriya
Mr. Guriya
Mr. Basak
Mr. Basak
Mr. Basak
Mr. Tomar
Mr. Parminder
Mr. Basak
Mr. Basak
Mr. Basak
Mr. Manjit
Mr. Mukesh
Mr. Nalin
Mr. Guriya
Mr. Guriya
Name
Name of
of Process
Process
Name
Name of
of Process
Process
Classif.
Classif.
Item
Item
Detailed Item
Detailed Item
Findings
Findings