Zero Defect Competition @ July 22.pptx

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ZERO DEFECT SUPPLIER REVIEW
6/25/2023 1
Photo
Talbros automotive component ltd. (FBD)
Mobile No: 09650011062
E-mail: Nitin_thakur@talbros.com
Photo
NitinThakur
QA-Head
SonuTyagi
Customer Support

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 Review customer communication on - line and field complaints
 List down all processes in the organization with risk analysis throughTurtle diagram / FMEA or any other tool.
 Review Composite Score where you scored zero for which parameter
 Review QMSAudit / Supplier Re-evaluation sheet where you score less respective sections
 Project prioritization and selection of case studies based on high risk
 Risk Mitigation for identified a projects
 Other approaches for zero defect journey can also be
Guide Lines for Selection of Zero Defect Project

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QMS Certification
with validity
Major Esteem Customers and KOEL Share of Business
in %
(Attach Logos & Pie Chart)
Family of Parts Manufactured
( Attach Photographs )
Future Business Plan Future Infrastructure Improvement
1. New business of IWH
2. Heat shield business to be expand
o Plant re-layout to increase the space .
o Extension of plant to increase capacity by adding new
power press for heat shield segment .
Photo Photo
QMS Certificate &
Date of Validity
Supplier Name: Talbros Automotive Components Ltd.
COMPANY PROFILE
TATA
CUMMINS
28%
HERO
23%
VOLVO
14%
TATA
MOTORS
13%
SIMPSON
3%
ASHOK
LEYLAND
2%
ESCORTS
2%
MSIL
2%
KO
Others
11.5%
TATA CUMMINS HERO
VOLVO TATA MOTORS
SIMPSON ASHOK LEYLAND
ESCORTS MSIL
KOEL Others
Date of Certification: 19 Jan ‘2022
Date of expiration: 18 Jan’ 2025

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4
6 6
0 0 0 0
0
1
2
3
4
5
6
7
No. of parts Parts
confirms to
KOEL latest
drg. spec.
Process
Needs to
correct
Drawing
needs to
correct
Layout yet to
complete
Part drawing
and process
both need to
address
Layout Summary
Total Parts Status
6
11
0 0 0
0
2
4
6
8
10
12
No. of parts Cp, Cpk
identified -
Nos
Cp, Cpk
monitored -
Nos
Cp, Cpk
achieved - Nos
Cp, Cpk Not
achieved - Nos
Cp, Cpk Summary
Total Parts Status
6 6
0
0
2
4
6
8
No. of Parts Drg. as Per
KOEL Revn.
Drg. Not as Per
KOEL Revn.
Drawing Revision Status
Composite Score Extract
6 6
0 0
0
1
2
3
4
5
6
7
No. of parts QP Submitted QP Approved QP yet to submit
Quality Plan Summary
Total Parts Status
Data Under
Monitoring
6 6
1 1 1 1 1 1
0 0 0 0 0 0
0
1
2
3
4
5
6
7
No of
parts
Total no.
of RM
handled
RM -1
(CRCA)
RM -2
(Copper)
RM -3
(NON asb)
RM -4
(Stainless
steel)
RM -5 (Tin
PLate)
RM -6 (R
C Steel )
Total RM Types Confirms to spec. Not confirms to spec.
Raw Material Summary

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Learning / Take Away :
1. Documents verification & update knowledge
2. Integrating ideas and implementation in to
real
3. Enhancing risk based approach to identify and
filling gaps
4. Getting way of continual improvement
5. Enhancing knowledge about statistical
approach
Action Planned/Owner/Target:
1. Cp & Cpk monitoring has been started – Cont..
2. Submission of quality plan -25.07.22
Composite Score Summary
0
10
20
30
40
50
60
70
80
90
100
* Millipore Value
* Packaging aproval
* MSA
* Gauge/Fixture aval
*Cp Cpk
* PPAP Sub.
* Proactive Fail Safes
* Q / W issues
* Traceability
*Layout report
*RM Inspection
*Online PDI
Aesthetic Approval
Capacity Establised
Approved QP
Touch Points
Approved drawings
FP &LP aproval
In-process Gauges
Internal Handling facility
PerformanceTesting
Machining Fixture aval
Millipore Setup aval
Drawing rev. status
Part Identification
Permanent Tooling
PPAP Approval
Preservation Process
Production Cutting Tools
Special Process Validation
SA aproval & sign off
Approved kitting
FY 21-22 FY 22-23

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Re-evaluation Audit Summary
Evaluation Criteria Evidence
Quality Plans are documented& availablefor receipt, in-process & final
inspection.
Mandatory
Inspection tools & gauges are availableat each stages and processes. Mandatory
Stds, Room/MetallurgicalFacilities availablein-house. Ext. check record
exists.
Mandatory
Inspection area is following5S. Mandatory
Rejected Parts are Properly identified. Mandatory
Customer ComplaintHandlingProcedure exist. Mandatory
Alldocumentarychanges and evidences for customer complaint actions
available.
Mandatory
Quality Circles are formed for Quality improvement projects/initiatives. Mandatory
External Agencycertification like ISO/9001 Carried out and available. Mandatory
Calibrationsystem for fixture exists and followed. Mandatory
Process Capabilitystudyis donefor critical parameters. Initial Pp/Ppk>1.67. Mandatory
Delay or Advance in Manufacturing plan is visible& clear actions are taken. Mandatory
Storage Locationin racks / bins of each item & quantity is defined & followed. Mandatory
Component Development follows all Phases of Development Cycle. Mandatory
If yes, does scope includeall the product & processes being carried out? Mandatory
What are significant risks & existing controls? If No, reasons & commitment
to it.
Mandatory
0
10
20
30
40
50
60
70
80
90
100
1.Quality- Standard
2.Quality- Tools and
Environment
3.Quality- NC
Management
4.Quality- Continual
Improvement
5. Production-
Standard
5. Production-
Standard
6.Production- Shop
Floor Management
7. Production- Store
Management, FIFO…
8. Maintenance-
Management
09. Development-
New Product…
Management
Business Performance
Environment
Management System
Health and Safety
SUPPLIER RE-EVALUATION
Old Score
New Score
Old Rank: 285
New Rank: 299

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00
1 1
0 0 0
0
0.2
0.4
0.6
0.8
1
1.2
NC Count
FY 21-22 NC Count
7
5230 5230
0 0 0
0
1000
2000
3000
4000
5000
6000
PPM Trend
FY 20-21 FY 21-22 Monthly PPM Trend
100% 96% 96% 96% 96%
0%
20%
40%
60%
80%
100%
Composite Score Overall %
FY 21-22 Monthly Composite Score
18
2 2
0 0
18
2 2
0 0
0
5
10
15
20
Zero Defect Projects
FY 21-22 Project Identified Project Completed
100 100 100 100 100
0 0 0 0 0 0 0 0
0
20
40
60
80
100
EHS Score
FY 21-22 Monthly EHS Score
Enabler and Result Matrix
Complaint
Closed
0
100%
92%
76%
100%
100%
10%
30%
50%
70%
90%
Performance Index
FY 21-22 Monthly Performance

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Total no. of
parts
Total no. of
R 550
Parts
QR Code Status
QR Code
on Parts
-Nos
QR Code on
Invoice /
Packing -
Nos
Date of
Implementat
ion if there is
no progress
6 NA 1 ( GP-3 ) 6 After approval
Total no.
of parts
Total no.
of R 550
Parts
Quality Plan Submission & Approval
QP
Submitt
ed -
Nos
QP Not
Submitt
ed Nos
QP
Approved
Nos
QP
Pending
for
Approval
Nos
6 NA 6 0 0 6
Initiatives Response/ Remarks Status (R / G)
Online Uploading of PDI & MTC Online PDI reports submission process has
been started.
G
System Self Re-evaluation & Evidence PPT PPT attached – refer slide no. 6 G
QR Code Implementation & Other Initiatives

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MANUFACTURING PROCESS MAPPING THROUGH TURTLE DIAGRAM / VDA FMEA
NUMBEROF PROCESS
MAPPED/ TOTAL
PROCESS
NUMBEROF PROJECTS IDENTIFIED IN THE EACH ELEMENT OF THE TURTLE
INPUT
INFRA. &
MEASR
PROCESS RISKS
INVOLVED
PROCESS OWNER
COMPETENCY
PROCESS
DOC./ REC
PROCESS
EFFI./ EFFE
TOTAL
13 (Nos.) / 20 (Nos.)
0 (Nos.) 10 (Nos.) 4 (Nos.) 1 (Nos.) 2 (Nos.) 0 (Nos.) 17 (Nos.)
BUSINESS PROCESS MAPPING THROUGH TURTLE DIAGRAM / VDA FMEA
NUMBEROF PROCESS
MAPPED/ TOTAL
PROCESS
NUMBEROF PROJECTS IDENTIFIED IN THE EACH ELEMENTOF THE TURTLE
INPUT
INFRA. &
MEASR
PROCESS
RISKS
INVOLVED
PROCESS
OWNER
COMPETENCY
PROCESS
DOC./ REC
PROCESS
EFFI./ EFFE
TOTAL
8 (Nos.) / 41 (Nos.)
1 (Nos.) 3 (Nos.) 3 (Nos.) 0 (Nos.) 3 (Nos.) (Nos.) 10 (Nos.)
IMPROVEMENT PROJECTS IDENTIFIED OTHER THAN ABOVE TWO METHODOLOGIES
NUMBEROF PROJECTS IDENTIFIED IN THE LISTED BELOW
Composite Score Customer Feedback Other( Specify if any)
2 (Nos.) (Nos.) 1 ( Hris )(Nos.)

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SERIAL
NUMBER
PROJECT DESCRIPTION
PROJECT BELONGS
TO WHICH
PROCESS
PROJECT
RATING FROM
SDM SHEET
IMPACTON
NUMBER OF
PROCESS
COMPLETION
STATUS
No online accessibility of EHS/ IATF Document Business Process 900 8
Calibration agencies scope verification Business Process 329 1
Control plan review system development Business Process 233 1
Implementation of work permit monitoring criteria Business Process 224 1
Daily validation of weighing machine .
Manufacturing
Process
217 1
Implementation of “DYNE PEN TEST” & “SPECIFIC HANGER “ for degreasing
process.
Manufacturing
Process
215 1
Implementation of Abnormality handling knowledge module
Manufacturing
Process 210 1
Design and implementation of dead block in tool .
Manufacturing
Process
167 1
PLC of machine password protected.
Manufacturing
Process 160 1
Implementation of fixture and work instruction for laser marking
Manufacturing
Process
142 1
1
2
3
4
5
6
7
8
9
10

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Name of Process: Human Resource Business Process
Project Description Online accessing of EHS/IATF document
Define
 To study the IATF/EHS document hard copy is required causing paper waste
Measure
 During day to day activities it is observed that to study the EHS/IATF documents
hardcopy is required
Analyze
 Number of documents uploaded on HR portal
Improvement
 Online document accessing now available .
Control
 Updation of IATF/EHS document on HR portal
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
BEFORE
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
AFTER
• Tool Used:DMAIC & Turtle diagram
• Project Start:- Oct’21
• Cut of Date: Continuous
RESULT YES / NO
Productivity Improvement
QualityImprovement:
Cost Reduction (Yearly) :
Environment& Safety:
Moral:

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Login through HR portals Opening knowledge base Accessing documents online for knowledge
Note: All the procedures / knowledge modules are uploaded on HR portal for enhancing /updating
knowledge among the employee

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Name of Process: Calibration Business Process
Project Description Calibration agencies scope verification
Define
 Currently verification/ monitoring of calibration agencies scope is not evident
Measure
 During procedure review we interview to the concern person for verification method
of calibration agencies and found there is no mechanism / guideline available .
Analyze
 Calibration agencies verification plan/frequency made
Improvement
 Agencies verification plan made and monitoring started. It will protect to get
calibration of instruments from expired agencies.
Control
 Updating of plan vs actual
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
BEFORE
AFTER

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DOCUMENT NO. - PQA07
ISSUE - 00
ISSUE DATE - 01.04.18
PURPOSE : To ensure accuracy of inspection, measuring & test equipments certified at all times. To provide a system of calibration for all the instruments
& gauges used for inspection, measuring & testing.
SCOPE :All the inspection / measuring instruments, standard & special purpose gauges used in the various departments including the equipment used for
calibration.
Job flow Resp Checking Point Document / Format
-Master equipments
-New equipments
Quality Assurance -Existing
Master List Cum Calibration
Schedule
From repective
user deptts.
Quality Assurance -External facility has to be
accredited to NABL or ISO/IEC17025
-Approved External Calibration
agency list to be maintained
- Enusre NABL logo on the
Quality Assurance calibration certificate
TITLE : CALIBRATION
IATF 16949:2016 Clause Ref. - 7.1.5, 7.2.1, 7.5.1, 10.3.1
National Accredition Body should be
a member of ILAC
I/H or
External
Calibration
?
Send to the External
approval agency for
calibration
Receipt.of calibrated
equipment&calibration
certificate from the external
agency
A
Preparation of Annual
Calibration schedule
Receiving of instrument /
equipments as per the
released schedule
Preparation of Master List-
Instruments & Gauges(New
& Existing)
I/H
External
Before After

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Name of Process: QMS Business Process
Project Description Control plan review system development
Define
 Currently periodic review of control plan is not in practice
 No criteria for periodic review of control plan mentioned in work instruction –WQA246
Measure
 In current practice we update the control plan during customer complaint and if any
process improvement done like , Poka Yoke, WI.
 As per IATF guideline it a shall requirement to periodically review the control plan
except above mention requirement .
Analyze
 Fulfillment of IATF guidelines pertaining to control plan
Improvement
 Periodic review of control plan
Control
 Adherence of control plan review plan
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
BEFORE
AFTER

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4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10 Also ensure updation of revision history in control plan for tracking change details
4.11
Note :
FMR 5.2
After making the control plan get it reviewed by Senior and close the findings if any
2. Scope :
4. Procedure :
Get input to make control plan that is PFD (Process Flow Diagram), FMEA (Failure Modes & Effects Analysis) & Customer specific
requirements if any.
Mention all the requirements as per PFD & FMEA .For example in receiving process,material grade,properties ,dimensions (as per
applicability) etc.to be addressed with the detail of sample size,frequency,inspection method etc. Mention reaction plan by assuming
non-compliance
All the requirements and controls of characteristics to be linked with FMEA
3. Responsibility :
Quality & R&D
DISTRIBUTION TO : Inprocess inspection / Production/R&D
PREPARED BY
This procedure is to provide guidelines to make control plan that defines all methods used for process control & complies
with customer-specified requirements .
Covers all parts/family manfactured in the plant (TACL).
1. Control plan for ''families'' of parts are acceptable if the new parts have been reviewed for commonality by the organization.
2. Sample size & frequency to be changed as per stage of part i.e.,prototype,pre-launch & production stage
Prototype (when required)-A listing of tests,evaluations and their associated specifications/tolerances used to assess an
experimental or developmental formulation.This may be the only control plan that is product specific.
Pre-launch-Documentation of the product/process control characteristics,process controls affecting Special
Characteristics,associated tests and measurement system employed during normal production.
Production-Documentation of the product/process control characteristics,process controls affecting Special
Characteristics,associated tests and measurement system employed during normal production.Additional items may be included at
the Organization's discretion.
Pre-launch and production control plans may be applied to a family of product or specific processes
Control Plan Elaboration
APPROVED BY
3. Control plan approval may be required by certain customer.
T.A.C.L
WORK INSTRUCTIONS
DOC. NO. :WQA-246
REV. NO. : 00
TITLE : GUIDELINES TO MAKE CONTROL
PLAN
DATE OF ISSUE :06.04.2021
PAGE :1 of 1
1. Purpose:
Then get a unique control no.for the same as per master list
Revise the control plan in case of any complaints & audits (Inhouse/Customer) or in case of any improvement points .Ensure linkage
of the improvement poins with the FMEA also
Issue the control copy of latest/revised control plan at manufacturing line/concern deptt. & compile the master copy in your record
(either soft or hard)
Take format of control plan available with the organization as per latest standard or also can use customer specific format if any.
Highlight special product/process characteristics & their controls
Link together source of control methods,instructions & specification/tolerance limits and reference them in one document
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10 Also ensure updation of revision history in control plan for tracking change details
Quality & R&D
T.A.C.L
WORK INSTRUCTIONS DOC. NO. :WQA-246
REV. NO. : 01
TITLE : GUIDELINES TO MAKE CONTROL
PLAN
DATE OF ISSUE :05.10.2021
PAGE :1 of 1
1. Purpose:
This procedure is to provide guidelines to make control plan that defines all methods used for process control & complies
with customer-specified requirements .
2. Scope :
Covers all parts/family manfactured in the plant (TACL).
3. Responsibility :
4. Procedure :
Take format of control plan available with the organization as per latest standard or also can use customer specific format if any.
Get input to make control plan that is PFD (Process Flow Diagram), FMEA (Failure Modes & Effects Analysis) & Customer specific
requirements if any.
Mention all the requirements as per PFD & FMEA .For example in receiving process,material grade,properties ,dimensions (as per
applicability) etc.to be addressed with the detail of sample size,frequency,inspection method etc. Mention reaction plan by assuming
non-compliance and define test frequency of error proofing device/Pokayoke if any.
All the requirements and controls of characteristics to be linked with FMEA
Highlight special product/process characteristics & their controls
Link together source of control methods,instructions & specification/tolerance limits and reference them in one document
After making the control plan get it reviewed by Senior and close the findings if any
Then get a unique control no.for the same as per master list
Revise the control plan in case of any complaints & audits (Inhouse/Customer) or in case of any improvement points .Ensure
linkage of control plan with the FMEA & WI .Also review as per set frequency .
1
1
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Planned
Actual
Planned
Actual
Planned
Actual
Planned
Actual
Planned
Actual
Planned
Actual
JUL AUG SEP
REMARKS
3905443 CPQA 01 TATACUMMINS
JAN FEB MAR APR MAY JUN
CONTROL PLAN REVIEW PLAN (2021-22)
PARTNO. CONTROLPLANNO. CUSTOMER
PLANNED/
ACTUAL
OCT NOV DEC
3927154 CPQA 01/2 TATACUMMINS
392715400 CPQA 01/1 TATACUMMINS
Before After
Control plan review plan

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Name of Process: EHS Business Process
Project Description Implementation of work permit monitoring criteria
Define
 Currently verification/ monitoring of workers safety adherence during working is not in
practice
Measure
 In our current practice there is no check point to review the permit during working .
Analyze
 Criteria for worker safety monitoring during working has been made
Improvement
 Monitoring started
Control
 Adequately closure of work permit
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
• Tool Used: DMAIC & Turtle diagram
• Project Start:- May 22
• Cut of Date: May 22
BEFORE
AFTER

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Before After

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Name of Process: Painting Manufacturing Process
Project Description Daily validation of weighing machine .
Define
 Variation observed during operation in weighing machine .
 No check point to validate the weighing machine.
Measure
 Zero error should display in machine in ideal condition ob served during Gemba.
Analyze
 We observed variation in machine due to use in open condition I.e. machine was
not covered
Improvement
 Daily weighing machine validation check sheet implemented in shop floor.
 All weighing machine covered.
Control
 Daily verification of weighing machine status checked by line supervisor .
 Weekly cross verification done by standard room person.
 Weight variation check point added in layer process audit check sheet .
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
• Project Start:- Oct ’ 21
• Cut of Date: Oct ‘21
BEFORE
AFTER

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Work instruction in English Work instruction in Hindi

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Name of Process: DEGREASING Manufacturing Process
Project Description
Implementation of “DYNE PEN TEST” & “SPECIFIC
HANGER “ for degreasing process.
Define
 No method to check the quality of degrease part after degreasing process.
 Part stick with each other during degreasing process.
Measure
 No method to measure quality of degrease part .
 No specific hanger available that maintain the gap between each layer.
Analyze
 Method to be developed to check the quality of part.
 Specific designed hanger to be use that maintain the gap between the layer.
Improvement
 “DYNE PEN TEST “ method developed to check the quality of part.
 Specific hanger made that maintain the gap between each layer.
Control
 DYNE PEN TEST “ check point added in work instruction and control plan .
 Specific hanger check point added in degreasing process work instruction .
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
• Project Start:- Apr’ 21
• Cut of Date: Apr’ 21
BEFORE
AFTER

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Evidences
Before
After
NA

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Name of Process: Assembly and reactivation Manufacturing Process
Project Description Implementation of Abnormality handling knowledge module
Define
 No visualization of abnormal condition in shop floor .
 Operator not aware about the abnormal situation in shop floor.
Measure
 OPERATOR OBSERVATION METHODOLGY not followed by the operator .
Analyze
 Operator not aware about the abnormal situation and there handling.
Improvement
 Abnormal handling module made and displayed in shop floor.
 On job training given to all operator and inspector .
Control
 Adherence of operator observation system.
 Abnormal situation handling management check point added in tool box meeting.
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
• Cut of Date: Apr’ 21
BEFORE
AFTER

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जमीन पर गिरे हुए पार्ट को माक
ट कर क
े
रैड/यैलो गिन में रखे
कभी भी जमीन पर गिरे हुए पार्ट को OK / WIP
गिन में न रखे
गिरे हुए पार्ट की हैंडगलिंि
1
गिरा हुआ पार्ट डेमेज हो
सकता है
Fallen parts rule

6/25/2023 26
ररजेक्ट पार्ट को हमेशा माक
ट कर क
े रेड
गिन में रखे
ररजेक्ट पार्ट को गिना माक
ट क
े और रेड गिन क
े
िाहर न रखे
इिंस्पेक्शन क
े दौरान ररजेक्ट पार्ट की हैंडगलिंि
ररजेक्ट पार्ट को माक
ट करो और
रेड र्ेि लिाओ
ररजेक्ट पार्ट को रेड गिन मे
रखो
NG
इिंस्पेक्शन क
े
दौरान ररजेक्ट पार्ट
गमला
2 Handling of rejected parts during inspection.

6/25/2023 27
सेगर्िंि क
े दौरान ररजेक्ट पार्ट को पहचान
कर क
े रेड गिन
में रखे
े दौरान ररजेक्ट पार्ट को गिना
पहचान क
े और रेड गिन
क
े िाहर न रखे
3 सेगर्िंि क
े दौरान ररजेक्ट पार्ट की हैंडगलिंि
े दौरान ररजेक्ट पार्ट
ररजेक्ट पार्ट गिना मागक
िं ि
क
े रेड गिन क
े िाहर रख
गदया
ट करो और रेड
र्ेि लिाओ
ररजेक्ट पार्ट को रेड
गिन मे रखो
Handling of rejected parts during setting.

6/25/2023 28
गिजली जाने क
े दौरान िने हुए
पार्ट को लाल गिन में डाले
कभी भी गिजली जाने क
े दौरान िने
हुए पार्ट को गिना मागक
िं ि क
े न रखे
े दौरान िने पार्ट की हैंडगलिंि
े दौरान िना
पार्ट–Welding NG
ररजेक्ट पार्ट को रेड गिन मे रखो
ट
करो और रेड र्ेि
लिाओ
गिना मागक
िं ि क
े
रखा पार्ट
पॉवर फ
े ल
4 Handling of rejected parts during power cut

6/25/2023 29
अपना प्रोसेस हमेशा पूरा कर क
े ही
स्टेशन छोड़े
कभी भी ब्रेक क
े दौरान अधूरा प्रोसेस छोड़ कर न
जाएिं
प्रोसेस पूरा करक
े पार्ट को WIP गिन/र्र ाली मे रखे
लिंच ब्रेक
अधूरा प्रोसेस ना छोड़े
गशफ्ट
खतम
र्ी ब्रेक पूरा प्रोसेस 2 वाशर
(उधारण)
अधूरा प्रोसेस गकया
हुआ पार्ट : 1 वाशर
INPUT OUTPUT
5 Don’t leave process without before completion

6/25/2023 30
6/25/2023 30
अधूरा इिंस्पेक्शन गकया हुआ पार्ट र्ेिल पर न
छोड़े
हमेशा पार्ट का पूरा इिंस्पेक्शन
कर क
े ही स्टेशन छोड़े
अधूरा इिंस्पेक्शन ना छोड़े
अधूरा इंस्पेक्शन
करक
े पार्ट र्ेबल पर
छोड़ दिया
OK पार्ट को OK गिन में रखें
पार्ट को पूरा
इंस्पेक्शन दकये
बगेर स्टेशन न
छोड़े
पार्ट इंस्पेक्शन करते
हुए
NG पार्ट को रेड गिन में रखें
6
लिंच ब्रेक गशफ्ट
खतम
र्ी ब्रेक
Don’t leave inspection in midway

6/25/2023 31
पार्ट उठाकर OK गिन में रख
गदया
पार्ट उठाकरWIP गिन में रख
गदया
गिना पहचान वाले पार्ट को उठाकर
रेड गिन में रखें
गिना पहचान वाले पार्ट को उठाकर OK/WIP गिन
में न रखें
गिना पहचान वाले पार्ट की हैंडगलिंि
7
गिना पहचान वाला पार्ट उठाकर रेड गिन में रख गदया
गिना पहचान वाला
पार्ट
Handling of unidentified parts

6/25/2023 32
चैक गकये हुए और गिना
चैक गकये हुए पार्टटस
अलि-अलि गिन में रखें
चैक गकये हुए और गिना
चैक गकये हुए पार्टटस र्ेिल
पर एक साथ न रखें
गिना चैक गकये
हुए पार्टटस
चैक गकये हुए
पार्टटस
चैक गकये हुए
गिना चैक गकये हुए
इिंस्पेक्शन र्ेिल पर गसिंिल पार्ट फ्लो
रखें
इिंस्पेक्शन र्ेिल पर पार्ट की हैंडगलिंि
8 Handling of parts on inspection table

6/25/2023 33
पार्ट को स्टेंडडट गिन/र्र ाली में रखे
पार्ट को गिन में सही तरीक
े से रखें
नॉन स्टेंडडट गिन/र्र ाली में पार्ट न रखे पार्ट िलत तरीक
े
से नहीिंरखे
यगद पार्ट स्टेंडडट र्र ाली/गिन में नहीिंहै तो : STOP-CALL-WAIT गनयम का पालन करे
पैगक
िं ि स्टेंडडट – फाइनल पार्ट
9
स्टेंडडट गिन सेपरेर्र क
े साथ
नॉन स्टेंडडट गिन गिना सेपरेर्र क
े
Packing standard – Final part

6/25/2023 34
1. पार्ट स्टैण्डडट गिन में ही रखें
2. गिन में गनधाटररत सिंख्या क
े अनुसार ही पार्ट रखें
1. पार्ट नॉन-स्टैण्डडट गिन में न रखें
2.गिन में गनधाटररत सिंख्या से ज्यादा पार्ट न रखें
अिर पार्ट नॉन-स्टैण्डडट गिन में गमले तो STOP-CALL-WAIT गनयम का पालन करें
पैगक
िं ि स्टैण्डडट – चाइल्ड पार्ट
10
चाइल्ड पार्ट स्टैण्डडट िॉक्स में रखें हुए
चाइल्ड पार्ट (Rivets) नॉन-स्टैण्डडट गिन में रखें हुए असेंिली लाइन पर
पार्ट
गनधाटररत
सिंख्या में
रखे हुए
गनधाटररत
सिंख्या से
ज्यादा पार्ट
Packing standard – Child part

6/25/2023 35
गवगभन्न प्रकार क
े मर्ेररअल को अलि गिन मे
रखे !
एक गिन में गवगभन्न प्रकार क
े मर्ेररअल न
रखें !
मर्ेररअल गमक्स-अप क
े गलये
11
सभी मर्ेररअल क
े गलये सेपरेर् गिन है !
कई तरह क
े मर्ेररअल गिन मे गमक्स है !
अिर पार्ट नॉन-स्टैण्डडट गिन में गमले तो STOP-CALL-WAIT गनयम का पालन करें
For material mix-up

6/25/2023 36
पार्ट गडर्ेल्सएक एक
करक
े गप्रिंर् करें
गसिंिल पार्ट गडर्ेल्स गप्रिंर्
पार्ट गडर्ेल्स एडवािंस में
गप्रिंर्
र्रेगसगिगलर्ी एिनोरमेगलर्ी हैंडगलिंि
12
पार्ट गडर्ेल्स एडवािंस
में गप्रिंर् न करें
Traceability abnormality handling

6/25/2023 37
एक समान गदखने वाले पार्टस की लोक
े शन दू र दू र होनी
चागहए
14 एक समान गदखने वाले पार्टटस की हैंडगलिंि
एक समान गदखने वाले पार्टस को
एक साथ न रखे
एक समान
गदखने वाले
पार्टटस पास पास
रखे है
एक समान
गदखने वाले
पार्टटस दू री पर
रखे है
Similar looking part

6/25/2023 38
र्र ायल / प्री ई सी एन पार्टटस की हैंडगलिंि
14
रेिुलर प्रोडक्सन पार्टटस
र्र ायल पार्टटस
र्र ायल पार्टटस पहचान क
े साथ रखे हुए
र्र ायल पार्टटस को पहचान क
े साथ रखने का प्रावधान
होना चागहये
र्र ायल / प्री ई सी एन पार्टस को गिना पहचान
क
े और खुले में न रखे
गिना पहचान क
े र्र ायल पार्टस रखे हुए
Trial/pre ECN part

6/25/2023 39
प्रोडक्सन लाइन पर मोडल / वेररयेंर् चेंजओवर
15
गपछले मॉडल / वेररयेंर् क
े सेर्अप अप्रूवल
पार्टस
को वेररयिंर्/ मॉडल िदलते समय नहीिं हर्ाया िया
गपछले मॉडलक
े सेर्अप अप्रूवल पार्टस को वेररयिंर्/मॉडल
िदलते समय हर्ा गदया िया
गपछले मॉडल वाले सेर्अप अप्रूवल पार्टस को नहीिं
हर्ाया िया
गपछले मॉडल वाले सेर्अप अप्रूवल पार्टस को हर्ा गदया
िया
Model/variant changeover

6/25/2023 40
Help Me
एिनौरमेगलर्ी गसचुएशन हैंडगलिंि
प्रोसेस को रोगकये
सुपरवाईजर को िुलाइये
गनदेश का इिंतजार कररये
असामान्य पररस्थथती मे Rule
असामान्य पररस्थथगतयााँ
STOP
CALL
WAIT
1. गिजली जाना
2. र्ू ल / मशीन ब्रेकडाउन
3. लिातार NG पार्ट िनना(>2 nos)
4. पोका योक
े फ
े ल/NG
5. पार्ट गफर्मेंर् हाडट
6. गजि क्लैस्पिंि / डी क्लैस्पिंि नहीिंहोना
7. रोिोर् का गफक्सचर से र्कराना
8. हवा/क
ू लेंर् का ररसाव होना
9. स्टोर से चाइल्ड पार्ट खराि गमलना
10. स्टोर से चाइल्ड पार्ट गमक्स गमलना
11. कोई अन्य पररस्थथती, जो सामान्य नहीिंहै
Abnormality situation handling

6/25/2023 41
6/25/2023 41
Name of Process: Draw Operation – Heat shield Manufacturing Process
Project Description Design and implementation of dead block in tool . • Tool Used: DMAIC& Turtle diagram
• Project Start:-Apr’ 21
• Cut of Date:Continual Improvement
Define
 During draw operation no process / control to detect the profile as per requirement
Measure
 No visual / process parameter which ensure the profile of heat shield is same or not.
Analyze
 No process control available to define the profile of part as per requirement.
Improvement
 Identified the problematic part and implement the dead block tool.
 Control
 Verification of dead block during in process set up.
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Cost Reduction(Yearly) :
Moral:
BEFORE
AFTER

6/25/2023 42
6/25/2023 42
Evidences
50 No’s dead block
implemented-
Continues
improvement

6/25/2023 43
6/25/2023 43
Name of Process: Molding Process Manufacturing Process
Project Description PLC of machine password protected. • Tool Used: DMAIC& Turtle diagram
• Project Start:-Apr’ 21
• Cut of Date:Continual Improvement
Define
 PLC of machine not password protected resulting any one change the process
parameter.
Measure
 During Gemba on machine gap identified .
Analyze
 Machine PLC should be password protect so that only authorize person can only
change the process parameter.
Improvement
 Identified the problematic machine and provide the password protection in PLC.
 Control
 Authorized person matrix display on machine.
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
QualityImprovement:
Moral:
BEFORE
AFTER

6/25/2023 44
6/25/2023 44
Name of Process: Laser marking Manufacturing Process
Project Description Implementation of fixture and work instruction .
Define
 Laser marking done on wrong side .
 No work instruction available for location of laser marking on part.
Measure
 During Gemba audit interview the laser marking operator , he was not aware about
the location laser marking for similar looking part.
Analyze
 No work instruction available that define the location of laser marking on part .
 No fixture available that prevent the part from wrong side laser marking.
Improvement
 Work instruction made for each part .
 Exploring the feasibility to provide the fixture that ensure the correct side laser
marking done on part.
 Control
 Work instruction made and displayed in work station .
 Fixture provided for correct side laser marking .
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
Input
Infrastructure
resource
Risk
Involved in
process
Process owner
competency
Process
documents &
records
Process
efficiency &
effectivenes
s
RESULT YES / NO
ProductivityImprovement
QualityImprovement:
Moral:
• Cut of Date: Continual Improvement
BEFORE
AFTER

6/25/2023 45
6/25/2023 45
Evidences
5
8 7
13
3
0
10
20
Q-1 -2021 Q-2 -2021 Q-3-2021 Q-4-2021 Q-1 -2022
Visual Aids For Laser Marking Location
5 No’s of part
identified for fixture
Continues
improvement

6/25/2023 46
6/25/2023 46
SERIAL
NUMBER
PROJECT DESCRIPTION
PROJECT BELONGSTO WHICH
PROCESS
BENEFIT
1 No online accessibility of EHS/ IATF Document Business Process
Easily assessing documents online benefits
paper saving.
2 Calibration agencies scope verification Business Process Help in calibration from unauthorized agency
3 Control plan review system development Business Process Benefit in timely updation of requirements
4 Implementation of work permit monitoring criteria Business Process
Helps in monitoring during working to ensure
the safety of worker.
5 Daily validation of weighing machine . Manufacturing Process
Benefits in checking the variation in weighing
machine
6
Implementation of “DYNE PEN TEST” & “SPECIFIC HANGER “ for
degreasing process.
Manufacturing Process
To ensure the cleaning surface after
degreasing
7 Implementation of Abnormality handling knowledge module Manufacturing Process Benefits in tackling the abnormal situation
8 Design and implementation of dead block in tool . Manufacturing Process Benefits in rejection reduction
9 PLC of machine password protected. Manufacturing Process
Benefits in unauthorized editing of machine
parameters
10 Implementation of fixture and work instruction for laser marking Manufacturing Process Ensure the laser marking on exact location
Summary

6/25/2023 47
6/25/2023 47
Thank You
Zero Defect journey Continue…

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