QUALITY GROWTH SERVICES PVT LTD.MANUFACTURING EXCELLENCE-DIAGNOSTIC STUDY Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Information Required Name of the Organization Full Address Tel.

Tel. No. e mail id Key Contact Person(s) Phone No. of Key Contact Person(s) Nature of Business Key product(s) for TMTL Year of commencement Daily running hours Number of employees

Sr Management : Technical: Commercial: Workmen: Existing Management System (ISO 9001/TS 16949 etc.) Any existing improvement program(s): Lean/Kaizen/TPM etc. Company maintains defined business plan What are the key business performance issues, company wants to solve (on priority) 16 Attach Process Flow Chart of Products supplied to TMTL

QUALITY GROWTH SERVICES PVT LTD.MANUFACTURING EXCELLENCE-DIAGNOSTIC STUDY Response of Company R.L. Sharma Steel Fabricator Pvt. Ltd. Plot No. 62, Sec.24 N.I.T. Faridabad
manish0234@rediff.com,meenu0234@rediff.com

Meenu Gathouna Fabrication

Miss Meenu Mr. Ravi Iso 9001 No

Sr. No. Sr. No. A A1 B B1 B2 B3 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 C C1 C2 C3 C4 C5 C6 C7 C8 C9
C9.1 C9.2 C9.3 C9.4 C9.5 C9.6 C9.7 C9.8 C9.9

Name of Organization Contact Person General Brief details of manufacturing equipments Performance data analysis Availability and Analysis of Cycle time data for all products/ Op. Availability and Analysis of Productivity data Availability and Analysis of Set up time/ change over time data Availability and Analysis of Equipment Breakdown data Availability and Analysis of Setup scrap data Availability and Analysis of Production Scrap data Availability and Analysis of Quality scrap data Availability and Analysis of Rework data Availability and Analysis of Production Consumables data Availability and Analysis of WIP Inventory data Availability and Analysis of Plan vs Production data Availability and Analysis of OEE data Availability and Analysis of Process Capability data Availability and Analysis of Incoming quality ppm data Availability and Analysis of Shop quality ppm for BOP Availability and Analysis of Customer complaint data/ppm Availability and Analysis of BOP/ RM Inventory data Availability and Analysis of Finished product Inventory Availability and Analysis of Inventory Turn Over ratio

Score 1 3 1 2 1 1 2 2 1 1 2 1 2 2 2 3 2 2 3

STA

Practices Availability of Control Plan Availability of PFMEA Availability of Process Control Sheet/ Work standard at work station Availability of Setup Instruction 5S conditions and Audit system Availability of data driven disciplined Root Cause Analysis Poka Yoke monitoring and identification system Operator Competence Matrix Are the staff trained on the following Tools Problem solving FMEA MSA SPC Error Proofing Techniques Employee Suggestion Scheme Lean Tools TPM Tools Process Validation

3 3 3 2 2 2 2 1 2 3 2 1 1 2 1 2 2 2

C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 C36

Compliance of Control Plan Compliance of Work Standard Function wise performance goals and analysis system Availability and Analysis of Preventive Maintenance Availability and Analysis of Predictive Maintenance Availability and Analysis of Autonomous maintenance Analysis of Cost of Poor Quality Use of Control Charts Identification of Special Processes (Give Details) Manufacturing Process Validation System System for verification of Process Layout 1st piece/Set up verification Tooling/ Die control (Drg, History card, life monitoring) Product Identification for status at each stage Availability and Analysis of Process Audit system Availability and Analysis of Product Audit system Availability and Analysis ofNC product control system Availability and Analysis of Contingency Plan Morning meeting practices Area Information Board Staff and Operator trg. (Hrs/ Year) No. of Kaizens in the year Laid down stores layout Dedicated place for each item in stores and its adherence Inventory norms (Min, Max etc) for each item established Monitoring of stores against inventory norms Analysis of Inventory norms in ordering/ scheduling

2 2 2 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 2 2 1 2 2 2 2 1 1

me of Organization

STATUS/COMMENT
Not Available Data Available Not Available

Score
0 1 2 3

Performance
No data Limited data, no analysis Data available, Limited trend analysed Data available, trend analysed, un structured causal analysis and action Data available, trend analysed, structured causal analysis,action, effectiveness verification Process standardized, Complete Analysis, action, effectiveness verification, horizontal deployment

Practices
No activity Not documented. Isolated/ Limited practices Activity documented. Limited practices Activity documented. Practiced

Activity documented, displayed, practiced limited action for NC Well documented and standardized. Followed across the plant, Actions taken in case of non-compliance, reviewed by top management