Professional Documents
Culture Documents
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
INDIVIDUAL / ORGANISATION , WHO SUPPLIES RA MATERIALS, CATALOGUE ITEMS , PACKING MATER PRODUCTION CONSUMABLES TOOLING & GAUGES.
3.5
VENDOR
INDIVIDUAL / ORGANISATION , WHO SUPPL COMPONENTS TO RICO AUTO INDUSTRIES LIM AGAINST RICO AUTO INDUSTRIES LIMITED DRAWIN SPECIFICATIONS.
3.6
JOB-CONTRACTOR
ANY OUT SIDE AGENCY WHICH PERFORMS / PROVID JOB / SERVICES AS PER RICO AUTO INDUSTR REQUIREMENT EITHER AT HIS PLACE OF WORK INSIDE RICO AUTO INDUSTRIES PREMISES INCLUD JOB - WORK ON COMPONENTS. ANY ORDER RAISED FOR MATERIALS / BOUGHT OUT CONSUMABLES.
3.7
PURCHASE ORDER
3.8
ANY ORDER RAISED FOR PROCESSING , REPAIR A MAINTENANCE AT SUB-CONTRACTOR'S PLACE RICO AUTO INDUSTRIES LIMITED PREMISES.
3.9
PRODUCTION CONSUMABLE
MATERIALS WHICH ARE USED DIRECTLY IN T PROCESS OF PRODUCT MANUFACTURING SUCH WELDING ROD / BRAZING WIRE , FLUX AND GASES E
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
MATERIALS FOR WHICH MANUFACTURER PUBL THEIR CATALOGUE / LITRATURE INDICATING SPECIFICATION AND ARE AVAILABLE IN THE MARK THROUGH THEIR DISTRIBUTION NETWORK.
E.D.(FINANCE)
PURCHASE ASSISTANT
4.1
OVER ALL RESPONSIBILITY FOR IMPLEMENTATION OF THIS PROCEDURE LIES WITH HOD (MATERIALS). OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.
4.2
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
6.1.2
ENGINEER MATERIALS
6.1.3
6.1.4
DOCUMENT 6.1.5 RECEIVE AND ENTER THE DETAILS IN P.O. CONTROL REGISTER.
6.2 6.2.1
RAW MATERIAL & BOUGHT OUT PARTS IDENTIFY THE NEED ON THE BASIS OF PRODUCTION PLAN , INTERNAL REVIEW AND DEVELOPMENT PLAN IN CONSULTATION WITH HOD (MATERIALS) IDENTIFY FOR THE CAPABLE SUB-CONTRACTOR SECTION HEAD (MATERIALS)
6.2.2
INTRODUCTION FOR NEW COMPONENT. ENGG. CHANGES IN DRAWING. SECOND SOURCE / ALTERNATIVE SOURCE FOR EXISTING COMPONENTS.
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY HOD (MATERILS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) SECTION HEAD(QA)
6.2.4
6.2.5
RECEIVE THE SAMPLES ALONG WITH THE DOCUMENTS AND CARRY OUT INSPECTION AND PREPARE INSPECTION REPORT AND FORWARD TO HOD (QA) FOR REVIEW AND COMMENTS. REVIEW THE INSPECTION REPORT AND IF FOUND "O.K." RECOMMEND FOR SUPPLYING PILOT SUPPLY & SEND THE INSPECTION REPORT TO HOD (MATERIALS) / SECTION HEAD (MATERIALS) .
6.2.6
HOD (QA)
6.2.7
RECEIVE THE PILOT LOT SUPPLY AND INSPECT FOR CONFORMANCE . IF MATERIAL ARE ACCEPTABLE ALLOW FOR REGULAR SUPPLY AFTER APPROVAL OF PILOT LOT SUPPLY RELEASE REGULAR DELIVERY SCHEDULE.
6.2.8
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
6.2.9
AFTER THE STARTING OF REGUAR SUPPLY CARRY OUT THE VENDOR PERFORMANCE EVALUATION QUARTERLY. EXAMINE VENDOR PERFORMANCE RATING ON QUARTERLY BASIS AND TAKE NECESSARY ACTIONS. FOR HIGH IMPACT PARTS IDENTIFIED IN APPROVED VENDOR LIST, ARRANGE MIS DATA FROM VENDOR ON MONTHLY BASIS FOR KEY INDICATORS OF PROCESS / PRODUCTS OF SUPPLIER AS APPROPRIATE e.g. - Cpk DATA, INTERNAL REJECTION DATA, DELIVERY PERFORMANCE, R.M. STOCK ETC.
6.2.10
6.2.11
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY
6.3.2
PREPARE PURCHASE ORDER MENTIONING THE ITEM DESCRIPTION, REFERENCE / SPECIFICATION GIVEN IN THE CATALOGUE,
ANY OTHER REQUIREMENT LIKE TRANSPORTATION METHOD AND OTHER DELIVERY TERMS AND CONDITIONS. 6.4 6.3.3 JOB WORK ITEMS REVIEW THE PURCHASING DOCUMENT FOR ADEQUACY AND COMPLETENESS AND FORWARD TO PLANT MANAGER / HOD MATERIALS (CORP.). INCASE OF MATERIAL / COMPONENT TO BE SENT FOR JOB WORK FROM RICIO AUTO INDUSTRIES LIMITED, ADVISE STORE TO ISSUE THE MATERIAL / COMPONENTS TO THE SUB-CONTRACTORS FOLLOW STEP 5.3.3 TO 5.3.4 SCHEDULING OF SUB-CONTRACTOR BASED ON PPC REQUIREMENT, RELEASE THE PART WISE / VENDOR WISE SCHEDULE TO CONCERN VENDOR. IF SCHEDULING IS REQUIRED ON DAILY / WEEKLY / FORTNIGHTLY BASIS AND MENTION IT IN DELIVERY SCHEDULE (SPECIFICALLY IN SCHEDULE). MONITOR THE SCHEDULE ON DAILY BASIS AND TAKE ACTION ACCORDINGLY IN ORDER TO MAKE SUPPLIES 100% ON TIME. IF SUPPLIES ARE RECEIVED EXCEEDING 10% LIMIT NORMS OF SCHEDULE QTY HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / MATERIALS ENGR.
6.4.1
HOD (MATERIALS)
CONCERN PERSON
6.5.2
6.5.3
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
6.5.4
6.5.5
ACTIVITY SUPPLIER VERIFICATION AT SUBCONTRACTOR END ARRANGE AND SPECIFY THE VERIFICATION OF PURCHASED PRODUCT AT SUBCONTRACTOR END AND INDICATE THE REQUIREMENT ALONG WITH PURCHASE ORDER
RESPONSIBILITY
6.7 6.7.1
CUSTOMER VERIFICATION OF SUBCONTRACTED PART FIND OUT FROM APQP LEADER WHEATHER CUSTOMER VERIFICATION AT SUBCONTRACTOR END IS REQUIRED OR NOT. IF REQUIRED BY CUSTOMER INDICATE THE REQUIREMENT IN THE SUBCONTRACTOR PURCHASE ORDER AND ARRANGE ACCORDINGLY TO CUSTOMER REQUIREMENT HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
6.7.2
6.8
PART APPROVAL PROCESS (APPLICABLE IF CUSTOMER SPECIFIC PROCEDURE DOES NOT EXIST FOR TIER 2) RECEIVE SAMPLES ALONG WITH RELEVENT DOCUMENTS FROM SUBCONTRACTOR AS PER DEVELOPMENT REQUIREMENTS FILL THE SAMPLE EVALUATION REQUEST AND SUBMIT TO Q.A. DEPARTMENT FOR INSPECTION ENSURE THAT ALL APPROPRIATE DOCUMENTS ARE SUBMITTED ALONG WITH SAMPLES AS AGREED WITH Q.A. ARRANGE THE INSPECTION AND DO VENDOR VISIT FOR PROCESS IF REQUIRED SUBMIT THE REPORT TO HOD (Q.A.) FOR APPROVAL AND FURTHER ACTION. IF SAMPLE O.K. , ARRANGE PILOT LOT AS PER INSTRUCTION OF Q.A. DEPARTMENT RECORD THE SAMPLE DETAILS i.e. O.K. / REJECT & DATES ETC IN PART APPROVAL LOG SHEET HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
6.8.1
6.8.2
6.8.3
6.8.4
6.8.5
6.8.6
6.8.7
COPY ST
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY SECTION HEAD (Q.A.)
6.8.9
6.10 6.9.1
6.9.2
6.9.3
6.9.4
HOD (Q.A.) / SECTION HEAD (Q.A.) SECTION HEAD (MATERIALS) / ENGINEER (MATERIALS)
6.9.5
6.9.6
6.10 6.10.1
PREMIUM FREIGHT RECORD THE PREMIUM FREIGHT PAID BY EITHER US OR BY VENDOR IF ANY. AND INTIMATE TO MANAGEMENT ON MONTHLY BASIS FOR REVIEW & ACTION. HOD (MATERIALS) / SECTION HEAD (MATERIALS)
6.11 6.11.1
CUSTOMER APPROVED SOURCES WHERE SPECIFIED BY THE CONTRACT, ENSURE THAT PRODUCT / MATERIAL / SERVICES ARE SOURCED FROM APPROVED SOURCES. HOD (MATERIALS)
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY
6.13
4.27 Subcontractor Development (ISO/TS 16949:2002 7.4.1.2) 4.28 Customer approved sources (ISO/TS 16949:2002 cl. 7.4.1.3) 4.30 Scheduling subcontractors (ISO/TS 16949:2002 cl. 7.4.3.2)
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
PROCEDURE FOR INCOMING MATERIAL INSPECTION AND TES PROCEDURE FOR ISSUE OF MATERIAL FOR JOB-WORK. WORK INSTRUCTION FOR ASSESSMENT OF VENDOR RATING SYSTEM.
RETENT PERIO
RICO 08 QFO 01
5 YEA
(MATERIALS) RICO 08 QFO 02 DELIVERY SCHEDULE HOD (MATERIALS) HOD (MATERIALS) HOD (Q.A.) HOD (MATERIALS) HOD (MATERIALS) HOD (PURCHASE) HOD (MATERIALS)
1 YEA
RICO 08 QFO 03
ON GO
RICO 08 QFO 06
2 YEAR
RICO 08 QFO 07
PURCHASE REQUISITION
1 YEA
RICO 08 QFO 08
P.O.CONTROL REGISTER
1 YEA
RICO 08 QFO 09
RECEIPT MONITORING
1 YEA
RICO 08 QFO 10
1 YEA
NOTE :-
FORMATS ARE COMMON FOR BOTH PLANTS HENCE EITHER OF THE CONFIGURATION NUMBER PRINTED ON FORMAT CAN BE USED.
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
REVISION NO.
DATE
06
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
07
25-12-2003
MIS Data requirement added for high impact parts identified in approved list
08
15-04-2004
08
15-04-2004
09
05-05-2004
10
25-01-2006
EQUIREMENTS.
- CONTRACTOR.
CH PERFORMS / PROVIDES RICO AUTO INDUSTRIES T HIS PLACE OF WORK OR TRIES PREMISES INCLUDING
UT
USED DIRECTLY IN THE MANUFACTURING SUCH AS IRE , FLUX AND GASES ETC
COPY STATUS
SHEET 01 OF 10
MANUFACTURER PUBLISH TURE INDICATING THE AVAILABLE IN THE MARKET ION NETWORK.
E.D.(FINANCE)
PURCHASE ASSISTANT
COPY STATUS
SHEET 02 OF 10
RESPONSIBILITY
REF.DOC
RICO 08 QFO 01
ENGINEER MATERIALS
COPY STATUS
SHEET 03 OF 10
DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY HOD (MATERILS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) SECTION HEAD(QA)
HOD (QA)
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
COPY STATUS
SHEET 04 OF 10
RICO 08 QFO 07
RICO 08 QFO 01
HOD (MATERIALS)
CONCERN PERSON
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) COPY STATUS SHEET 05 OF 10
RESPONSIBILITY
REF.DOC
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)
DOES NOT
HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (Q.A.) / SECTION HEAD (Q.A.) SECTION HEAD (Q.A.)
COPY STATUS
SHEET
06 OF 10
HOD (Q.A.) / SECTION HEAD (Q.A.) SECTION HEAD (MATERIALS) / ENGINEER (MATERIALS) HOD (Q.A.) / SECTION HEAD (Q.A.)
HOD (MATERIALS)
COPY STATUS
SHEET 07 OF 10
HOD (MATERIALS)
COPY STATUS
SHEET 08 OF 10
SELECTION OF
NT OF VENDOR RATING
1 YEAR
HOD (MATERIALS)
ON GOING
HOD (MATERIALS)
2 YEARS
HOD (Q.A.)
1 YEAR
HOD (MATERIALS)
1 YEAR
HOD (MATERIALS)
1 YEAR
HOD (PURCHASE)
1 YEAR
HOD (MATERIALS)
COPY STATUS
SHEET 09 OF 10
W.e.f.
APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
25-06-2003
25-12-2003
15-04-2004
15-04-2004
Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
05-05-2004
25-01-2006
COPY STATUS
SHEET 10 OF 10
DOCUMENTS :
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
INTERNAL
SCOPE : This procedure is applicable to identified sub-contractors of bought out parts (H, Q, C, R Class) and carrying out job work (JW Class) on components.
3 3.1 3.2
ABBREVIATION AND DEFINITION : BOP H-Class (High Impact Supplier) Brought Out Parts
Supplier come in the High Impact supplier category, If it falls in any of flollowing criteria (a) New Supplier (b) New part with existing supplier (c) New technology to supplier (d) Monthly Quality PPM is higher than standard target for consecutiv 3 months (e) Environmental, Health, Safety Risk Involved in the process (f) Others as specified by CFT Quality Class i.e. Item important w.r.t. Form, Fit, Function, Safety, Government & Apperanace C-Class i.e. Item not much important w.r.t. end use Properiery Class Raw Material Class Raw Material Properiery Class
3.3
Q-Class Supplier
Note : Any supplier which is supplying multiple part no. The supplier will be designated accordingly to the most severe class of Part no, supplying to RICO i.e. any supplier having parts within C-Class and Q-Class. Supplier will come in Q-Class category.
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
ORGANISATION CHART AND RESPONSIBILITY For organisation please refer organisation chart
HOD-Corp. Quality
HOD-Material Plants
Section Head
Section Head
Engineers (Quality)
Engineers
4.1 4.2
Hod (materials) is over all responsible for implementation of this procedure. Hod (Corp.- Quality) is over all responsible for reviewing of implementation of corrective and preventive actions Identified audit teams are responsible for carrying out systems audits. Other responsibilities are as mentioned against each activity
4.3 4.4
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
Process Input
Sl.No
Process Input
Supplier selection criteria EHS specific requirements Specification of the material to be procured Customer specific requirement.
Source / Supplier
HOD QA MR Process Owner HOD QA
1 2 3 4
5.2
Process Output
Sl.No Process Output
Sl.No 1 2 5.3
Process Output Timely procurement of the material conforming to customer specified requirement, user specification, all other applicable specifications. Quality System Complying Vendors
6 SL.NO 6.1
DESCRIPTION ACTIVITY Classify the Bought Out Parts and Job Work Components according to end use , status of supplier performance. viz - H, Q, C, P, R, RP and CSP Class Prepare list of approved sub-contractor for bought out parts as well as sub contractors doing job work on components for development of system.
6.2
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.4
6.5
(d) Monthly Quality PPM is less than standard target for consecutive 3 months (e) Environmental, Health, Safety Risk Involved in the process (f) Others as specified by CFT (Annual Auidit as per RICO 06 QFO 88) 2Q - Class Category Supplier Minimum ISO 9001:2000 Certified suppliers supplying Quality Product (Annual Auidit as per RICO 06 QFO 23) C - Class Category Supplier
Minimum ISO 9001:2000 Certified suppliers supplying Parts having relatively less important on Quality
3-
(Annual Auidit as per RICO 06 QFO 23, but these C-Class items are not Audited during Audit) 4P - Class Category Supplier Suppliers supplying Proprietary items (Not in Audit Scope) R - Class Category Supplier Minimum ISO 9001:2000 Certified suppliers supplying Quality Product (Annual Auidit as per RICO 06 QFO 23) JW - Class Category Supplier Minimum ISO 9001:2000 Certified suppliers carrying Job Works. (Annual Auidit as per RICO 06 QFO 23) RP - Class Category Supplier Raw Material Properiery Supplied Product (Not in Audit Scope) CSP - Class Category Supplier Customer Supplied Product (Not in Audit Scope)
5-
6-
7-
8-
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
FOLLOWING IS THE CRITERIA FOR DECIDING THE AUDIT CHECK LIST S.NO
1 H - Class Category Supplier
CATEGORY
2 3 4 5 6 7 8 9
Q - Class Category Supplier R - Class Category Supplier Q - Class Category Supplier Become H - Class Category Supplier H - Class Category Supplier Become Q - Class Category Supplier R - Class Category Supplier Become H - Class Category Supplier H - Class Category Supplier Become R - Class Category Supplier JW - Class Category Supplier Become H - Class Category Supplier H - Class Category Supplier Become JW - Class Category Supplier
6.6
Get Quality System Certificate i.e. ISO 9001:2000, ISO TS 16949:2002 & other applicable system certificate as per requirement
6.7
Prepare Annual Audit Schedule in consultation with HOD (Corp.-Quality). The Audit Plan consists of H-Class Suppliers & Q-Class Suppliers
6.8
Intimate the Supplier for audit in advance as per Annual Audit Schedule. Decide Date & Time in consultation with supplier to be audited
6.9
6.10
Perform Audit as per Rico Defined Check List. (1) H-Class Category Supplier (2) Q-Class Category Supplier
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.11
Appraise the supplier with system conformances & non-conformances and Hand over the audit report to supplier for taking action at their end and submission of short term & long term action plan for issues raised by RICO Submit the audit report to HOD (Corp.-Quality) / Hod (Plant Quality) and HOD (Plant Purchase) for Review Do follow up with supplier for getting feed back regarding corrective and preventive action submission. Perform Audit at least once in a year for each supplier unless other wise waived by HOD (Quality Corporate) Do the audit of supplier based on the supplier status (Class / Category) of that month receive the corrective and preventive action report from supplier Review the effectiveness of counter measure taken by supplier . Visit the supplier for checking the effectiveness and implementation if required Q-Class Category Supplier becomes H-Class category Supplier, if its Monthly PPM for consecutive 3 Months is more than 100 PPM & H-Class Category Supplier becomes Q-Class Category supplier, if its Monthly PPM for consecutive 3 Months is less than 100 PPM Review the Sub-supplier list at three month frequency and reallocate the supplier in H-Class Category & Q-Class Category based PPM Performance. Re-schedule the supplier audit plan based on this changed category
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.23
NOTE :
Customer designated sub-supplier / Quality system developed by customer. So it will not come under perview of Rico sub-supplier system development Depending upon the subcontractor size certain sub element can be waived by Audit Team. Properietary part & c-class items are not included in the subcontractor system development and audit. In case of customer specific requirement, follow the customer advise for sub-contractor development. Minimum 60% quality rating must be achieved in the assessment to become potential supplier to Rico or To be continued as supplier to RICO.
2 3
DOCUMENTS : RICO 08 QSP 01 RICO 08 QSP 02 RICO 06 QWI 02 RICO 06 DOC 02 Procedure for Purchasing. Procedure for Assessment and selection of Sub-Supplier Work Instruction For Assessment of Vendor Rating System Classification of Boughtout Parts
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
REVISION NO.
DATE
05
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
06
05-05-2004
07
25-01-2006
08
05-09-2006
08
05-09-2006
APPROVED BY
ISSUED BY
MENT
.4
H, Q, C, R Class)
COPY STATUS
SHEET 01 OF 08
MENT
.4
orrective and
COPY STATUS
SHEET 02 OF 08
MENT
.4
ource / Supplier
When To Collect The Input (Frequency Of Collection) Before vendor development and procurement of the engineering goods
User / Customer
REF.DOC ___
___
COPY STATUS
SHEET 03 OF 08
MENT
.4
DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY Section Head (Quality Assurance) HOD (Plant Materials)
___
COPY STATUS
SHEET 04 OF 08
MENT
.4
RICO 06 QFO 23 RICO 06 QFO 23 RICO 06 QFO 88 RICO 06 QFO 23 RICO 06 QFO 88 RICO 06 QFO 23 RICO 06 QFO 88 RICO 06 QFO 23
y Supplier
y Supplier
y Supplier
y Supplier
ory Supplier
ory Supplier
Section Head (Plant Quality) / Section Head (Plant Materials) Section Head (Plant Quality) / Section Head (Plant Materials)
COPY STATUS
SHEET 05 OF 08
MENT
.4
Section Head (Plant Quality) / Section Head (Plant Materials) Section Head (Plant Manterials)
Section Head (Plant Quality) / Section Head (Plant Materials) Section Head (Plant Quality) Section Head (Plant Quality) Section Head (Plant Quality) Section Head (Plant Quality) Section Head (Plant Quality)
COPY STATUS
SHEET 06 OF 08
MENT
.4
sessment to become
COPY STATUS
SHEET 07 OF 08
MENT
.4
1 Year
HOD(QA)
1 Year
HOD(QA)
CRIPTION
W.e.f.
APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
25-06-2003
r Ford Q1 Programme
05-05-2004
25-01-2006
development of sub-
05-09-2006
development of sub-
05-09-2006
COPY STATUS
SHEET 08 OF 08
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
INTERNAL
HOD(HPDC)
HOD (MP&L)
HOD(M/C SHOP-I)
HOD(M/C SHOP-II)
4.1 4.2
PLANT MANAGER IS RESPONSIBLE TO RECEIVE THE CUSTOMER PRODUCTION SCHEDULE. HOD (MP&L ) / SECTION HEAD (MP&L) IS RESPONSIBLE TO CONVERT THE CUSTOMER PRODUCTION / DELIVRY SCHEDULE IN TO RICO AUTO INDUSTRIES LIMITED PRODUCTION PLAN. OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.
4.3
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.2
6.3
6.4
ON TIME DELIVERY
FOR HHML DHARUHERA & GURGAON / AUTOFIT TAKE DAY'S PRODUCTION PLAN FROM HHML BY MEANS OF PHONE / E-MAIL ETC ON DAILY BASIS. TAKE PHYSICAL STOCK DATA OF OUR PARTS BY MEANS OF PHONE / E-MAIL OR VIA PHYSICAL UNDERTAKING AT CUSTOMER END BY OUR REPRESENTATIVE. DECIDE DESPATCH PLAN (IN CONCSULTATION WITH PLANT MANAGER) FOR DAY AND INTIMATE TO ALL CONCERNED.
6.5.1.2
6.5.1.3
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.5.1.5
6.5.1.6
6.5.2 6.5.2.1
FOR MARUTI UDYOG LIMITED RECEIVED THE "DI" FROM THE CUSTOMER / MARKETING BY FAX / E-MAIL HOD (MP&L)
6.5.2.2
INTIMATE TO ALL CONCERNED WELL IN ADVANCE FOR "DI" REQUIREMENT OF MUL. ARRANGE THE "DI" REQUIREMENT PARTICULAR DAY IN ADVANCE APPROPRIATE OF AS
HOD (MP&L)
6.5.2.3
HOD (PRODN.)
6.5.2.4
ARRANGE THE DESPATCH AS PER "DI" REQUIREMENT IN ORDER TO REACH SUPPLY ON REQUIREMENT DATE AND TIME AS WELL AS AT REQUIRED LOCATION OF MARUTI STORES. KEEP TRACK WITH CUSTOMER FOR CHANGE IN "DI" SCHEDULE / NON "DI" SCHEDULE FOR NECESSARY ACTION AT OUR END. ENSURE 100% ON TIME DELIVERY AS PER DI GIVEN BY MUL.
HOD (PRODN.)
6.5.2.5
6.5.2.6
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.5.3.2
6.5.3.3
PREPARE PRODUCTION PLAN / DESPATCH PLAN FOR INHOUSE PRODUCTION , RAW MATERIAL PLANNING & PROCUREMENT & SCHEDULING OF SUB-CONTRACTORS & VENDORS FEED THE DESPATCH PLAN IN THE ERP SYSTEM, WHICH WILL TAKE CARE OF UNAUTHORISED SHIPMENTS TO CUSTOMER
6.5.3.4
SECTION HEAD(MP&L)
6.5.3.5 6.5.3.6
MP&L PROCESS TO AVOID POTENTIAL PROBLEM REVIEW THE CMMS3 ON DEFINE INTERVAL DISCUSS THE PRODUCTION REQUIREMENT IN PRODUCTION MEETING MAKE SURE THE PRODUCTION AS PER PLAN , IF ANY ABNORMALITY INFORM TO HOD FOR NECESSARY ACTION. INCASE OF POTENTIAL FAILURE IN MP&L SERVICES , INFORM TO CUSTOMER WELL IN ADVANCE SO THAT POSSIBLE ACTION CAN BE TAKEN BY CUSTOMER KEEP TRACK WITH CUSTOMER FOR CHANGE IN "CMMS3 / EDI" SCHEDULE / NON "CMMS3 / EDI" SCHEDULE FOR NECESSARY ACTION AT OUR END. ENSURE 100% ON TIME DELIVERY AS PER CMMS3 / EDI GIVEN BY EXPORT CUSTOMER.
SECTION HEAD(MP&L)
6.5.3.7
6.5.3.8
HOD (MP&L)
6.5.3.9
6.5.3.10
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
FORMAT ON WEEKLY BASIS 6.5.4.2 SEND THE PIPE LINE DETAIL TO WAREHOUSE AT LEAST ONCE IN A MONTH ARRANGE RECONCILING WITH THE WAREHOUSE PERSONNEL INCASE OF DISAGREEMENT, DETECT THE CAUSE AND TAKE CORRECTIVE ACTION AS PER ADVICE OF HOD (MP&L)
6.5.4.3
6.5.4.4
6.5.4.5
(BETWEEN WAREHOUSES & CUSTOMER) REVIEW THE CMMS3 IN THE FIRST WEEK OF MONTH FOR LAST QTY. RECEIVED FOR PREVIOUS MONTH AND TOTAL SHIP QTY. TO CUSTOMER RECONCILE IT IF THERE IS DISCREPANCY, DISCUSS WITH CUSTOMER AND FIND OUT THE ROOT CAUSE IMPLEMENT THE CORRECTIVE ACTION IN ADVICE WITH DIRECTOR WARE HOUSE. FOR OTHER CUSTOMER RECEIVED THE SCHEDULE FROM MARKETING FOR DISPATCH INTIMATE TO ALL CONCERNED ACCORDINGLY VIA FLASH REPORT ARRANGE DESPATCH AS PER SCHEDULE
6.5.4.6
6.5.4.7
6.5.5 6.5.5.1
6.5.5.2
6.5.5.3
6.5.5.4
KEEP TRACK WITH MARKETING FOR ANY ALTERATION IN DESPATCH PLAN AND INTIMATE TO ALL CONCERNED (IF APPLICABLE) ENSURE 100% ON TIME DELIVERY.
6.5.5.5
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
TITLE
SL.NO ACTIVITY
6.6
PLANNING AMENDMENT RECEIVE THE AMENDMENT DETAIL FROM CUSTOMER / HEAD OFFICE BY WRITTEN MEDIA OR VERBALLY PREPARE THE AMENDMENT NOTE AS PER INFORMATION RECEIVED INDICATING SOURCE DETAIL OF AMENDMENT REVIEW THE AMENDMENT FOR VALIDITY
6.7
6.8
HOD (MP&L)
6.9
HOD (MP&L) / SECTION HEAD (MP&L) HOD (STORES) HOD (MP&L) / SECTION HEAD
6.10
CARRY OUT MONTHLY PHYSICAL INVENTORY AND INTIMATE TO ALL CONCERN REGARDING PLAN AND MACHINE LOADING INLINE WITH INVENTORY STOCK. DISCUSS AND REVIEW THE FLASH REPORT IN DAILY PRODUCTION MEETING ALONG WITH ALL CONCERN HODS AND DECIDE ACTION ON IMPROVING DELIVERY PERFORMANCE. PREPARE MONTHLY FLASH SUMMARY REPORT INDICATING THE REASON OF DELIVERY FAILURE AND IDENTIFY THE AREA / CUSTOMER WHERE DELIVERY PERFORMANCE NEED IMPROVEMENT. MAKE CORRECTIVE ACTION PLAN IN CASE OF DELIVERY FAILURE.
6.11
6.12
6.13
HOD (HODC) / HOD (M/C SHOP) / HOD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)
6.14
INTIMATE TO CUSTOMER WELL IN ADVANCE WITH REGRET, IN CASE OF SUPPLIES CAN NOT BE MADE ON DUE DATE AND TIME. PREMIUM FREIGHT RECORD THE PREMIUM FREIGHT PAID BY EITHER US OR BY VENDOR IF ANY. AND INTIMATE TO MANAGEMENT ON MONTHLY BASIS FOR REVIEW & ACTION.
6.15 6.15.1
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.16
PLANT TEAM
6.17
MKT. / MP&L
6.18
CFT
6.19
CFT
6.20
MKT. / MP&L
6.21
MKT. / MP&L
6.22
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
RICO 09 QFO 02
MP&L
RICO 09 QFO 03
FLASH REPORT
MP&L
RICO 09 QFO 04
MP&L
RICO 09 QFO 05
MP&L
RICO 09 QFO 06
MP&L
------
MP&L
-------
MP&L
-------
WEEKLY SHIP SCHEDULE CMMS3 (SOFT COPY) DAILY SHIP SCHEDULE CMMS3 (SOFT COPY)
MP&L
-------
WARE HOUSE
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
REVISION NO.
DATE
06
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
07
05-05-2004
08
11-11-2004
09
25-01-2006
10
16-03-2006
Capacity Enhancement Process of Suppliers & Subsupplier on the basis of Customer Requirement added.
10
16-03-2006
Capacity Enhancement Process of Suppliers & Subsupplier on the basis of Customer Requirement added.
PREPARED BY
APPROVED BY
ALUMINIUM PLANTS
.5
Q.A,PURCHASE,DEVELOPMENT)
HOD (MATERIALS)
HOD(M/C SHOP-II)
DUCTION SCHEDULE.
COPY STATUS
SHEET 01 OF 09
ALUMINIUM PLANTS
.5
RESPONSIBILITY HOD (MP&L) / SECTION HEAD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)
REF.DOC
RICO 09 QFO 06
RICO 09 QFO 03
S.H. (MKT.) / HOD (MP&L) / SECTION HEAD (MP&L) S.H. (MKT.) / HOD (MP&L) / SECTION HEAD (MP&L)
COPY STATUS
SHEET 02 OF 09
ALUMINIUM PLANTS
DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) / S.H. (MARKETING) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.)
.5
HOD (MP&L)
HOD (MP&L)
HOD (PRODN.)
HOD (PRODN.)
COPY STATUS
SHEET 03 OF 09
ALUMINIUM PLANTS
.5
SECTION HEAD(MP&L)
HOD (MP&L)
COPY STATUS
SHEET 04 OF 09
ALUMINIUM PLANTS
.5
HOD (MP&L) / HOD (PRODN.) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) COPY STATUS SHEET 05 OF 09
ALUMINIUM PLANTS
DOC. NO.
RICO 09 QSP 01
.5
10 16-03-2006 REF.DOC
RICO 09 QFO 01
HOD (MP&L)
HOD (MP&L) / SECTION HEAD (MP&L) HOD (STORES) HOD (MP&L) / SECTION HEAD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)
RICO 09 QFO 03
HOD (HODC) / HOD (M/C SHOP) / HOD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)
COPY STATUS
SHEET 06 OF 09
ALUMINIUM PLANTS
.5
PLANT TEAM
RICO 14 QSP 03
MKT. / MP&L
CFT
CFT
MKT. / MP&L
MKT. / MP&L
MKT. / MP&L
COPY STATUS
SHEET 07 OF 09
ALUMINIUM PLANTS
.5
LOCATION
MP&L
MP&L
1 YEAR
HOD (MP&L)
MP&L
1 YEAR
HOD (MP&L)
MP&L
1 YEAR
HOD (MP&L)
MP&L
1 YEAR
HOD (MP&L)
MP&L
1 YEAR
HOD (MP&L)
MP&L
3 MONTHS
HOD (MP&L)
MP&L
1 YEAR
HOD (MP&L)
MP&L
3 YEARS
HOD (MP&L)
WARE HOUSE
3 YEARS
COPY STATUS
SHEET 08 OF 09
ALUMINIUM PLANTS
.5
CRIPTION
W.e.f.
APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
25-06-2003
r Ford Q1 Programme
05-05-2004
ancement system
11-11-2004
25-01-2006
16-03-2006
16-03-2006
COPY STATUS
SHEET 09 OF 09
MENT
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
INTERNAL
ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION, PLEASE REFER ORGANISATION CHART.
4.1 4.2
OVER ALL RESPONSIBILITY LIES WITH PLANT MANAGER. HOD'S ARE RESPONSIBLE FOR MATERIAL HANDLING, PRESERVATION AND MOVEMENT IN THEIR RESPECTIVE AREA. HOD (STORES) IS RESPONSIBLE FOR HANDLING, PRESERVATION AND MOVEMENT OF MATERIAL IN MAIN STORES, RECEIPT STORE AND FEEDING TO PRODUCTION LINES. OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY. PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - STORES, MATERIL HANDLING & INVENTORY)
4.3
4.4 5
6 SL.NO 6.1
6.1.1
ARRANGE TO PUT CARRIER LOADED WITH RAW MATERIAL IN THE ALLOCATED AREA. UNLOAD THE MATERIAL AT APPROPRIATE LOCATION BY ANY OF FOLLOWING METHOD AS APPLICABLE. FOR RICO DHARUHERA (I) RAW MATERIAL > 10 TONS USE HEAVY DUTY CRANE. (II) RAW MATERIAL > 3 TONS USE CHAIN PULLY BLOCK. (III) RAW MATERIAL > 20 KG BUT < 3 TONS USE FORK LIFT. (IV) RAW MATERIAL < 20 KG MANUAL / FORK LIFT / PALLET ETC.
6.1.2
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.1.4
6.1.5
6.2
6.2.1
AND
PROVIDE IDENTIFICATION TAG ON INCOMING AREA. PROTECT THE MATERIAL KEPT IN STORES FROM RUST AND DAMAGES FOLLOW FIRST IN FIRST OUT (FIFO) FOR ITEM HAVING LIMITED SELF LIFE. TRANSFER THE MATERIAL FROM STORE TO THE RESPECTIVE SHOPS. TRANSFER THE REQUIRED RAW MATERIAL TO RESPECTIVE SHOP (HPDC, MACHINE SHOP, PAINT SHOP & ASSY. LINES) BY MEANS OF HAND PALLETS OR MANUALLY. SUPPLY BOUGHT OUT PARTS TO MACHINE SHOP BY MEANS OF HAND PALLETS OR MANUALLY.
6.2.3
6.3
6.3.1
6.3.2
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.4 6.4.1
6.4.2
6.4.3
6.4.4
MOVE THE LADDLE UP TO HOLDING FURNACE FOR POURING. DO CROSS MOVEMENT UP FURNACE FOR POURING. TO HOLDING
6.4.5
6.4.6
POUR THE METAL IN TO HOLDING FURNACE BY CROSS WHEEL. PICK UP THE METAL WITH SPOON. POUR THE METAL IN SLEEVE.
6.4.7 6.4.8
6.5 6.5.1
HANDLING OF MATERIAL DURING PROCESS HANDLE THE MATERIAL DURING PROCESS IN BINS / TROLLEYS WITH HAND PALLET.
6.5.2
KEEP THE PARTS IN SUCH A WAY THAT THEIR MACHINED SURFACE SHOLD NOT TOUCH EACH OTHER DURING PROCESS / MATERIAL HANDLING. APPLY RUST PREVENTIVE OIL ON THE MATERIAL IN RAINY SEASON ON UNPAINTED MATERIAL / SURFACES (IF REQUIRED).
6.5.3
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.6.1
6.6.2
ENSURE UTMOST PRODUCT SAFETY DURING HANDLING LOAD THE PART ON THE CONVEYOR HANGER CAREFULLY AFTER THE PAINT TRANSFER THE MATERIAL TO NEXT OPERATION / FINAL INSPECTION & PACKAGING. PACK THE PARTS AS PER PACKAGING WORK INSTRUCTION
6.6.3
6.6.4
6.6.5
6.6.6
DESPATCH THE MATERIAL TO CUSTOMER IN SPECIAL TROLLEYS , BINS & CONTAINERS PACKED IN CORRUGATED BOX & WOODEN BOX AS APPLICABLE. FOLLOW THE WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF FINISHED GOODS.
6.6.7
6.6.8
6.7 6.7.1
CONTROL OF CONTAINER & DUNNAGE STORE CONTAINER & DUNNAGE IN ALLOCATED AREA TO AVOID DAMAGE ASSUME THAT RETURNABLE CONTAINER AND DUNNAGE ARE RETURNED IN TIMELY MANNER AND IN ACCEPTABLE CONDITION.
6.7.2
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
7.1 7.2
___
____
___
___
____
___
PREPARED BY
APPROVED BY
ISSUED BY
INTERNAL
REVISION NO.
DATE
07
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
08
05-05-2004
09
05-08-2004
Material handling guidelines for operator provided for machining parts in process and in handling in column 6.5.2
10
25-12-2004
11
25-01-2006
TURTLE DIA
DOCUMENT NO. : INTERFACE
- ALL EMPLOYEE OF ORGANISATION - PURCHASE DEPT. - QUALITY ASSURANCE DEPT. - PRODUCTION, PLANNING & CONTROL DEPT. - HPDC SHOP - M/C SHOP - PAINT SHOP - HR & TRAINING DEPT.
- INTERNAL & EXTERNAL CUSTOMERS REQUIREMENTS ON HANDLING AND STORAGE - BOP'S - RAW MATERIAL - RECEIPT OF MATERIAL FROM SUPPLIER - CUSTOMER SPECIFIC REQUIREMENTS
PROCEDURES
RICO 16 QSP 01 / QSP/RICO GGN/ 15.1 RICO 16 QSP 02 RICO 14 QSP 04 / QSP/RICO GGN/ 15.3 RICO 15 QSP 01 / QSP/RICO GGN/ 18.1 PROCEDURE FOR STORES PROCEDURE FOR ISSUE OF MATERIAL FOR JOB WORK PROCEDURE FOR INVENTORY MANAGEMENT PROCEDURE FOR TRAINING
ALUMINIUM PLANTS
.5
SO AS TO PREVENT
AND MOVEMENT IN
RESPONSIBILITY
REF.DOC
COPY STATUS
SHEET 01 OF 06
ALUMINIUM PLANTS
.5
OPERATOR
SECTION HEAD
RECEIPT STORE
COPY STATUS
SHEET 02 OF 06
ALUMINIUM PLANTS
.5
MELTING FURNACE OPERATOR MELTING FURNACE OPERATOR MELTING FURNACE OPERATOR M/C OPERATOR
COPY STATUS
SHEET 03 OF 06
ALUMINIUM PLANTS
.5
HOD'S
OPERATOR
OPERATOR
OPERATOR
RICO 14 QSP 02
RICO 14 QWI 01
HOD (MP&L)
HOD (MP&L)
COPY STATUS
SHEET 04 OF 06
ALUMINIUM PLANTS
.5
LOCATION ___
___
___
___
___
___
___
COPY STATUS
SHEET 05 OF 06
ALUMINIUM PLANTS
.5
CRIPTION
W.e.f.
APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
25-06-2003
r Ford Q1 Programme
05-05-2004
05-08-2004
6.7
25-12-2004
25-01-2006
1. STORE MANAGEMENT AS PER SYSTEM REQUIREMENT 2. IMPROVEMENT IN STORAGE CONDITION TO AVOID DAMAGE AND DETERIOTATION
PERFORMANCE
EFFECTIVENESS (1) INVENTORY TURN OVER RATIO (2) MONTHLY INVENTORY TREND VS SALES (3) TREND IN OBSOLETE / NON MOVING STOCK IN INR (4) NO OF TIMES FIFO FAILURE (5) TREND IN REJECTION FOLLOWING PERIODIC STOCK VARIATION (6) TRENDS IN ACCIDENTS RELATING TO HAZARDOUS MATERIAL HANDLING EFFICIENCY (1) REDUCING TREND IN INVENTORY IN RUPEES
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
INTERNAL
ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION, PLEASE REFER ORGANISATION CHART.
4.1 4.2
HOD (MP&L) IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE. HOD (HPDC) / HOD (M/C SHOP) / SECTION HEAD (PAINT SHOP) / HOD (MP&L) IS RESPONSIBLE FOR DAY TO DAY MONITORING OF THE ACTIVITIES OF THE DEPARTMENT. OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY. PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - )
4.3 5
6 SL.NO 6.1
6.2
REMOVE THE BURR CHIPS AND OTHER FORIGN PARTICLES CLEAN THE PARTS PROPERLY.
6.3
6.4
DO PACKAGING & LABELLING AS PER WORK INSTRUCTION AND / OR AS CONFIRMED BY CUSTOMER DURING PPAP. INCASE OF CUSTOMER HERO HONDA MOTERS LIMITED , PUT THE PARTS IN BINS / TROLLEYS AS APPLICABLE. TRANSFER THE SAME TO FINISHED GOODS STORES.
6.5
6.6
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
DESPATCH OF MATERIAL TO CUSTOMER 6.16 SHIP THE MATERIAL AS PER THE REQUIREMENT OF THE CUSTOMER. ALSO CONSIDER THE TRANSPORTATION MODE, ROUTING DEFINED BY THE CUSTOMER. RECEIVE ACKNOWLEDGEMENT FROM THE CUSTOMER FOR MATERIAL SUPPLIED AS A TOKEN OF RECEIPT OF MATERIAL. PREPARE THE DAILY STOCK STATEMENT INDICATING MATERIAL RECEIVED , MATERIAL DESPATCHED, STOCH IN HAND MONITOR DELIVERY PERFORMANCE AGAINST SCHEDULE / PLAN ON DAILY BASIS.
6.17
6.18
6.19
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.21
6.22
6.23
6.24 6.24.1
EXPORT SHIPPING PREPARE CONTAINER / VEHICLE LOADING PLAN TO ENSURE DAMAGE FREE TRANSIT NOTIFY TO CONCERN AGENCIES PREPARE PACKING LIST FOR MATERIAL TO BE DESPATCH ENSURE EACH BOX CONTAINING PRODUCTS IS IDENTIFIED BY LABEL / TAGS PREPARE / ARRANGE EFFICIENTLY THE NECESSARY DOCUMENTS FOR DESPATCH OF THE MATERIAL TO THE CUSTOMER AS PER CUSTOMER STANDARD BIZ. EXPORT INVOICE, PACKAGING LIST , EXCISE INVOICE, LABELS, SHIPPING BILL , FUMIGATION CERTIFICATE & INSURANCE CERTIFICATE. LOAD THE CONTAINER / VEHICLE AS PER PACKAGING LIST / CONTAINER LOADING PLAN
6.24.2
6.24.3
6.24.4
6.24.5
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
6.24.7
6.24.8
6.24.9
DEVIATION FROM MATERIAL PLANNING & LOGISTIC INSTRUCTION 6.24.10 INVESTIGATE THE ROOT CAUSE & COMMUNICATE TO CUSTOMER & SUPPLIER AS WELL FOR IMPLEMENTATION
6.25
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23 7.24 7.25 7.26
RICO 14 QWI 01 RICO 10 QWI 14 RICO 10 QWI 17 RICO 10 QWI 24 RICO 10 QWI 30 RICO 10 QWI 31 RICO 10 QWI 32 RICO 10 QWI 33 RICO 11 QWI 01 RICO 11 QWI 02 RICO 11 QWI 03 RICO 11 QWI 04 RICO 11 QWI 05 RICO 11 QWI 08 RICO 11 QWI 09 RICO 11 QWI 11 RICO 11 QWI 12 RICO 11 QWI 13 RICO 11 QWI 14 RICO 11 QWI 25 RICO 11 QWI 27 RICO 11 QWI 41 RICO 11 QWI 42 RICO 11 QWI 44
WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPAT FINISHED GOODS. WORK INSTRUCTION FOR PACKAGING OF SHROUD RADIATOR WORK INSTRUCTION FOR PACKAGING FOR MISC. COMPONEN ( M/S AMTEK AUTO & RICO GGN ) WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE P-40 WORK INSTRUCTION FOR PACKAGING OF OUTER CLUTCH (CD WORK INSTRUCTION FOR PACKAGING OF CENTRE CLUTCH (C WORK INSTRUCTION FOR PACKAGING OF PRESSURE PLATE (C WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE (CD 1 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR FRONT HUB (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR REAR HUB (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR FRONT PANEL (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR REAR PANEL (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR CFD-CD (HHML-I) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR C - PLATE (HHML-I , HHML-II & FCC-GGN) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR FFD - ASSY (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR GSD (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR CLUTCH ASSY (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR PR- PLATE (HHML-I , HHML-II & FCC-GGN) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR L - PLATE (HHML-I , HHML-II & FCC-GGN) WORK INSTRUCTION FOR MARUTI COMPONENT PACKAGING OPERATOR WORK INSTRUCTION FOR CLEANING AND PACKAGING OPERA OF OIL PUMP YE - 2 WORK INSTRUCTION FOR PACKAGING OPERATOR OF H.S.P.P.L WORK INSTRUCTION FOR PACKAGING OPERATOR OF A.V.R. WORK INSTRUCTION FOR PACKAGING UPPER & LOWER BRACKET.
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
TITLE
7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23
DOCUMENTS : (APPLICABLE TO RICO HPDC DIV. GURGAON) RICO 10 QWI 17 WORK INSTRUCTION FOR PACKAGING OF FCC RICO CASTING COMPONENTS RICO 10 QWI 18 WORK INSTRUCTION FOR PACKAGING OF CRANK CASE RIGHT RICO 10 QWI 34 RICO 10 QWI 35 RICO 10 QWI 36 RICO 10 QWI 37 RICO 11 QWI 06 RICO 11 QWI 07 RICO 11 QWI 08 RICO 11 QWI 09 RICO 11 QWI 10 RICO 11 QWI 11 RICO 11 QWI 12 RICO 11 QWI 13 RICO 11 QWI 14 RICO 11 QWI 15 RICO 11 QWI 16 RICO 11 QWI 17 RICO 11 QWI 18 RICO 11 QWI 19 RICO 11 QWI 20 RICO 11 QWI 21 RICO 11 QWI 22
W.I FOR PACKAGING OF FCC COMPONENTS ( OUTER CLUTCH) W.I FOR PACKAGING OF FCC COMPONENTS ( LIFTER PLATE)
WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HUB FRONT WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HUB REAR WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FRONT PANEL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF REAR PANEL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FLANGE FINAL DRIVEN ASSY. WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 8086 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HLOF 8954 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 0551 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HFF 969 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HFF 331 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER REAR 1043 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER VALVE 404 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER VALVE 405 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER VALVE 404 / 405 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HFF 969 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 551 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF STRICKER LEFT FOR LGI
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF STRICKER RIGHT FOR LGI WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FMD FOR FCC RICO WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FORKS (6 TYPES) FOR MUL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER THERMO FOR HSCIL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER WATER OUTLET FOR HSCIL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PANEL ASSY. FRONT FOR HMSI WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER CYLINDER HEAD F8D FOR MUL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER CYLINDER HEAD F10D FOR MUL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 1819 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF AIRCON BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FAN IDLER BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PAS BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PQU 500022 BRACKET FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PQU 500032 BRACKET FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF AUTO CLOSURE PLATE FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HOUSING TUNNEL ASSEMBLY FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF ALTERNATOR BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF ARC BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER GEAR SHIFT FOR HMSI
WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HLOF FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM7069 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF STAY CHANGE WIRE FOR HSCIL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER COMPOUND WATER OUTLET FOR HSCIL
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CLUTCH ASSY FOR HHML WORK INSTRUCTION FOR PACKAGING OF PROTOTYPE OR PV TEST PARTS W.I. FOR PACKAGING OF PAS BRACKET ( AJ 42 / 44) W.I. FOR PACKAGING OF ALTERNATOR BRACKET ( AJ 42/44)
PACKAGING OF ADOPTER (ATM PRESS) (166-6693) FOR CATER PACKAGING OF MANIFOLD (168-0300) FOR CATERPILLER WORK INSTRUCTION FOR PACKAGING OF COVER REAR 3967200 FOR CUMMINS USA WORK INSTRUCTION FOR PACKAGING OF COVER INTAKE MANIFOLD (3965566 & 3957907) FOR CUMMINS USA WORK INSTRUCTION FOR PACKAGING OF TRANSFER BOX
WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING WORK INSTRUCTION FOR PACKAGING OF BKT SUPPORT AC
WORK INSTRUCTION FOR PACKAGING OF BKT AC ALTERNATOR (30731398) W.I. FOR CHECKING , WASHING OILING & PACKAGING OF CIM & COVER REAR WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING
RICO 11 QWI 111 RICO 11 QWI 112 RICO 11 QWI 114 RICO 11 QWI 117 RICO 11 QWI 119 RICO 11 QWI 120
WORK INSTRUCTION FOR PACKAGING OF COVER COMP. THRUST (HSCIL) WORK INSTRUCTION FOR PACKAGING OF EGR PLATE (HSCIL) WORK INSTRUCTION FOR CHECKING, WASHING,PACKAGING FOR PAS BKT - 6R83-3K738-BA WORK INSTRUCTION FOR PACKAGING OF 2.2 LTR PAS BKT
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT FLY WHEEL SENSOR WORK INSTRUCTION FOR PACKAGING OF PAS BKT - 6R83-3K
WORK INSTRUCTION FOR PACKAGING OF CRANK CASE COVE WORK INSTRUCTION FOR PACKAGING OF BKT 683 WORK INSTRUCTION FOR PACKAGING OF OIL FILTE HEAD VERTICAL - PERKINS WORK INSTRUCTION OF PACKAGING - BACK PLATE
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
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PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
REVISION NO.
DATE
08
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
08
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
09
15-04-2004
10
05-05-2004
11
25-01-2006
12
20-05-2006
PREPARED BY
APPROVED BY
ISSUED BY
ALUMINIUM PLANTS
.5
P&L) IS RESPONSIBLE
REF.DOC
HELPER
OPERATOR / HELPER
HELPER
HELPER
COPY STATUS
SHEET 01 OF 11
ALUMINIUM PLANTS
DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (PRODN) SECTION HEAD EXCISE SECTION HEAD PPC / EXCISE SECTION HEAD EXCISE SECTION HEAD EXCISE SECTION HEAD EXCISE SECTION HEAD PPC
.5
HELPER
SECTION HEAD
SECTION HEAD EXCISE / SECTION HEAD (PPC) PLANT MANAGER / HEAD (PP/LOGISTICS)
COPY STATUS
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DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY PLANT MANAGER / HOD (MP&L)
.5
COPY STATUS
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ALUMINIUM PLANTS
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inventory
COPY STATUS
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CKAGING OF LIFTER PLATE P-40 CKAGING OF OUTER CLUTCH (CD 100) CKAGING OF CENTRE CLUTCH (CD 100) CKAGING OF PRESSURE PLATE (CD 100) CKAGING OF LIFTER PLATE (CD 100) CKAGING & SPECIFICATION FOR
CKAGING OPERATOR
CKAGING OPERATOR
COPY STATUS
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ALUMINIUM PLANTS
DOC. NO.
RICO 14 QSP 02
.5
12 20-05-2006
COPY STATUS
SHEET 06 OF 11
ALUMINIUM PLANTS
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CKAGING SPECIFICATION & DEVELVERY 8D FOR MUL CKAGING SPECIFICATION & DEVELVERY 10D FOR MUL CKAGING SPECIFICATION & DEVELVERY
CKAGING SPECIFICATION & DEVELVERY GUAR / FORD CKAGING SPECIFICATION & DEVELVERY JAGUAR / FORD CKAGING SPECIFICATION & DEVELVERY
CKAGING SPECIFICATION & DEVELVERY R LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY R LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY OR LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY BLY FOR LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY OR JAGUAR / FORD CKAGING SPECIFICATION & DEVELVERY
COPY STATUS
SHEET 07 OF 11
ALUMINIUM PLANTS
.5
CKAGING OF BKT AC
ECKING, WASHING,PACKAGING
COPY STATUS
SHEET 08 OF 11
ALUMINIUM PLANTS
.5
COPY STATUS
SHEET 09 OF 11
ALUMINIUM PLANTS
.5
LOCATION
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CRIPTION
W.e.f.
25-06-2003
25-06-2003
Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
15-04-2004
r Ford Q1 Programme
05-05-2004
25-01-2006
ction added to
20-05-2006
COPY STATUS
SHEET 11 OF 11
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
HOME
INTERNAL
INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION , PLEASE REFER ORGANISATION CHART
PLANT MANAGER IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE. HOD PURCHASE IS RESPONSIBLE FOR PROCUREMENT OF MATERIAL REQUIRED. OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY. PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - STORES, MATERIL HANDLING & INVENTORY)
DESCRIPTION ACTIVITY RECEIPT STAGE DECIDE THE MINIMUM & MAXIMUM LEVELS.THE LEVELS IS BEING MONITORED IN THE SYSTEM
ON DAILY BASIS BY THE PURCHASE DEPTT. ACCORDINGLY. NOTE : - NON CRITICAL HIGH VALUE SPARES WILL NOT BE HAVING ANY LEVEL. THESE WILL BE PROCURED AGAINST PURCHASE REQUISITION. 6.1.2 INITIATE THE ACTION FOR PROCUREMENT.
6.1.3
RECEIVE THE NECESSARY DOCUMENT OF MATERIAL RECEIPT AT SECURITY GATE OFFICE. ENTER THE RELEVANT DETAIL IN THE COMPUTOR FOR SCHEDULED QTY. TO BE RECEIVE FROM VENDOR.
6.1.4
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.1.6
6.1.7
6.1.8
RECEIVE THE MATERIAL AND STORE IN SUCH A WAY THAT STOCK CAN BE ROTATED ON REGULAR BASIS AND FIFO CAN BE FOLLOWED IN CASE OF SELF LIFE ITEMS. DO MONTHLY PHYSICAL STOCK TAKING. UPDATE THE STOCK LEVELS AND INFORM TO HOD (PURCHASE) IN CASE THE STOCK VARIES WITH RESPECT TO LEVEL DECIDED BASED ON 5.1.9 ABOVE , REVIEW THE DELIVERY SCHEDULE & PASS ON NECESSARY INSTRUCTION TO THE CONCERN SUBCONTRAC-
6.1.9 6.1.10
6.1.11
TOR AS REQUIRED. 6.1.12 ISSUE THE MATERIAL TO CONCERN USER CONSIDERING THE FIFO / STOCK ROTATION.
6.2 6.2.1
WORK IN PROGRESS RECEIVE PRODUCTION PLAN DEPARTMENT MAINTAIN THE PRODUCTIVITY RESPECTIVE SHOPS FROM PPC
6.2.2
NORM
OF
6.2.3
GET THE MATERIAL ISSUED FROM THE STORES IN ADVANCE AS PER PLANNING. CARRY OUT PRODUCTION AS PER PLANNING SCHEDULE.
6.2.4
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.2.6
6.2.7
6.2.8
6.2.9
REVIEW THE INVENTORY REPORT AND TAKE NECESSARY CORRECTIVE / PREVENTIVE ACTION TO ELIMINATE OR MINIMISE THE VARIATION IN DOCUMENTED AND PHYSICAL STOCK. FINISHED GOODS STORES DECIDE THE INVENTORY LEVEL TAKING CUSTOMER REQUIREMENT IN CONSULTATION WITH PLANT MANAGER. RECEIVE THE CONFORMING MATERIAL AFTER FINAL INSPECTION. ARRANGE TO SEND THE MATERIAL CUSTOMER WITH RELEVANT DOCUMENT. TO
6.3 6.3.1
6.3.2
6.3.3
6.4
DO MONTHLY INVENTRY & FILL RG-1 FORM FOR INVENTORY ANALYSIS AND EXCISE PURPOSE. NOTE : DIRECT DATA LINK WHERE APPLICABLE AND CUSTOMER MENDATORY REQUIREMENT, RICO WILL USED INTERACTIVE INVENTORY MANAGEMENT SYSTEM E.G. DDL (DIRECT DATA LINK) & HOD (MP&L) WILL BE RESPONSIBLE TO ANSWER DAILY SHORTAGE AND NEW MODEL LAUNCH REQUIREMENT ACCURATELY AND IN ACCORDANCE TO THE FORD PROCEDURE. THIS DDL COVERAGE WILL BE PROVIDED TO CUSTOMER IN CUSTOMER OPERATING HOURS.
6.5
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
RECORDS : RECORD DESCRIPTION FORM NO ------TITLE MONTHLY INVENTRY DATA FOR RM / BOP, WIP & FINISH STORE, EXCISE LOCATION
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
REVISION NO.
DATE
07
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
08
05-05-2004
09
25-01-2006
PREPARED BY
APPROVED BY
ISSUED BY
ALUMINIUM PLANTS
.5
ORK IN PROGRESS ,
RESPONSIBILITY
REF.DOC
HOD (PURCHASE) / SECTION HEAD (PURCHASE) SECTION HEAD (SECURITY) SECTION HEAD (SECURITY)
COPY STATUS
SHEET 01 OF 05
ALUMINIUM PLANTS
DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (SECURITY) SECTION HEAD (SECURITY) SECTION HEAD ( STORES) HOD (STORES)
.5
RICO 16 QFO 02
RICO 16 QWI 04
RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD
COPY STATUS
SHEET 02 OF 05
ALUMINIUM PLANTS
DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD
.5
PLANT MANAGER
HOD (MP&L)
SECTION HEAD (EXCISE) HOD (MP&L) / SECTION HEAD(EXCISE) SECTION HEAD (EXCISE)
COPY STATUS
SHEET 03 OF 05
ALUMINIUM PLANTS
.5
LOCATION
STORE, EXCISE
COPY STATUS
SHEET 04 OF 05
ALUMINIUM PLANTS
.5
CRIPTION
W.e.f.
APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.
25-06-2003
r Ford Q1 Programme
05-05-2004
25-01-2006
COPY STATUS
SHEET 05 OF 05
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
QUALITY MANUAL
PRODUCT REALIZATION PURCHASING
A : PURPOSE Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence. B : SCOPE Applicable for all purchased raw materials, bought out components, packing materials other consumable items and services which have bearing on the quality of the products made by RICO AUTO Dharuhera / HPDC Gurgaon
C : RESPONSIBILITY AND AUTHORITY Hod (Purchase) is responsible for ensuring the requirements of this chapter Hod (Q.A.) is responsible for verification and take corrective action in case of nonconformance. D : DESCRIPTION 7.4 PURCHASING 7.4.1 PURCHASING PROCESS RICO AUTO INDUSTRIES LIMITED ensures that purchased product conforms as per purchasing to specified purchase requirements. The type and extent of control applied to the supplier and the purchased product is depended upon the effect of the purchased product on subsequent product realization or the final product. The purchasing department selects suppliers on the requisites of quality, price, and delivery. The selection criteria is documented and based on one or more of the following: A inspection of final product at the sub-contractors facility. B inspection of final product upon delivery C historical performance of adherence to purchasing requirements D sub-contractors conformance to an international standard When there are mergers, acquisitions or affiliations associated with suppliers, the organization will verify the continuity of the suppliers quality system and its effectiveness. 7.4.1.1 REGULATORY COMPLIANCE All purchased products or materials used in product satisfy applicable regulatory requirements. 7.4.1.2 SUPPLIER QUALITY MANAGEMENT SYSTEM DEVELOPMENT RICO AUTO INDUSTRIES LIMITED has a defined procedure for development of subcontractor RICO AUTO INDUSTRIES LIMITED performs supplier quality management system development with the
goal of supplier compliance to this technical specification. 7.4.1.3 CUSTOMER- APPROVED SOURCES Where specified by the contract, RICO AUTO INDUSTRIES LIMITED purchases products, materials or services from approved sources. The use of customer-designated sources, including tool/gauge suppliers, does not relieve the RICO AUTO INDUSTRIES LIMITEDs responsibility for ensuring the quality of purchased products
ISSUED BY
EDITION - 04 SHEET 01 OF 03
QUALITY MANUAL
PRODUCT REALIZATION PURCHASING
7.4.2 PURCHASING INFORMATION Purchasing documents contain data that clearly describes the product ordered, including where applicable: Purchasing documents are reviewed and approved for adequacy of specified requirements prior to release. A The type class, grade, requirements, or other precise identification. B The title or other positive identification applicable to the issue of specifications, drawings, process requirements, inspection instructions, and other relevant technical data, including requirements for approval or qualification of personnel / or product. C Quality management system requirements. 7.4.3 VERIFICATION OF PURCHASED PRODUCT RICO AUTO INDUSTRIES LIMITED has established and maintained for the verification of purchased product upon receipt. Purchased product failing to meet requirements is documented and returned to the supplier. Records of purchased product verification are maintained as quality records. If so required by contract or agreement, the customer is afforded the right to inspect our subcontractors. The verification arrangements and product validation will be stated in purchasing documentation. The customers acceptance of the product does not absolve the company or the supplier from providing acceptable product or meeting specifications. 7.4.3.1 INCOMING PRODUCT QUALITY RICO AUTO INDUSTRIES LIMITED has a process to ensure the quality of purchased product utilizing one or more of the following methods: - Receipt of, and evaluation of, statistical data by the organization. - Receiving inspection and/or testing such as sampling based on performance. - Second or third party assessments or audits of supplier sites, when coupled with records of acceptable quality performance. - Part evaluation by a designated laboratory. - Another method agreed with the customer. 7.4.3.2 SUPPLIER MONITORING Supplier performance is monitored through the following indicators: - Delivered part quality performance. - Customer disruptions including field returns. - Delivery schedule performance (including incidents of premium freight).
- Special status customer notifications related to quality or delivery issues. RICO AUTO INDUSTRIES LIMITED promotes supplier monitoring of the performance of there manufacturing processes. E : RECORDS Records are maintained as described in the procedure.
ISSUED BY
EDITION - 04 SHEET 02 OF 03
QUALITY MANUAL
PRODUCT REALIZATION PURCHASING
FOR ALUMINIUM DIVISIONS RICO 08 QSP 01 RICO 08 QSP 02 RICO 08 QSP 03 RICO 06 QSP 01 RICO 18 QSP 01 RICO 06 QSP 06 RICO 06 QSP 07 RICO 06 QSP 09
Procedure for Purchasing Procedure for Assessment and selection of Supplier Procedure for Supplier development Procedure for Incoming material inspection and testing Procedure for product realization / advanced product quality planning Procedure for control on non-conforming product. Procedure for corrective and preventive action Procedure for control of quality records
FOR FERROUS FOUNDRY DIVISION QSP/RICO GGN/ 06.1 Procedure for Purchase specification QSP/RICO GGN/ 06.2 Procedure for Evaluation selection and development of sub contractors QSP/RICO GGN/ 06.3 Procedure for Purchase document release QSP/RICO GGN/ 10.1 Procedure for Receiving inspection and testing QSP/RICO GGN/ 02.1 Procedure for Advanced product quality planning ( apqp) QSP/RICO GGN/ 13.1 Control of non conforming product QSP/RICO GGN/ 14.1 Corrective & preventive action QSP/RICO GGN/ 16.1 Procedure for control of quality records
DATE
W.e.f.
DATE
W.e.f.
04 / 01
15-12-2003
Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual
15-122003
PREPARED BY
APPROVED BY
ISSUED BY
EDITION - 04 SHEET 03 OF 03
QUALITY SYSTEM DOCUMENT HOME QUALITY SYSTEM DOCUMENT DOC. NO : CHAPTER : RICO 01 QM 01 7.5
QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION
A : PURPOSE Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence.
B : SCOPE Covers all customer supplied product , such as components , toolings, gauges & Consumables and returnable packaging. C : RESPONSIBILITY AND AUTHORITY Plant manager is responsible for ensuring control measures during different stages of operations. specific responsibilities are detailed in the relevant procedures It is the responsibility of all the employees to follow the procedure laid down specific responsibilities wherever applicable are referred to in the relevant procedures. HOD (Q.A.) / Respective Shop Heads are responsible for maintaining inspection and test status at different stages of operations.
D : DESCRIPTION 7.5 PRODUCTIONS AND SERVICE PROVISION 7.5.1 CONTROL OF PRODUCTION AND SERVICE PROVISION. A : production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence. B : documented work instructions, where necessary, define the specific methods to be used at operations where the absence of work instructions would be detrimental to product realization. C : production operations are accomplished with appropriately maintained tooling and machines, equipment. D : measuring and monitoring devices are utilized to evaluate the product in process, at various stages of production, and to evaluate the result of product realization. E : employees responsible for the individual operations as well as in-process inspection perform product monitoring by quality control personnel. Final product acceptance is the responsibility of the quality control department. F : defined processes are established, maintained, and responsibilities assigned, for product release, delivery, and applicable post-delivery activities such as customer complaint. 7.5.1.1 CONTROL PLAN RICO AUTO INDUSTRIES LIMITED develops control plans for pre-launch and productions that take into account the manufacturing process fmea outputs. The control plan does - List the controls used for the manufacturing process control - Include methods for monitoring of control exercised over special characteristics defined by both the customer and the organization, - Include the customer required information, if any, and - Initiate the specified reaction plan when the process becomes unstable or not statistically capable.
ISSUED BY
EDITION - 04 SHEET 01 OF 04
QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION
Control plans shall be reviewed and updated when any change occurs affecting product, manufacturing process, measurements, logistics, supply sources or fmea. Customer will review control plan, if it is in agreement with customer at the time of contract 7.5.1.2 WORK INSTRUCTIONS RICO AUTO INDUSTRIES LIMITED prepares documented standard operating procedure, quality documents for various activities and works instructions for all employees having responsibilities for the operation of processes. These instructions are accessible for use of the workstation. These instructions are derived from sources such as the control plan and the product realization process. 7.5.1.3 VERIFICATION OF JOB SET-UPS Job set-ups are verified whenever performed, such as initial run of a job, material changeover, and job change. Work instructions are available for set-up personnel. RICO AUTO INDUSTRIES LIMITED uses statistical methods or verification where applicable. Last-off-part inspection is carried out to compare the first-piece approval part. 7.5.1.4 PREVENTIVE AND PREDICTIVE MAINTENANCE RICO AUTO INDUSTRIES LIMITED identifies key process equipment and provides resources for machine / equipment maintenance and has developed an effective planned total preventive maintenance system. The system includes following: - Planned maintenance activities - Packaging and preservation of equipment, tooling and gauging, - Availability of replacement parts for key manufacturing equipment, - Documenting, evaluating and improving maintenance objectives. RICO AUTO INDUSTRIES LIMITED utilizes predictive maintenance methods to continually improve the effectiveness and the efficiency of production equipment. 7.5.1.5 MANAGEMENT OF PRODUCTION TOOLING RICO AUTO INDUSTRIES LIMITED provides resources for tool and gauge design, fabrication and verification and activities. RICO AUTO INDUSTRIES LIMITED has established and implements a system for production tooling management including: - Maintenance and repair facilities and personnel. - Storage and recovery. - Set-up. - Tool-change programs for perishable tools. - Tool design modification documentation, - Tool modification and revision to documentation - Tool identification, defining the status, such as production, repair or disposal. RICO AUTO INDUSTRIES LIMITED has a system to monitor these activities if any work is out sources. 7.5.1.6 PRODUCTION SCHEDULING Production is scheduled in order to meet customer requirements, such as just in time supported by an information system that permits access to production information at key stages of the process and is order driven. 7.5.1.7 FEEDBACK OF INFORMATION FROM SERVICE This is not applicable since after sales service not applicable 7.5.1.8 SERVICING AGREEMENT WITH CUSTOMER This is not applicable since after sales service not applicable.
ISSUED BY
EDITION - 04 SHEET 02 OF 04
QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION
7.5.2 VALIDATION OF PROCESSES FOR PRODUCTION AND SERVICE PROVISION RICO AUTO INDUSTRIES LIMITED do validation of the product at periodic intervals. Validation arrangements are defined and established and include, - Qualification of processes; - Qualification of equipment and personnel - Use of specific methods and procedures - Requirements for records - Re-validation 7.5.3 IDENTIFICATION AND TRACEABILITY The identification of the product is established and maintained for all products, to all applicable drawings, or other documentation during all stages of product realization and delivery. Where traceability is specified, the products have a recorded unique lot number. 7.5.4 CUSTOMER PROPERTY At RICO AUTO INDUSTRIES LIMITED customer supplied products are verified, stored and properly maintained. Lost or unsuitable property is reported to customer and records are maintained. 7.5.4.1 CUSTOMER OWNED PRODUCTION TOOLING At RICO AUTO INDUSTRIES LIMITED, all customer owned toolings are permanently marked with suitable means 7.5.5 PRESERVATION OF PRODUCT RICO AUTO INDUSTRIES LIMITED has established procedure for preservation during storage, process and finished product to prevent deterioration in the product quality RICO AUTO INDUSTRIES LIMITED has established procedure for packing, packaging , marking which also Takes care of customer packaging standard and labeling requirements. 7.5.5.1 STORAGE AND INVENTORY Designated storage area are provided for storage of material with required facilities for preventing damages and deterioration . Receipt and issue from stores is approved by authorized personnel . Item having limited shelf life are identified and first in first out (FIFO) procedure is followed for issuing those items. Provisions are also made to assess the condition of these items at a defined frequency. RICO AUTO INDUSTRIES LIMITED has established and implemented inventory management system at all stages and assures stock rotation. Obsolete products are also considered as non-conforming products. E : RECORDS Records are maintained as described in the procedure.
ISSUED BY
EDITION - 04 SHEET 03 OF 04
QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION
F : REFERENCES FOR ALUMINIUM DIVISIONS RICO 10 QSP 01 RICO 11 QSP 01 RICO 19 QSP 01 RICO 09 QSP 01 RICO 16 QSP 01 RICO 06 QSP 15 RICO 06 QSP 10 RICO 06 QSP 14 RICO 13 QSP 01 RICO 12 QSP 01 RICO 14 QSP 04
Procedure for process control & production (HPDC) Procedure for process control & production (Machine shop & F.M.) Procedure for process control & production (Paint shop) Procedure for process control & production (PPC) Procedure for Stores Procedure for Identification and traceability Procedure for customer complaint resolution Procedure for Control of customer supplied product Procedure for Maintenance Procedure for Control plan Procedure for Inventory control
FOR FERROUS FOUNDRY DIVISION QSP/RICO GGN/ 09.0 Procedure for Procedure for process control QSP/RICO GGN/ 09.3 Procedure for Production of castings in foundry shop QSP/RICO GGN/ 09.4 Procedure for production ofcomponents in m/c shop QSP/RICO GGN/ 09.5 Procedure for paint shop QSP/RICO GGN/ 09.2 Procedure for Production planning & control QSP/RICO GGN/ 15.1 Procedure for Handling & storage QSP/RICO GGN/ 08.1 Procedure for Product identification and traceability QSP/RICO GGN/ 14.2 Procedure for Customer complaint handling & disposition QSP/RICO GGN/ 07.1 Procedure for Control of customer supplied product QSP/RICO GGN/ 09.1 Procedure for Maintenance QSP/RICO GGN/ 02.4 Procedure for Control plan ( cp ) establishment
DATE
W.e.f.
04 / 01
15-12-2003
Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual
15-122003
HOME QUALITY SYSTEM DOCUMENT DOC. NO : CHAPTER : A : PURPOSE Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence. B : SCOPE Covers all gauges & equipment used in RICO AUTO INDUSTRIES LIMITED. C : RESPONSIBILITY AND AUTHORITY HOD(Q.A.) is responsible for control and calibration of all equipments covered under calibration procedure. He is also responsible for measurement system analysis. D : DESCRIPTION 7.6 CONTROL OF MEASURING AND MONITORING DEVICES All measuring devices are maintained and established ensuring the suitability of measuring and monitoring devices. Measuring and monitoring devices are consistent with the degree of accuracy needed to evaluate conformity of the product during all phases of the manufacturing process. Measuring and monitoring devices are controlled as a numbering system for each device in use is maintained and periodic cleaning, re-calibration is conducted and results are recorded. A Measuring and monitoring devices are calibrated and adjusted at defined intervals to ensure continued accuracy and usability. Calibration activities, where applicable, are traceable to NPL / national equivalent. B Results of initial calibration and re-calibration or adjustment of measuring and monitoring devices is recorded. RICO 01 QM 01 7.6
QUALITY MANUAL
PRODUCT REALIZATION
CONTROL OF MONITORING AND MEASURING DEVICES
C All measuring and monitoring devices identify the calibration status. D All precision measuring and monitoring devices are maintained for protection from damage during handling, maintenance, and storage. E In the event a measuring and monitoring device is found to be out of calibration, corrective action is taken to validate previous results. 7.6.1 MEASUREMENT SYSTEM ANALYSIS Measurement system analysis is also carried out for all type of measurement system to analyze the variation, using statistical technique as per msa reference manual 7.6.2 CALIBRATION / VERIFICATION RECORDS Rico has identified measurements to be made and the accuracy required for measurement. accordingly, the inspection, measuring & test equipments selected. hardware and software used for inspection and testing that need calibration are also identified. Unique identification numbers are allocated to these equipments. This listing includes details of equipment type, identification number, location, frequency of check, check method and accuracy required, acceptance criteria and action taken when results are unsatisfactory. The calibration is carried out in accordance with the laid down procedure as per in house qualified lab which come under lab scope or otherwise done by calibration facilities accredited to iso/iec guide or national equivalent .
ISSUED BY
EDITION - 04 SHEET 01 OF 03
QUALITY MANUAL
PRODUCT REALIZATION
CONTROL OF MONITORING AND MEASURING DEVICES
The calibration records are maintained against each of such equipment coming under the calibration activity. The equipments coming under the calibration activity are identified to show the calibration status. The persons using the calibrated equipments are adequately instructed to store and handle them in such a way that the fitness for use and accuracy are maintained. Provision to safeguard the calibrated equipments from adjustment and setting are also made as and where applicable. The calibration is carried out under standard conditions, detailed in relevant procedures. During calibration of the equipment, if the equipment is found to be out of calibration , the validity of previous inspection and test results are assessed through the quality records /available product / customer complaint and documents. Customers are informed about the shipment of the suspected products. If an equipment is not conforming to the laid down acceptance criteria, it is identified and removed from the point of use. Calibration of inspection, measuring or test equipment is conducted in as per RICO'S laboratory scope matrix (calibration & testing) and laboratory quality system procedure as per lab scope. If required by customer RICO uses accredited lab for laboratory work perform from out side. From time to time, an assessment is made by HOD (Q.A.) in consultation with concerned heads of department, to identify the need for any new inspection, measuring and test equipments. RICO to ensure notification to the customer if suspect product or material has been shipped.
7.6.3 LABORATORY REQUIREMENTS 7.6.3.1 INTERNAL LABORATORY Rico has established and implemented all applicable laboratory requirements which come under laboratory scope. Rico has documented its policy,system procedure, of laboratory to assure that test result generated within lab scope. Rico have professionals with relevant background and experience for laboratory process decision making. Rico has established procedure for product identification and testing, products are being kept in lab as per requirements. Process control conditions are monitored and recorded that may influence quality. Rico has established all lab test method either agreed by customer or current issue of national / international standards. System has been established for verification of lab capability and appropriate statistical technique is used to verify the activities where applicable. The sampling norms for inspection if applicable, are indicated in the relevant procedures. Before dispatch of the products, it is ensured that inspection and testing has Carried out as per the relevant procedures and records are available clearly Indicating the authority responsible for release of product.
ISSUED BY
EDITION - 04 SHEET 02 OF 03
QUALITY MANUAL
PRODUCT REALIZATION
CONTROL OF MONITORING AND MEASURING DEVICES
7.6.3.2 EXTERNAL LABORATORY External / commercial / independent laboratory (if required) facilities used for inspection, test or calibration services by RICO AUTO INDUSTRIES LIMITED has defined laboratory scope that includes the capability to perform the required inspection, test or calibration, and the laboratory accredited to iso/iec 17025 or national equivalent, or there shall be evidence that the external laboratory is acceptable to the customer
F : REFERENCES
FOR ALUMINIUM DIVISIONS RICO 06 QSP 16 RICO 06 QSP 17 RICO 06 QSP 05 RICO 06 QSP 12 RICO 06 QSP 09
Procedure for Laboratory management Procedure for Laboratory process control & testing Procedure for Measurement system analysis Procedure for Control of inspection measuring and test equipment Procedure for Control of quality records
FOR FERROUS FOUNDRY DIVISION QSP/RICO GGN/ 10.5 Procedure for Laboratory management procedure QSP/RICO GGN/ 11.1 Procedure for Control of inspection, measuring and test equipment QSP/RICO GGN/ 11.2 Procedure for Measurement system analysis QSP/RICO GGN/ 16.1 Procedure for control of quality records
DATE
W.e.f.
04 / 01
15-12-2003
Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual
15-122003
PREPARED BY
APPROVED BY
ISSUED BY
EDITION - 04 SHEET 03 OF 03
cts, materials or
EDITION - 04 SHEET 01 OF 03
oduct utilizing
with records of
there manufacturing
EDITION - 04 SHEET 02 OF 03
quality planning
of sub contractors
APPROVED BY
EDITION - 04 SHEET 03 OF 03
ges of operations.
der controlled
sed at operations
stics defined by
ot statistically capable.
EDITION - 04 SHEET 01 OF 04
manufacturing
alization process.
is out sources.
pported by an
EDITION - 04 SHEET 02 OF 04
icable drawings,
ng , marking which
EDITION - 04 SHEET 03 OF 04
bration procedure.
e in use is maintained
mage during
ctive action is
of check, check
EDITION - 04 SHEET 01 OF 03
e calibration activity. on status. The persons uch a way that the out under standard
d heads of department,
decision making.
kept in lab as
o has established
EDITION - 04 SHEET 02 OF 03
st equipment
EDITION - 04 SHEET 03 OF 03
INTERNAL
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
3.3
REPAIR
ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT THE PRODUC FUL FILL THE INTENDED USAGE, ALTHOUGH THE PRODUCT MAY NOT CO TO THE ORIGINAL REQUIREMENT. ANY OPERATION DONE BY THE OUT SIDE PARTY ON THE MATERIAL BELONGING TO RICO AUTO INDUSTRIES LIMITED , DHARUHERA.
3.4
JOB-WORK
3.5
RE-OFFER
3.6
MISSC. ITEM
ITEM NOT UNDER INVENTORY CONTROL ( LIKE PANTRY ITMS , STATIONA OFFICE EQUIPMENT AND OTHERS ) HAVING NO EFFECT ON OUT GO PRODUCTS.
ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION , PLEASE REFER ORGANISATION CHART.
4.1
OVER ALL RESPONSIBILITY TO IMPLEMENT THIS PROCEDURE LIES WITH HOD (STORES) /
SECTION HEAD (EXCISE). 4.2 OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.
PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - STORES)
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.1.2
6.2 6.2.1
6.2.2
6.2.3
ALL INCOMING MATERIAL. 6.2.4 RECORD AND VALIDATE THE SUPPLIER'S DOCUMENT , DATA WITH PURCHASE ORDER ON STORE COMPUTER TERMINAL FOR THE PREPARATION OF MRR . IF THE DOCUMENT CONFORM THE PURCHASE ORDER REQUIREMENTS , GET MRR PRINTED FOR FURTHER PROCESSING. IF THE P.O. IS NOT AVAILABLE , PROVIDE UNIQUE CODE 9999 ON MRR AND SEND IT TO FURTHER PROCESS. AFTER RECEIPT OF MRR FROM CONCERN DEPARTMENT APPROVAL . ARRANGE THE P.O. FROM VENDORS / PURCHASE.
6.2.5
6.2.6
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.2.8
6.2.9
6.2.10
6.2.11
MOVE ACCEPTED MATERIAL TO THE MAIN STORE TO THE RESPECTIVE BAYS AND BINS ALONG WITH PRODUCT IDENTIFICATION TAG . ONCE THE MATERIAL IS KEPT ON THE IDENTIFIED LOCATION , PRODUCT IDENTIFICATION TAG MAY BE REMOVED.
6.2.12 6.2.13
AUTHORISE THE MRR AFTER APPROVAL DESPATCH COPY OF MRR AND RELATED DOCUMENT TO ACCOUNTS DEPARTMENT THROUGH DESPATCH REGISTER. RE - OFFER MATERIAL PREPARE RE-OFFER MRR FOR SEGREGATION / REWORK / REPAIR OF MATERIAL FROM PURCHASE DEPARTMENT DULY APPROVED BY HOD (QA). RE-OFFER MRR WILL BE HAND OVER TO STORE DEPARTMENT AND TAKE MATERIAL ACCORDINGLY TAKE ACTION AND ENTER THE DETAILS IN RE-OFFER MRR AND SEND TO STORE SECTION
6.3 6.3.1
6.3.2
6.3.3
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.4.2
6.4.3
MATERIALS WHOSE QUALITY GETS AFFECTED DUE TO ENVIRONMENTAL CONDITIONS, ENSURE SUITABLE PRESERVATIVES ARE APPLIED. ENSURE THAT FRAGILE ITEMS ARE EASILY ACCESSIBLE TO AVOID DAMAGE IN HANDLING. PREPARE LIST OF ITEMS WHICH ARE OVER STOCKED ON MONTHLY BASIS. CHECK THE CONDITION OF STOCK, IF FOUND DETERIORATED, APPLY SUITABLE PRESERVATIVE ON THESE ITEMS OR INFORM TO HOD(QA) FOR DISPOSAL ( IF REQUIRED ).
6.4.4
6.4.5
6.5 6.5.1
LINE REJECTION MATERIAL RECEIVE THE LINE REJECTION ALONG WITH THE REJECTION REPORT. VERIFY THE DESCRIPTION AND QUANTITY GIVEN IN THE REJECTION REPORT MOVE THE LINE REJECTION TO REJECTION STORE AND TAKE FURTHER ACTION WHERE APPLICABLE. TREAT OBSELETE PRODUCT SIMILAR TO NON-CONFIRMING PRODUCT AND KEEP IN REJECRTION STORE IN PROPER MANNER.
6.5.2
6.5.3
6.5.3
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.6.2
CHECK THE ISSUE SLIP FOR DESCRIPTION AND DETAIL DULLY FILLED. ISSUE THE MATERIAL TO CONCERN PERSON / DEPARTMENT. FOLLOW "FIFO SYSTEM" FOR ALUMINIUM ALLOY.
6.6.3
6.6.4
6.6.5
FOR BOUGHT OUT PART, ENSURE FIFO BY PROVIDING SEPARATION IN BETWEEN EACH LOT AND ISSUE THE OLD LOT FIRST. FINISH GOOD STORAGE MANAGEMENT LIST OF FINISHED GOODS LYING IN STOCK IS RECEIVED BY STORES FROM EXCISE DEPARTMENT IN THE BEGININGING OF EVERY MONTH. THE LIST IS RECEIVED OF FINISHED GOODS & STOCK LYING FOR MORE THAN ONE YEAR IS INTIMATED TO HOD (Q.A.) HOD (Q.A.) AFTER APPROPRIATE VERIFICATION, INTIMATES STORES THROUGH INSPECTION REPORT. (I) BASED ON DECISION, IF THE STOCK NEEDS TO BE REMOVED FOR 100% VERIFICATION / REPROCESSING, THE SAME IS CONVEYED TO EXCISE DEPARTMENT FOR FURTHER NECESSARY ACTION. (II) MOVE THE SUSPECTED QUARNTINE SEGREGATION SEGREGATION. STOCK TO AREA FOR
6.7 6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
TITLE
SL.NO 6.7.6 ACTIVITY
KEEP THE FINISH GOODS IN SUCH A WAY THAT STOCK CAN BE ROTATED REGULARLY AND "FIFO" CAN BE FOLLOWED
6.7.7
REVIEW THE STORAGE PROCESS / AREA FOR ANY WATER LEAKS, STACKING METHOD, HEIGHT, WALL CONDITION, TEMPERATURE AND ATMOSPHERIC REQUIREMENT AND MAINTAIN AS PER REQUIREMENT. ENSURE THAT PRODUCTS / IN PROCESS PARTS / BOP AND OTHER ITEMS ARE PROTECTED FROM RUST, CONTAMINATION, DUST ETC AND DO NOT STORE THE PRODUCT OUT SIDE. DO PACKAGING VARIFICATION / INSPECTION AT INCOMING STAGE FOR PACKAGING REQUIREMENTS
6.7.8
6.8
6.2
6.2.1
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.2.3
6.3
6.4
6.5.
6.7
6.8
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
6.10
6.11
6.12
6.13
6.14
(C) FINISH GOOD STORAGE MANAGEMENT 6.13.1 LIST OF FINISHED GOODS LYING IN STOCK IS RECEIVED BY STORES FROM EXCISE DEPARTMENT IN THE BEGININGING OF EVERY MONTH. THE LIST IS RECEIVED OF FINISHED GOODS & STOCK LYING FOR MORE THAN ONE YEAR IS INTIMATED TO HOD (Q.A.) HOD (Q.A.) AFTER APPROPRIATE VERIFICATION, INTIMATES STORES THROUGH INSPECTION REPORT.
6.13.2
6.13.3
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
IF NO DETERIORATION IS REPORTED BY Q.A., THE STOCK IS RETAINED IN THE STORAGE AREA. KEEP THE FINISH GOODS IN SUCH A WAY THAT STOCK CAN BE ROTATED REGULARLY AND "FIFO" CAN BE FOLLOWED
6.13.6
6.13.7
REVIEW THE STORAGE PROCESS / AREA FOR ANY WATER LEAKS, STACKING METHOD, HEIGHT, WALL CONDITION, TEMPERATURE AND ATMOSPHERIC REQUIREMENT AND
MAINTAIN AS PER REQUIREMENT. 6.13.8 ENSURE THAT PRODUCTS / IN PROCESS PARTS / BOP AND OTHER ITEMS ARE PROTECTED FROM RUST, CONTAMINATION, DUST ETC AND DO NOT STORE THE PRODUCT OUT SIDE. DO PACKAGING VARIFICATION / INSPECTION AT INCOMING STAGE FOR PACKAGING REQUIREMENTS
6.14
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT WORK INSTRUCTION FOR FIFO SYSTEM OF RAW MATERIAL
7.6 7.7
7.8 8
LOCATION ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM
---------
REQUISITION SLIP
---------
TRANSFER POSTING
---------
---------
RICO 06 QFO 13
RETURN DELIVERY ( M/C SHOP) (LINE REJECTION) RETURN DELIVERY ( HPDC) (LINE REJECTION)
RICO 10 QFO 02
PREPARED BY INTERNAL
APPROVED BY
ISSUED BY
STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5
REVISION NO.
DATE
07
25-06-2003
Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements
08
05-05-2004
09
25-01-2006
APPROVED BY
ISSUED BY
ALUMINIUM PLANTS
.5
ND ISSUE OF MATERIAL.
FROM MAIN STORE. RNED FROM SHOPS. EM AND CUSTOMER H GOOD STORAGE
PRODUCT SO THAT THE PRODUCT WILL UGH THE PRODUCT MAY NOT CONFORM
TH HOD (STORES) /
COPY STATUS
SHEET 01 OF 11
ALUMINIUM PLANTS
.5
RESPONSIBILITY
REF.DOC
HOD (STORES)
HOD (STORES)
RICO 16 QWI 03
RICO 16 QFO 03
COPY STATUS
SHEET 02 OF 11
ALUMINIUM PLANTS
.5
CONCERN HOD
HOD(STORES) HOD(STORES)
COPY STATUS
SHEET 03 OF 11
ALUMINIUM PLANTS
.5
SECTION HEAD (STORES) SECTION HEAD (STORES) RICO 16 QWI 02 RICO 16 QFO 01
RICO 16 QWI 01
COPY STATUS
SHEET 04 OF 11
ALUMINIUM PLANTS
.5
SECTION HEAD (STORES) SECTION HEAD (STORES) SECTION HEAD (STORES) SECTION HEAD (STORES) RICO 16 QWI 04
HOD (Q.A.)
HOD (EXCISE)
HOD (EXCISE)
HOD (EXCISE)
COPY STATUS
SHEET 05 OF 11
ALUMINIUM PLANTS
RICO 16 QSP 01 09
.5
25-01-2006 REF.DOC
HOD (EXCISE)
SECURITY INCHARGE
STORES ASST.
STORES ASST.
COPY STATUS
SHEET 06 OF 10
ALUMINIUM PLANTS
.5
STORE ASSTT.
STORE ASSTT.
STORE OFFICER
STORE OFFICER
STORE ASSTT.
STORE ASSTT.
STORE ASSTT.
COPY STATUS
SHEET 07 OF 11
ALUMINIUM PLANTS
.5
STORE ASSTT.
STORE INCHARGE
STORE INCHARGE
STORES OFFICER
HOD (Q.A.)
COPY STATUS
SHEET 08 OF 11
ALUMINIUM PLANTS
.5
HOD (EXCISE)
HOD (EXCISE)
HOD (EXCISE)
COPY STATUS
SHEET 09 OF 11
ALUMINIUM PLANTS
.5
LOCATION ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM
RETENTION PERIOD
AS PER SAP SYSTEM
HOD (STORES)
HOD (STORES)
HOD (STORES)
HOD (STORES)
HOD (STORES)
HOD (STORES)
COPY STATUS
SHEET 10 OF 11
ALUMINIUM PLANTS
.5
CRIPTION
W.e.f.
25-06-2003
r Ford Q1 Programme
05-05-2004
25-01-2006
COPY STATUS
SHEET 11 OF 11
DOCUMENTS :
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE
M.R. OFFICE