Commodity:-Sheet Metal & Prop: Daily Work Management - Supplier Quality

Daily Work Management - Supplier Quality
Commodity :- Sheet Metal & Prop

S.No. Area
1 DWM Monthwise.
2 LR PPM (Ownership supplier)
3 CVL monitoring.
4 Audit summery.
5 Special Project.
6 Training
7 IP
8 DFR
9 QMS Status.
10 Debit Note
11 TGR TGW
Supplier Quality
Officer :- Mukesh Gupta

Commodity :- Sheet Metal & Prop

S.No. Area
Monitoring
PQCDSM Responsibility
Frequency
1 DWM Monthwise. Q Monthly Mukesh Gupta
2 LR PPM (Ownership supplier) Q Monthly Mukesh Gupta
3 CVL monitoring. Q Monthly Mukesh Gupta
4 Audit summery. Q Monthly Mukesh Gupta
5 Special Project. Q Monthly Mukesh Gupta
6 Training Q Monthly Mukesh Gupta
7 IP Q Monthly Mukesh Gupta
8 DFR Q Monthly Mukesh Gupta
9 QMS Status. Q Monthly Mukesh Gupta
10 Debit Note Q Monthly Mukesh Gupta

ity
Officer :- Mu
Author:
Achievement
Level 1 - Department as per Parameter
Level - Routine L5 Target Identification & monitoring mechanism exis
April'15 May'15 June'15 July'15

Level Aug'15following
2 - Department Sep'15
Revised Oct'15
approach of Nov'15 Dec'15
DWM (Deployed thru MP-CP)
Level 3 - Control Limits are identified for Routine Parameters and abnormalities are identifie
trends
Level 4 - Department is following IT enabled DWM & Standardization System and Dashboar
taking Decisions
& monitoring mechanism exist
Jan'16
ployed thru MP-CP) Feb'16 Mar'16
nd abnormalities are identified through
ization System and Dashboards are used for

Month :- Feb-16 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots
% GR Rejection Inspected Lots
% GR #DIV/0!
Rejected Qty
LR PPM Received Qty
LR PPM #DIV/0!
RQA MIS /DFR

updation in eye Daily monitoring in eye chart
chart
No. of CVLs Raised 0 0 0 0
(Cum) Closed 0 0 0 0
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)
No. of SCAR Raised 0 0 0 0

(DFR) Closed 0 0 0 0
No. of days for SCAR no. 14 14 14 14

closure of SCAR Days 0 0 0 0
Audit Plan Vs. Plan 0 1 3 1

Actual Actual 0 0 0 0
Plan 0 1 3 1
No. of visit days
Actual 0 0 0 0
Monthly
Closed File attached
Doc. Verified File attached
VPPAP Doc. RFT File attached
VPPAP Audits File attached
Audit RFT File attached
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Solution Identification
Solution validation/
Selection
Solution Implementation
Parked
Improvement
Monthly - File Attached
Projects
Training Monthly - File Attached

Significant
achievement
No. parts handed

overRev:03
DWM//04/01
Effective Date:- 28.04.2010

w5 Total
hly
/0!
/0!
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
5
0
5
0
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Jan-16 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 29
% GR Rejection Inspected Lots 948
% GR 3.06
Rejected Qty 156

LR PPM Received Qty 276091
LR PPM 565
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 0 1 0 4
No. of visit days
Actual 0 0 0 4
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
8
6
6
91
5
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
5
4
5
4
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Dec-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 32
% GR 3.31
Rejected Qty 33
LR PPM 108
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 0 1 3 3
No. of visit days
Actual 0 1 3 2
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

Officer :- Mukesh Gu
Total
0
0
14
0
0
0
14
0
7
6
7
6
ched
ched
ched
ched
ched
Month :- Nov-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 22
% GR 3.33
Rejected Qty 18
LR PPM 113
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 1 0 1 3
No. of visit days
Actual 0 0 1 3
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
1
3
16
3
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
5
4
5
4
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Oct-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 5
% GR 0.23
Rejected Qty 76
LR PPM 193
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 0 1 0 2
No. of visit days
Actual 0 1 0 1
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
5
3
95
3
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
0 3
0 2
0 3
0 2
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Sep-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 2
% GR 0.09
Rejected Qty 42
LR PPM 116
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 2 0
(Cum)



Plan 1 2 0 3
No. of visit days
Actual 1 2 0 2
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
1
9
29
6
0 1
0 1
14 14
0 0
0 0
0 0
14 14
0 0
6
5
0 6
0 5
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Aug-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 21
% GR 0.66
Rejected Qty 48
LR PPM 94
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 31 0
(Cum)



Plan 1 0 3 3
No. of visit days
Actual 0 1 2 1
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
1
6
85
0 1
0 1
14 14
0 36
0 0
0 0
14 14
0 0
7
4
7
4
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Jul-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 37
% GR 0.79
Rejected Qty 50
LR PPM 87
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 0 2 2 1
No. of visit days
Actual 0 1 0 0
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
6
9
26
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
0 5
0 1
0 5
0 1
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Jun-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 6
% GR 0.11
Rejected Qty 30
LR PPM 60
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 0 2 2 1
No. of visit days
Actual 0 1 2 1
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
0
1
22
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
0 5
0 4
0 5
0 4
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- May-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 3
% GR 0.05
Rejected Qty 254

LR PPM 510
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 1 1 2 0
No. of visit days
Actual 0 1 2 0
Monthly
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects

Significant
achievement
No. parts handed

overRev:03
DWM//04/01

w5 Total
hly
9
5
4
21
0
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
0 4
0 3
0 4
0 3
ached
ached
ached
ached
ached
hly
e Attached
e Attached
e Attached
e Attached
e Attached
Month :- Apr-15 Commodity :- Sheet Metal & Pr Officer :- Mukesh Gu
WK 1 WK 2 WK 3 WK 4
Monthly
Rejected Lots 6
% GR 0.11
Rejected Qty 41
LR PPM 95
RQA MIS /DFR

chart
No. of days for

Plan 14 14 14 14
closure of CVLs
Actual 0 0 0 0
(Cum)



Plan 0 0 1 1
No. of visit days
Actual 0 0 1 0
Monthly
Closed 0
Doc. Verified 0
VPPAP Doc. RFT 0
VPPAP Audits 0
Audit RFT 0
Monthly
No of projects
Problem Defination
Data Collection &
Observation
Analysis
Special project
Selection
Parked
Improvement
Projects
Training Monthly
Training Monthly
Significant
Monthly
achievement
No. parts handed

Monthly
overRev:03
DWM//04/01

w5 Total
hly
8
1
76
0 0
0 0
14 14
0 0
0 0
0 0
14 14
0 0
0 2
0 1
0 2
0 1
hly
e Attached
hly
hly
hly
hly
Commodity: -Sheetmetal & Prop Aggregate: - All Officer :- Mukesh Gupta Rejectio
Rejection Base Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16
Inspected Lot 16009 5438 5719 5400 4676 3161 2171 2185 661 968 948
GR% Rejected lot 44 6 3 6 37 21 2 5 22 32 29
GR% 0.27 0.11 0.05 0.11 0.79 0.66 0.09 0.23 3.33 3.31 3.06 #DIV/0!
Rejected Qty 466 41 254 30 50 48 42 76 18 33 156
LR PPM Received Qty 1609500 429476 497921 501322 573026 512285 361529 393595 159416 305843 276091
LR PPM 290 95 510 60 87 94 116 193 113 108 565 #DIV/0!
LR PPM 15% Imp 246
290
290 Month Achieved Status
286 April
95
283 May
510
279 June
60
276 July
87
272 August
94
268 September
116
373426911.xls - Rejection 50 of 87
265 October
193
261 November 113
257 December 105
254 January 565
250 February
247 March
ction
Mar-16 F16 H1 F16 H2
26565
4762
75
88
#DIV/0! 0.28 1.85
465
283
2875559
1134945
#DIV/0! 162 249
Commodity: - Sheet metal & Prop Officer :-
Sr. no. Month Aggregate CVL CVL Date CVL No.
1 Apr-15 Nill
2 May-15 Nill
3 Jun-15 Nill
4 Jul-15 Nill
5 Aug-15 Tractor Woodruff key missing in steering knuckle 18-Aug-15 CVL F16_54
6 Sep-15 Tractor Turn Buckle brocken in two parts 21-Sep-15 006/014/015
373426911.xls - CVL 53 of 87
7 Oct-15 Nill
8 Nov-15 Nill
9 Dec-15 Nill
10 Jan-16 Nill
373426911.xls - CVL 54 of 87
Mukesh Gupta CVL
Closure No. of Days For

Action taken
Date Closure
1) Shared the present practise at supplier end to ensure

the presence of woodruff key already there is 100%
inspection after assy by manufacturing supervisor and
100% ispection by Quality inspector before dispatch
2) Supplier representative has visited the Dealer and no
abnormality observed MOM attached
23-Sep-15 36 days
FW Regarding wood ruff key missing in field.msg
--- Different stages are identified for tack welding and

full welding
--- Check point added at consecutive operation and at
final PDI
23-Sep-15 2 days
PENETRTION REPORT.msg
Turn buckle - Broken from weld joint - Nepal Export Model.msg SCAR-A.m sg
373426911.xls - CVL 55 of 87
373426911.xls - CVL 56 of 87
Daily Work Management - Supplier Quality Training
Commodity: - Sheetmetal & Prop. Officer :- Mukesh Gupta
Sr.
Training Attended Date Month
no.
e-learning course Beginners Guide :Basics of QC and
5 15-Sep-15 Sep-15
its USE Offered by MIQ and JUSE
6 e-learning cource "Leadership Through Sustainability" 07-Dec-15 Dec15
7 Certified Quality engineer 05-Dec-15 Dec15
Policy deployment/DWM
8 Lean/VSM 19/01/2016 ~ 21/01/2016 Jan 16
Poka-Yoke/ low cost automation
373426911.xls - Training 57 of 87
ISO/ TS 16949 Status of Ownership Supplier (SM/prop)
S.No SUPPLIER S.Code Type QMS valid Date
1 Alf Engg,Haridwar DA030C ISO /TS 16949:2009 06.06.2018
2 Auto Ignition,Rudrapur DA074A ISO 9001:2008 21.04.2018
3 Avanti Bufa,Haridwar DA096A ISO /TS 16949:2009 8.8.2016
4 Banco Products DB006C ISO 9001:2008 11/1/2017
5 Bentex Engg. DB016C ISO 9001:2008 2/21/2017
6 Brakes India,Sitarganj DB050D ISO /TS 16949:2009 2/3/2018
7 Fedral Mogul,Rudrapur DG028D ISO /TS 16949:2009 11/17/2017
8 Mangla Tubes,Rudrapur DM121A ISO 9001:2008 9/3/2017
9 Minda Corp,Rudrapur DM078F ISO /TS 16949:2009 7/1/2017
10 Minda Industries,Rudrapur DM076E ISO /TS 16949:2009 10.03.16
23073533:
11 Musco,Rudrapur DM223A ISO /TS 16949:2009 26.12.2015
Audit is
12 PMP Components,Rudrapur DP038F ISO 9001:2008 planned
28.07.16
between
13 Polar Auto, Rudrapur DP039A ISO 9001:2008 5/27/2017
07/03/2016 ~
14 Pricol,Rudrapur DP132D ISO /TS 16949:2009 5/2/2017 ---
11/03/2016
15 Platesmith KGM DV047B ISO 9001:2008 Certification
4/12/2016
agency
16 Rane Madras,Rudrapur DR017C ISO /TS 16949:2009 9/14/2018
changed from
17 Sai Auto,Rudrapur DS145A ISO 9001:2008 9/26/2016
TUV re to TUV
18 Sudtrac Linkages,Rudrapur DS157A ISO 9001:2008 Nord across all
9/14/2018
Mahindra CIE
19 VMS Automech DV047A ISO 9001:2008 12.4.2016
group led to
20 Wheels India,Rudrapur DW006D ISO /TS 16949:2009 the delay
9/23/2016
21 Windals Precision DW008A ISO /TS 16949:2009 17.09.16
22 VI-SON CABLES PVT. LTD. DV043C ISO /TS 16949:2009 11/27/2017
23 Minda Horn M00018 ISO /TS 16949:2009 7/14/2018
Newly Added Supplier
24 Interface microsystems DI028B ISO /TS 16949:2009 12/22/2017
25 Dali & sameer ltd DO559A ISO 9001:2008 9/11/2017
26 Turbo energy ltd DT049A ISO /TS 16949:2009 5/1/2016
Author:
27 Polar Auto, Faridabad DP039
added in theISO 9001:2008
month of Sep 10/22/2018
2015
pplier (SM/prop)
Commodity
SM
prop
SM
prop
SM
Prop
prop
prop
Prop
prop
073533:
dit is SM
nned prop
ween
prop
03/2016 ~
03/2016 --- prop
tification SM
ncy
nged from prop
V re to TUV SM
d across all SM
hindra CIE
up led to SM
delay prop
SM
prop
Prop
Prop
SM
Prop
SM
Supplier improvement projects
S.No SUPPLIER S.Code Type Commodity TPM
1 Alf Engg,Haridwar DA030C ISO /TS 16949:2009 SM
2 Auto Ignition,Rudrapur DA074A ISO 9001:2008 prop
3 Avanti Bufa,Haridwar DA096A ISO /TS 16949:2009 SM
4 Banco Products DB006C ISO 9001:2008 prop
5 Bentex Engg. DB016C ISO 9001:2008 SM
6 Brakes India,Sitarganj DB050D ISO /TS 16949:2009 Prop
7 Fedral Mogul,Rudrapur DG028D ISO /TS 16949:2009 prop
8 Mangla Tubes,Rudrapur DM121A ISO 9001:2008 prop
9 Minda Corp,Rudrapur DM078F ISO /TS 16949:2009 Prop TPM
10 Minda Industries,Rudrapur DM076E ISO /TS 16949:2009 prop
11 Musco,Rudrapur DM223A ISO /TS 16949:2009 SM TPM
12 PMP Components,Rudrapur DP038F ISO 9001:2008 prop
13 Polar Auto, Rudrapur DP039A ISO 9001:2008 prop TPM
14 Pricol,Rudrapur DP132D ISO /TS 16949:2009 prop
15 Platesmith KGM DV047B ISO 9001:2008 SM
JQM winner
16 Rane Madras,Rudrapur DR017C ISO /TS 16949:2009 prop organisation
17 Sai Auto,Rudrapur DS145A ISO 9001:2008 SM
18 Sudtrac Linkages,Rudrapur DS157A ISO 9001:2008 SM
19 VMS Automech DV047A ISO 9001:2008 SM
20 Wheels India,Rudrapur DW006D ISO /TS 16949:2009 prop
21 Windals Precision DW008A ISO /TS 16949:2009 SM
22 VI-SON CABLES PVT. LTD. DV043C ISO /TS 16949:2009 prop
23 Minda Horn M00018 ISO /TS 16949:2009 Prop
Newly Added Supplier
24 Interface microsystems DI028B ISO /TS 16949:2009 Prop
25 Dali & sameer ltd DO559A ISO 9001:2008 SM
Author:
26 Turbo energy added
ltd in the month of Sep
DT049A ISO /TS 16949:2009 Prop
27 Polar Auto, 2015
Faridabad DP039 ISO 9001:2008 SM
s
Lean Manufacturing Remarks
Laen Manufacturing
Lean Manufacturing
Commodity: - Sheet metal & prop Officer :- Mukesh Gupta Supplier Audit
No. of Visit
Sr. no. Month Supplier Code Supplier Name Location Planned Date Actual Date Action Plan Status
Days
DB006C Banco Rudrapur 21-Apr-15 28-Apr-15 1 Received
1 Apr/15
Resheduled due to TS audit and NPD at supplier
DG028D Fedral Mughal Rudrapur 28-Apr-15 Resheduled 0
end
Activity of VPPAP could not be completed on

DB016c Bentex Rudrapur 06-May-15 Resheduled 0
5th and 6th of May hence resheduled
DG028D Fedral Mughal Rudrapur 14-May-15 14-May-15 1 Received

F59AD44C.msg
2 May-15
DV047A VMS Rudrapur 22-May-15 20-May-15 1 Received

1B150CD2.msg
DI028B Interface Rudrapur 19-May-15 22-May-15 1 Received
DM121A Mangla Rudrapur 08-Jun-15 08-Jun-15 1 received
3 DB016C Bentex Rudrapur 10-Jun-15 27-Jun-15 1 Received

5FF1F045.msg
Jun/15 DA096A Avantibufa Roorkee 18-Jun-15 18-Jun-15 1 Received

F6CDC9E2.msg
DA030C Alf Haridwar 19-Jun-15 19-Jun-15 1 Received

E5D171F0.msg
Due to seniour team time not available on

DT049A Turbo Rudrapur 23-Jun-15 Resheduled 0
planned date
DT049A Turbo Rudrapur 09-Jul-15 30-Jul-15 1.0 Parked
23073533:
Resheduled due to Visit of No
Athley sir and
supplies fromDOL
12 July
DA074A Auto ignition Rudrapur 14-Jul-15 Resheduled 0
meet 2015 to till 01/12/2015
As per supplier rep the set

Resheduled due to Visit of up is notsir
Athley present now ( Mr
and DOL
4 Jul-15 DM223A Mahindra CIE Rudrapur 16-Jul-15 Resheduled 0
meet Satish--- Turbo)
Resheduled due to Visit of Athley sir and DOL

DS145A Sai Auto Rudrapur 21-Jul-15 Resheduled 0.0
meet
Resheduled due to Visit of Athley sir and DOL

DS157A Sudtrack Rudrapur 24-Jul-15 Resheduled 0.0
meet
DS157A Sudtrack Rudrapur 05-Aug-15 08-Aug-15 1 Received

D69B66D7.msg
DS145A sai auto Rudrapur 18-Aug-15 18-Aug-15 1 Received

FD939BD.msg
DW006A Wheels India Rudrapur 19-Aug-15 19-Aug-15 1 No issue
Resheduled due to 'Persons at medical leave at

5 Aug/15 DP039A Polar Auto Rudrapur 21-Aug-15 resheduled 0
M/s Polar auto ref mail dated 18/08/2015
DA074A Auto ignition Rudrapur 25-Aug-15 25-Aug-15 1 Received

C5AB6010.msg
Resheduled due to TS audit at Mahindra CIE on

DM223A Mahindra CIE Rudrapur 27-Aug-15 Resheduled 0
25th & 26th Aug 2015
DR017A Rane Madrass Rudrapur 28-Aug-15 Resheduled 0 Not confirmed by supplier
DP039A M/s Polar Auto Rudrapur 07-Sep-15 07-Sep-15 1 Received

DFD2BF23.msg
DM223A M/s mahindra CIE Rudrapur 09-Sep-15 09-Sep-15 1 Received

D0FFEDB9.msg
DR017C M/s Rane Rudrapur 11-Sep-15 11-Sep-15 1 Received

6D752F3C.msg
6 Sep-15
DV047B M/s Platesmith Kath Godam 28-Sep-15 28-Sep-15 1 Received

D7C81C21.msg
VPPAP MOM
DV047A VMS Rudrapur 29-Sep-15 29-Sep-15 1
Regular audit resheduled due to VPPAP
DO0559A Dali and Sameer Rudrapur 30-Sep-15 30-Sep-15 1 Received

F390910A.msg
DV047A VMS Rudrapur 12-Oct-15 12-Oct-15 1 Received

16E443F3.msg
Not Done ( Due to shut Resheduled to Nov 2015 due to shut down at
7 Oct/15 DP038F PMP Rudrapur 26-Oct-15 0
down at supplier end) supplier end
M00018 Minda Horn Rudrapur 28-Oct-15 28-Oct-15 1 No observation
DP038F PMP Rudrapur 06-Nov-15 27-Nov-15 1 Received
DP039 Polar Auto Faridabad 23-Nov-15 23-Nov-15 1 Received
8 Nov/15 DV043C Vision Cables Kala Amb 24-Nov-15 24-Nov-15 1 Received

76FC4870.msg
Resheduled to dec 2015

DB016C Bentex Rudrapur 26-Nov-15 0 Resheduled to dec 2015 due to No production
due to No production
DS145A Sai auto Rudrapur 28-Nov-15 28-Nov-15 1 Received

AA365079.msg
DB016C Bentex Rudrapur 16-Dec-15 16-Dec-15 1 Received
Dec/15 DM121A Mangla Tubes Rudrapur 22-Dec-15 29-Dec-15 1 Pending
DB050D Brakes India Sitar ganj 24-Dec-15 28-Dec-15 1 No issue
DA074A Auto ignition Rudrapur 25-Jan-16 25-Jan-16 1 Pending
Jan-16 DM221A Mahindra CIE Rudrapur 27-Jan-16 29-Jan-16 1 No NC
DV047A VMS Rudrapur 28-Jan-16 28-Jan-16 1 Pending

Commodity :- Sheet Metal and Prop

Month Supplier Name Supplier Code
Apr-15 Nill
May-15 Nill
Jun-15 M/s Rane DR017C
Jul-15 Nill
Aug-15 Nill
Sep-15 Nill
Oct-15 Nill
Nov-15 Nill
Dec-15 Nill
Jan-15 M/s Bentex DB016C
op Officer :- Mukesh Gupta

Debit details Debit Amount Remarks
Nill
Nill
Leakage reported from Steering gear box 5 cases 100000 Completed
Nill
Nill
Nill
Nill
Nill
Nill
Weight 36 Kg supplied in wet condition 50000 Processing pending
VPPAP Status F'15
Developed by Documen Process
S.No S.Code Commodity Supplier Location Part No Part Description Reason for Development Saving to company VPPAP Status Date Month Year YEAR Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16
RDP/ KND tation compliance
6 D0559A Sheet metal Dali and sameer Rudrapur 0B7904248B92 Fuel tank Localisation Yes RDP closed 08 9 2015 Yes Yes f16
15 DP039A Sheet metal Polar Auto Rudrapur 007607410B91 Brake pedal Engineering Change ( Clavs dim changed from 34 mm to 25.4 Yes RDP Closed 18 2 2015 yes Yes 2015 0 0
18 H1 /overall/16940 DP039A Sheet metal Polar Auto Rudrapur 007607410B91 Brake pedal CRE width reduced flate width Yes RDP Closed 19 5 2015 yes Yes F 16 0 0 0
19 H1 /overall/16941 DP039A Sheet metal Polar Auto Rudrapur 007607411B91 Brake pedal CRE width reduced flate width Yes RDP Closed 19 5 2015 yes Yes F 16 0 0 0
20 H1/Overall Tractor/17034 DM223A Sheet metal Mahindra CIE Rudrapur 007532128B91 Fender LT LH Engineering Change ( Material changed from EDD to D) Yes RDP Closed 27 4 2015 Yes Yes F 16 0 0 0
21 H1/Overall Tractor/17035 DM223A Sheet metal Mahindra CIE Rudrapur 007532123B91 Fender LT RH Engineering Change ( Material changed from EDD to D) Yes RDP Closed 27 4 2015 Yes Yes F 16 0 0 0
22 H1/Overall Tractor/17856 DB006C Prop Banco Rudrapur 006005541B92 Radiator Assy Coul Lokalisation Yes RDP Closed 05 8 2015 yes yes f 16 0 0 0
23 H1/Overall Tractor/17420 DM223A Sheet metal Mahindra CIE Rudrapur 006005541B92 FENDER_CPTE_RH CRE Yes KND open
24 H1/Overall Tractor/17430 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 007537387B13 Brake pedal LH CRE PROJECT - H1 Brake pedals width change to 35 X12 Yes RDP Closed 23 5 2015 Yes Yes F 16 0 0 0
25 H1/Overall Tractor/17432 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 007537366B13 Brake pedal RH CRE PROJECT - H1 Brake pedals width change to 35 X12 Yes RDP Closed 23 5 2015 Yes Yes F 16 0 0 0
26 H1/Overall Tractor/17304 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 007607411b92 Brake pedal wet land oib lh CRE PROJECT - H1 Brake pedals width change to 35 X12 yes RDP Closed 23 5 2015 Yes Yes F 16 0 0 0
27 H1/Overall Tractor/17303 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 007607410B92 Brake pedal wet land oib rh CRE PROJECT - H1 Brake pedals width change to 35 X12 yes RDP Closed 23 5 2015 Yes Yes F 16 0 0 0
28 H1/Overall Tractor/17421 DM223A Sheet metal Mahindra CIE Rudrapur 007531808B11 FENDER_CPTE_LH CRE Yes KND Open
29 H1/Engine/17522 DG028D Prop Fedral Mughal Rudrapur 006026933B91 ASSEMBLY PISTON FMGL 255 ELS CRE Projects yes RDP Closed 1 6 2015 yes yes F 16 0 0 0
30 H1/Overall Tractor/17523 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 006506673B92 BRAKE PEDAL CPTE RH CRE PROJECT - H1 Brake pedals width change to 35 X12 yes RDP Closed 1 6 2015 Yes Yes F 16 0 0 0
31 H1/Overall Tractor/17524 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 006504960B92 BRAKE PEDAL CPTE LH CRE PROJECT - H1 Brake pedals width change to 35 X12 yes RDP Closed 1 6 2015 Yes Yes F 16 0 0 0
32 H1/Overall Tractor/17525 DW008A Sheet metal Windal Rudrapur 007904455B91 SUB. ASSY. FR. AXLE CPTE FOR 255DI CRE yes RDP closed 12 2015 Yes Yes F 16 0
33 H1/Overall Tractor/17531 DR017C Sheet metal Rane Madrass Rudrapur 005557341R95 STEERING GEAR BOX - GROUP NO. CRE yes RDP Closed 5 6 2015 Yes Yes F 16 0 0 0
34 H1/Overall Tractor/17311 DM121A Prop Mangla Rudrapur 007905176B91 Battery Retainer assy CER Yes RDP Closed 5 6 2015 Yes Yes 2015 0 0 0
35 H1/Overall Tractor/17629 DV043C Prop Vison Cables kala Amb 005559253R92 CABLE BATTERY SOLENOID +VE CRE Projects Yes RDP Closed 30 6 2015 Yes Yes F 16 0 0 0
36 H1/Overall Tractor/17630 DV043C Prop Vison Cables kala Amb 007700411A2 BATTERY POSITIVE CABLE CRE Projects Yes RDP Closed 30 6 2015 Yes Yes F 16 0 0 0
37 H1/Overall Tractor/17511 DW008A Sheet Windal Rudrapur 007904455B91 Front axle assy CRE Yes RDP Open
38 H1/ Overall Tractor/ 17879 DV047A Sheet metal VMS Rudrapur 008001711B2 FRONT_AXLE_WEIGHT ER Yes RDP Closed 3 9 2015 Yes Yes F16 0 0 0 0
39 H1/ Overall Tractor/ 17979 DV047B Sheet metal Plate smith Kathgodam 007902969B91 Stay Rod 3CYL Localisation Yes RDP Closed 12 9 2015 Yes Yes F16 0 0 0 0
40 H1/ Overall Tractor/ 17980 DV047B Sheet metal Plate smith Kathgodam 007902972B91 Stay Rod 3CYL Localisation Yes RDP Closed 12 9 2015 Yes Yes F16 0 0 0 0
41 H1 Overall Tractor 17825 DM223A Sheet metal mahindra CIE Rudrapur 005557851R93 Hood and Radiator grill 255 Localisation Yes RDP Closed 16 9 2015 Yes Yes F16 0 0
45 H1 Overall Tractor 17996 DV047A Sheet metal Rudrapur Rudrapur 005552394R95 FOOT PLATE BP LH 255 MODEL Localisation Closed 30 10 2015 Yes Yes Yes 0 0 0
46 H1 Overall Tractor 17997 DV047A Sheet metal Rudrapur Rudrapur 005555743R92 FOOT PLATE BP RH 255 MODEL Localisation Closed 30 10 2015 Yes Yes Yes 0 0 0
47 H1 Overall Tractor 17995 DV047B Sheet metal Plate smith Kathgodam 007903933B91 Weight 16 Kg Localisation Yes RDP Closed 9 10 2015 Yes Yes F16 0 0 0
48 H1 Overall Tractor 18072 DM223A Sheet metal Mahindra CIE Rudrapur 007531808B11 Fender LH Engineering Change Yes RDP Closed 9 10 2015 Yes Yes F16 0 0 0
49 H1/Overall Tractor/18064 DM223A Sheet metal Mahindra CIE Rudrapur 007532128B91 FENDER_CPTE_LH Engineering Change Yes RDP Closed 12 10 2015 Yes Yes F16 0 0 0
50 H1/Transmission/18040 DB050D Prop Brakes India Sitar ganj 006510138B91 BRAKE_OIB_LH Sub contractor for act disc changed Yes RDP Closed 22 10 2015 Yes Yes F16 0 0 0
51 H1/Transmission/18041 DB050D Prop Brakes India Sitar ganj 006510139B91 600000001854_BRAKE_OIB_RH Sub contractor for act disc changed Yes RDP Closed 22 10 2015 Yes Yes F16 0 0 0
CHANGE 1 - U CLIP DUIM CHANGED FROM 191MM TO
175MM CHANGE 2 - 3 PLATE OIB TO BE WRITTEN ON
52 H1/Overall Tractor/18199 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 006514140B91 PEDAL BRAKE RH OIB Yes RDP Closed 29 10 2015 Yes Yes F16
LEVER INSTEAD OF BP OIB UPG CHANGE 3 - CLEVIS DIM
CHANGED FROM 25.4MM TO 16.4MM 0 0 0

175MM CHANGE 2 - 3 PLATE OIB TO BE WRITTEN ON
53 H1/Overall Tractor/18198 DB016C Sheet metal BENTEX ENGINEERING PVT Rudrapur 006514255B91 PEDAL BRAKE LH OIB Yes RDP Closed 29 10 2015 Yes Yes F16
LEVER INSTEAD OF BP OIB UPG CHANGE 3 - U CLIP DIM
CHANGED FROM 7.0MM(+1-0) TO 10 +-1MM
0 0 0
175MM
CHANGE 2 - 3 PLATE OIB TO BE WRITTEN ON LEVER
54 H1/Overall Tractor/18197 DP039A Sheet metal Polar Auto Rudrapur 006514140B91 PEDAL BRAKE RH OIB Yes RDP Closed 29 10 2015 Yes Yes F16
INSTEAD OF BP OIB UPG
CHANGE 3 - CLEVIS DIM CHANGED FROM 25.4MM TO
16.4MM 0 0 0

175MM
55 H1/Overall Tractor/18196 DP039A Sheet metal Polar Auto Rudrapur 006514255B91 PEDAL BRAKE LH OIB CHANGE 2 - 3 PLATE OIB TO BE WRITTEN ON LEVER Yes RDP Closed 29 10 2015 Yes Yes F16
INSTEAD OF BP OIB UPG
CHANGE 3 - U CLIP DIM CHANGED FROM 7.0MM(+1-0) TO
10 +-1MM 0 0 0
56 H1 Overall Tractor 18177 DS145A Sheet metal Sai Auto Rudrapur 007904114B91 BOTTOM_SEAL_PLATE_ASSLY_CPTE localization of bottom seal assly 3DI with SAI AUTO. Yes RDP Closed 29 10 2015 Yes Yes F16 0 0 0
Engineering change
1) Dim Added
57 H1/Overall Tractor/18249 DM223A Sheet metal Mahindra CIE Rudrapur 007505916B2 Scuttle Panel BP Yes RDP Closed 7 12 2015 Yes Yes F16
2) Dim 10.3 and 500 mm made ref
3) Tolerance added for Dim 479.4 mm ( 0.8) 0 0
58 DM121A Sheet metal Mangla Tubes Rudrapur 007905176B91 Battery Retainer CRE Open
59 H1/Transmission/18354 DB 050D Prop Brakes India Sitar ganj 006514126B91 BRAKE OIB LH CRE Yes RDP Closed 28 12 2015 Yes Yes F16 0
60 H1/Transmission/18353 DB 050D Prop Brakes India Sitar ganj 006514127B91 BRAKE OIB RH CRE Yes RDP Closed 28 12 2015 yes Yes F16 0
61 H1/Overall Tractor/18393 DW008A Sheet Metal WINDALS PRECISION Rudrapu Rudrapur 005559928B91 SUB ASSY FRONT AXLE BOW TYPE WITH LIN Engineering change Yes RDP Closed 25 12 2015 yes Yes F16 0
Steering knuckle seal dislocation while greasing in H1 for
62 H1/Overall Tractor/18392 DW008A Sheet Metal Windal Rudrapur 005560036B91 SUB ASSY. FRONT AXLE south axle. Yes RDP Closed 25 12 2015 F16
Rubber bush outer dia reduced. yes yes 0
Steering knuckle seal dislocation while greasing in H1 for
63 H1/Overall Tractor/18391 DW008A Sheet Metal Windal Rudrapur 005559930B91 SUB ASSY.FRONT AXLE south axle.
Rubber bush outer dia reduced. Open
64 H1/Overall Tractor/18381 DM121A Sheet Metal Mangla Rudrapur 008006115B11 BRACKET MTG REAR TOW HOOK Special project Open
65 Dhruv/Transmission/18538 DM121A Sheet Metal Mangla Rudrapur 007208407V91 SUCTION STRAINER ASSEMBLY for Dhruv eco line --- RDP Open
66 Dhruv/Transmission/18539 DM121A Sheet Metal Mangla Rudrapur 007208499V91 SUCTION STRAINER ASSEMBLY FOR RCRPTO Dhruv Ecoline 31HP --- RDP Open
67 H1/Overall Tractor/18559 DM121A Sheet Metal Mangla Rudrapur 007905149B91 HEAVY DUTY_REAR TOW HOOK Department accessories project part
68 H1/Overall Tractor/18558 DM121A Sheet Metal Mangla Rudrapur 008006115B11 BRACKET MTG REAR TOW HOOK accessories project part
69 H1/Overall Tractor/18393 DW008A Sheet Metal WINDALS PRECISION Rudrapu Rudrapur 005559928B91 SUB ASSY FRONT AXLE BOW TYPE WITH LINKAGE & FAS
Things Gone right and Things gone wrong
Month TGR
1) Achieved LR PPM as low as 10 PPM ( only 3 parts reject
in LR) for ownership suppliers.
2) Trial of herquline primer completed succesfuly on 5
parts.
Feb/15
1) Implimentation of square type spring washer in Rane

Steering gear box from 26th of May 2015
Mar/15 2)
1) Square Type spring washer implimented -- for Washer

expand issue
May/15 2) Drifting gauges of The m/s Rane Mysoore and M/s rane
RDP commonized to ensure the interchangability of parts
1) Issue of Front axle support fouling with crank case

casting resolved ( Support supplied by M/s Kai)
2) Issue of Power steering cylinder leakage resolved
Jun/15
1) All old rejection of M/s Standard spring Total qty 17000

Nos cleared from the plant
July
Aug/15
Sep/15
Oct/15
Nov/15
1) Issue of Hood stoper bolt fouling with front weight
leading to hood Gap resolved thru design change
Dec/15
1) Detection type poke yoke implimented to eliminate the

issue of length excess in suction strainer
2) Detection type poka Yoke implmented at welding fixture
and ar receiving gauge of NVH silencer
3) Design change sulutions worked out to eliminate the
field issue og silencer Agni NVH by increasing the
Jan/15 thickness of rain cap from 1.5 mm to 2 mm , thickness of
pipe from 1.6 mm to 3.2 mm and increased the gusset
length and design
4)
5)
and Things gone wrong
TGW
1) Leakage from seam joint repeated 6th time in Fuel tank

of dali and sameer.
2) High rejection of clip of M/s Klipco due to issue of
Slipage.
3) Issue of Oil pump CD oversize took more than 1 week
for resolution.
4) issue of leakage from filter (Big bolts) M/s Bosch ---
permanent action is still not confirmed.
1) Scuttle support Angle 10 observed 1 lead to major

Line rejection -- Polar Auto
1) Cluster Body Crack -- M/s Minda high rejection reprted

2) Leakage from steering gear box repeated 5 Times
3) Fuel tank Leakage --2 nos dali and sameer ( pin holes
near fosset welding zone) and 1 No M/s Mahindra CIE
( Seam Join)
1) Oil Pan M/s Bentex --- rib on mounting face miss and
heavy wrinkles on butting face lead to rejection of Two
Lots at GR stage
2) Clip M/s standard spring major rejection due to Profile
not bend correctly leading to bolt fitment issue
3) cauge nut M/s Standard spring --- Old rejection lying in
plant 17000 Nos leading to line irritaation
1) Cylinder leakage reported M/s Wipro

2) Angle 9 of scuttle support observed 13
3) Suction strainer length observed over size at Nagpur
and Rudrapur
1) Silencer Agni NVH --- Failure at 46 Hrs reported from
Gujrat
2) Silencer Agni NVH --- Mounting hole shifted reported
from Rajkot --- High rejection report
Supplier Performance Monitoring Sheet
Review remarks
S.No Supplier name Supplier code Commudity Area
Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16 Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16
1 Alf Engg,Haridwar DA030C Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
2 Auto Ignition,Rudrapur DA074A Prop GR % 0 0 0 0 0 0 0 0 0 0
3 Avanti Bufa,Haridwar DA096A Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
4 Banco Products DB006C Prop GR % 0 0 0 0 0 0 0 0 0 0
--- Oil pan Joint face embosing
height observed zero--- 01 Lot
--- Oil Pan Embosing incomplete and Action Plan :-
major Die mark observed --- 02 Lots 1) Provide training to operator.
Action plan :- 2) To maintain pressure 1000psi
5 Bentex Engg. DB016C Sheet metal 0 0 0 5.26 2.5 0 0 0 0 0 1) Frequency decided for Tool mention in sop.
maintainance (15000 nos stoke)
2) Correction done in Embossing
tool.
3) Grinding done in 1st and 2nd draw
GR % tool .
6 Brakes India,Sitarganj DB050D Prop GR % 0 0 0 0 0 0 0 0 0 0
7 Fedral Mogul,Rudrapur DG028D Prop GR % 0 0 0 0 0 0 0 0 0 0
8 Minda Industries,Rudrapur DM076E Prop GR % 0 0 0 0 0 0 0 0 0 0
Alternator one terminal fulley covered
9 Minda Corp,Rudrapur DM078F Prop GR % 0 0 0 0 0 0 0 0 0 0 with black tape -- one lot
10 Mangla Tubes,Rudrapur DM121A Prop GR % 1.41 1.49 1.49 0 3.53 0 0.95 0 19.32 18.46
11 PMP Components,Rudrapur DP038F Prop GR % 0 0 0 0 0 0 5.88 0 0 0
Brake pedal --- ID 13 0.5 mm
observed 14.2 mm -- 1 Lot
Action Plan :-
1) New welding fixture and Receving
gauge
2) Material checked 100% and
12 Polar Auto, Rudrapur DP039A Prop 1.41 1.07 0 0 0 0 0 0 0 0 marking on bush.
Bush Id 34.98 / 35.03 mm go gauge

GR % not qualifying
13 Pricol,Rudrapur Prop GR % 0 0 0 0 0 0 0 0 0 0
14 Rane Madras,Rudrapur DR017C Prop GR % 0 0 0 0 2.34 0.70 0 0 0 0
15 Sai Auto,Rudrapur DS145A Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
16 Sudtrac Linkages,Rudrapur DS157A Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
17 VI-SON CABLES PVT. LTD. DV043C Prop GR % 0 0 0 0 0 0 0 0 0 0
18 VMS Automech DV047A Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
19 Platesmith KGM DV047B Sheet metal GR % 0.9 0 0 0 0 0 0 0 0 0
20 Wheels India,Rudrapur DW006D Prop GR % 0 0 0 0 0 0 0 0 0 0
21 Windals Precision DW008A Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
22 Minda Horn M00018 Prop GR % 0 0 0 0 0 0 0 0 0 0
23
Musco,Rudrapur Changed to MahindraPLRD01/DM223A
CIE Sheet metal GR % 0.02 0 0.07 1.05 0.76 0.08 0.09 2.38 3.73 1.9
24 Interface DI028B Prop GR % 0 0 0 0 0 0 0 0 0 0
25 Dali and Sameer DO559A Sheet metal GR % 0 0 0 0 0 0 0 0 0 0
26 Turbo energy DT049A Prop GR % 0 0 0 0 0 0 0 0 0 0
27 Polar Faridabad DP039A Sheet metal GR % Added in the month of Sep 2015 0 0 0 0
23073533:
1) LT fender L bracket shift
Special process Details Audit plan
S.No SUPPLIER S.Code Commodity Remarks Dec-15 Jan-16
3 Avanti Bufa,Haridwar DA096A SM Yes
5 Bentex Engg. DB016C SM Yes
8 Mangla Tubes,Rudrapur DM121A prop Yes
11 Musco,Rudrapur DM223A SM Yes
13 Polar Auto, Rudrapur DP039A prop Yes Done
15 Platesmith KGM DV047B SM Yes
16 Rane Madras,Rudrapur DR017C prop Yes
17 Sai Auto,Rudrapur DS145A SM Yes Done
18 Sudtrac Linkages,Rudrapur DS157A SM Yes
19 VMS Automech DV047A SM Yes
21 Windals Precision DW008A SM Yes
Author:
added in the month of
Sep 2015
Audit plan
Feb-16 Mar-16
a
Daily Work Management - Supplier Quality Achievement
Commodity: -Sheet Metal& Prop Officer :- Mukesh Gupta
Sr. no. Significant Achievement Date Month

1 Square spring washer implimented in Rane spring washer 26-May-15 may
2 Drifting gauge of drop arm comenize in Rane RDP and Rane Mysoore 07-May-15 may
373426911.xls - Achievement 73 of 87
373426911.xls - Achievement 74 of 87
No.
Of Runni Tractor
Seri Date Tractor Sr. Reported
Sr. No. Year es Cases Month Ref No. Model ng Manufactur
Released No. form
(RDP Hours ed (Month)
Tr.)
CVL
2 F16 H1 1 May-15 14-May-15 RKBB03119 575 BP 260 Jul-14 Kota
F16_005
CVL
5 F16 H1 1 Jun-15 16-Jun-15 RKBB04748 575 BP 48 Dec-14 Bhopal
F16_023
CVL
7 F16 H1 1 Jun-15 25-Jun-15 RENB02422 265 BP 1 Dec-13 Bhopal
F16_025
CVL
10 F16 H1 1 Jul-15 11-Jul-15 RFNH04202 275 BP 157 Nov-13 Raipur
F16_033
RJBA02033,
RJBA02025, 275
CVL RJNH01678, NBP,575 Bhubenesh
11 F16 H1 1 Jul-15 30-Jul-15 1 Jul-15
F16_042 RJBA02018, NBP,475 wer
RKNW0301 NBP
6
CVL Ahemadaba
16 F16 H1 1 Sep-15 23-Sep-15 RFNB11483 275 BP 12 Jan-15
F16_065 d
21 F16 H1 1 Nov-15 20-Nov-15 CVL F16 86 RJBP01158 475 BP 6 hrs Jul-15 Mohali
265,475 140
CVL F16 89 REBW08486 Hrs , Jun'15,Aug' Lucknow
24 F16 H1 2 Dec-15 02-Dec-15 , RJEH00026 BP 15 ,Kota
78Hrs
27 F16 H1 1 Dec-15 16-Dec-15 CVL F16 96 RYNH01309 275 BP 38 hrs Jul-15 Ranchi
Category
PU Issue Commodity Supplier Status Target Date Closing Date
Front Wheel
Tractor Supplier Casting KIEEPL closed 26-May-15 12-Jun-15
Wobbling
Foreign Material
Engine Found (bolt ) in Supplier Casting Bharat Auto closed 28-Jun-15 28-Jun-15
Engine Oil sump
M/s
Rubber Bellow TC Rubber &
Tractor Supplier Premier closed 7-Jul-15 26-Jun-15
cover Damage Plastic Seals
Transmissio Abnormal Noise Fairfield
in transmission Supplier closed 23-Jul-15 20-Jul-15
n atlas
High neutral Gear
water entry into

tractor Air Cleaner oil Supplier Sheet Metal Sai Auto closed 11-Aug-15 26-Aug-15
Bowl.
Transmissio Leakage from

transcase -Blow Supplier Casting closed 5-Oct-15 15-Oct-15
n hole
Abnormal sound
from engine
Engine (Cylinder Head Oil mfg/Supplie Casting SEACO resolved 2-Dec-15 28-Nov-15
r
gallery hole not
matching)
Transmission Oil
Transmissio leakage from Rear Supplier Casting Pritika Resolved 14-Dec-15 18-Dec-15
n Axle carrier-Blow
hole
Transmissio clutch housing supplier Casting Ushaprabha open 28-Dec-15 23-Dec-15

n crack
Days for Owner Remarks/ Actions
Resoln
1)For Flange thickness-

a) The reference will be taken flange side to control the flange thickness instead of flange pad during rough
tourning on lathe m/c.
B) Existing jaw of lathe m/c will be modified to resting the flange instead of flange pad.
29 C) Snap gauge will be made for 100% inspection in final insp. and record will maintained.And it will be
added in calibration plan and calibration will be done as per plan and record will maintain.
(Befor that 100% inspection will done by Vernier calliper & record will maintain immediately).
d) Pattern is modified to increase the flange thickness by 1.0mm.
Supplier Visit done regarding the CVL & following points were verified at supplier end.
1. M6X1 threading along with gauge calibration for checking-Found OK.

2. Bolt hardness and material Found ok 8.8 Grade (Checked in-house)
3. Bolt threading found OK.
4. Torque application 9-11NM found less i.e. up to 5 NM in 01 bolt out of 04 bolts.
5. Cover height for bolt thread engagement is checked as per drg. And found ok.
12 Action taken:-
1. Additional check point added as quality audit in process.

2. Yellow paint dot is applied as a cut off for improved control over process.
Similarly process controls at other source are verified to bench mark practice. (No gap observed)
Existing stock at Nagpur and Rudrapur is being checked 100% for torque and getting issued on line
CC Is requested to provide failed parts i.e Rubber bellow and Clip for Analysis
Fresh Part inspection done, No non confirmity observed.
Failed part inspection done, Supplier NC observed.

Issue taken up with supplier M/s Premier Seals, SCAR awaited
1 SCAR submitted (Refer attachment)-
Action are as follows-
1. Production of other customer Bellow (less % PVC-OT 50) sifted to other plant to avoid the mixup.-
Completed
2. Burn test started for every batch to confirm the NBR 70% & PVC 30% combination at Raw material
Reciept stage.-Completed
3. Quality alert has been displayed at working area.- Completed
Analysis of failed part completed, supplier non confirmance observed.
Issue is taken up with supplier M/s Fairfield atlas.

Root Cause Analysis :
Occurrence - 1)After monitoring shaving process
contineously,the Process observed within control.As this NC part produced in Oct 2013 .
2) While monitoring PCD Runout after bore grinding observed twords higher
specification Detection (Process)-
1) Current inspection method at shaving stage is every 2per/hour is not adequate
2) Current inspection method of PCD at process 2per shift not adequate at grinding stage
9 Detection (Final) - 1)During Final inspection DOP
Checking 100% with pin -mice
System :
1)Inspection method of DOP with pin & micrometer 100% 2) Inspection
method of PCD with dail indiactor 2/shift
Correction & Corrective Action

1. Every 5th part DOP Inspection at process Inspection started
2. 100% DOP Inspection at Final Inspection
3. 5per shift ROP Checkinmg by operator at grinding stage
Action taken at Supplier :-1.correct and improved rubber ring sealing is to be used 2.Thickness increased
27 from (2-2.2mm) to 3.2-3.4 mm
Analysis of both failed part done alonge with supplier.

Blow hole observed on both the cases. Vendor debit done
22
Problem Defination - Noise from engine due to rocker assembly Jammed.
Re-Defination of Problem -Oil hole on Cyl. head missing causing no oil to rocker assembly resulted into
seizure of Rocker Assembly.
Root Caused- Skip from inspection at supplier as well as plant.
Actions -
8
Actions plan received from Supplier M/s Seaco -
1. POKA YOKE is Introduced at Next operation of Oil hole and at Continuity checking stage in such way
that part loading is not possible 22.11.15
2. 100% inspection is started with marking 27.11.15
3. Stocks at NGP, RDP & supplier end 1554 checked 26.11.15
Kandivali Manufacturing This POKA-YOKE is already in place on Machine No- C-1284.
Problem Defination -Transmission Oil leakage from Rear Axle carrier due to Blow hole.
Root Caused-
1)Cause for generation - Component is witnessed & observed that it is blowhole defect. Cores are sent on
batch of conveyor for drying (after core painting) in stacked condition to oven. Due to stacking cores at
lower side are not partially dried , which was resulted into blowholes.
2) Reason for no detection - Visual defect is skipped from visual inspection after fettling. Defect is not
revealed in leak testing operation at machine shop.
4
Actions -
Actions plan received from Supplier M/s Pritika -
1) Continuous type conveyor installed to ensure complete drying of core after painting.
2) Machine cutoff time reduces from 3:50-3:00 to 3:50-3:35 & cycle time increased from 45sec to 1 min.
3) Training provided to operators for blowhole detection.
4)Auto punch will be added on machine for leak testing identification.
7 less wall thickness of clutch hsg

In case of Repeat Ref Modified
Repeat Modified FMEA Modified SOP
No. Control Plan
Yes/No
No NA
NO
NO
NO
NO
NO
no
no
no

Commodity:-Sheet Metal & Prop: Daily Work Management - Supplier Quality

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Commodity:-Sheet Metal & Prop: Daily Work Management - Supplier Quality

Enviado por

Direitos autorais:

Formatos disponíveis

Daily Work Management - Supplier Quality

Commodity :- Sheet Metal & Prop

2 LR PPM (Ownership supplier)

Officer :- Mukesh Gupta

Commodity :- Sheet Metal & Prop

1 DWM Monthwise. Q Monthly Mukesh Gupta

2 LR PPM (Ownership supplier) Q Monthly Mukesh Gupta

3 CVL monitoring. Q Monthly Mukesh Gupta

4 Audit summery. Q Monthly Mukesh Gupta

5 Special Project. Q Monthly Mukesh Gupta

6 Training Q Monthly Mukesh Gupta

7 IP Q Monthly Mukesh Gupta

8 DFR Q Monthly Mukesh Gupta

9 QMS Status. Q Monthly Mukesh Gupta

10 Debit Note Q Monthly Mukesh Gupta

April'15 May'15 June'15 July'15

nd abnormalities are identified through

ization System and Dashboards are used for

RQA MIS /DFR

No. of days for

No. of SCAR Raised 0 0 0 0

No. of days for SCAR no. 14 14 14 14

Audit Plan Vs. Plan 0 1 3 1

Training Monthly - File Attached

No. parts handed

Effective Date:- 28.04.2010

Rejected Qty 156

RQA MIS /DFR

No. of days for

No. of SCAR Raised 0 0 0 0

No. of days for SCAR no. 14 14 14 14

Audit Plan Vs. Plan 0 1 0 4

Training Monthly - File Attached

No. parts handed

Effective Date:- 28.04.2010

RQA MIS /DFR

No. of days for

No. of SCAR Raised 0 0 0 0

No. of days for SCAR no. 14 14 14 14

Audit Plan Vs. Plan 0 1 3 3

Training Monthly - File Attached

No. parts handed

Effective Date:- 28.04.2010

RQA MIS /DFR

No. of days for

No. of SCAR Raised 0 0 0 0

No. of days for SCAR no. 14 14 14 14

Audit Plan Vs. Plan 1 0 1 3

Training Monthly - File Attached

No. parts handed

Effective Date:- 28.04.2010

RQA MIS /DFR

No. of days for

No. of SCAR Raised 0 0 0 0

No. of days for SCAR no. 14 14 14 14

Audit Plan Vs. Plan 0 1 0 2

Training Monthly - File Attached

No. parts handed

Effective Date:- 28.04.2010

RQA MIS /DFR

No. of days for

No. of SCAR Raised 0 0 0 0

No. of days for SCAR no. 14 14 14 14