Final Inspection

Sr.
No.

Roles, Responsibilities & Authority

What

To determine & ensure quality

production in 100% quantity as per
inspection standard.

Check all dimentional

parameters of all items
after last process

Update NC chart of
To communicate the defects / rejections Final Inspection, Record
of previous day to shop floor personnel / on CAP-D register &
suppliers.
discuss with concern
process.

Visual displays for monitoring of defects

Check effectiveness of
trends & corrective action's effectiveness
all defects
shall be available at this stage.
Verification of Dial
Gauge at Straigtening
M/c

To ensure calibration of measuring

instruments as per calibration master
plan.

To ensure all relevant inspection

documents with the customer supply.

Where

When

QA Room

Daily

Quality
Inspector

Final Inspection Reports

19 Hrs

Daily

Quality
Inspector

Final Inspection NC, Quality

Gate NC, Quality Alert Display,
CAP-D Register, Daily Quality
DWM

1 Hrs

30 Min

QA & Team
Room

Who

How

Man Hours

QA Room

Daily

Quality
Inspector

External & Internal feedback,

Final Inspection Pareto Chart, 6
month monitoring on 5 Rule
sheet, Visual Quality Board
Updation

QA Room

Daily

Quality
Inspector

Check By Master Pin & Records

20 Min

Thread Ring Gauge Verification

& Record, Gauge stock records
Updation, Master Calibration List
updation

3 Hrs

FI Report, Material Evalusation

Report & Plating reports

To update master
calibration list

QA Room

Weekly

Quality
Inspector

By giving all reports to

PDI Inspector

QA Room

Daily

Quality
Inspector

TOTAL MAN WORKING HOURS

20 HRS &
50 MIN.

PDI
Sr.
No.

Roles, Responsibilities & Authority

What

Where

When

Who

Parts passed through PDI shall confirm

Check material
Daily
to Quality, Packing & Handling
dimention, visual
PDI Station (After Getting PDI Inspector
requirements before dispatch to
parameters & packing
Despatch Plan)
customer.
requirement.

How

Check packed
material as per PDI
SOP & Check sheet

Packing Sticker & sign

Daily
on sticker, PDI
PDI Station (After Getting PDI Inspector
report of dimentional,
Despatch Plan)
material & Plating.

PDI shall essure the ok lots, duly

identified with signatures on stickers,
along with PDI Reports.

Signature & PDI

Stamp on Packing
Sticker

PDI shall have authority to stop the

dispatch of non-conforming material to
customer.

Stop N/c Material &

Communicate to Dy.
Quality Custodian

PDI Station

Daily
(During PDI)

PDI will communicate to Dy.Quality

Custodian for needful corrective &
preventive actions of non-conforming
products.

Sign. On PDI Cap-D

Register

QA Room

9.00 AM

PDI Inspector

Man Hours

12 Hrs.
15 Min.

If material not ok as
per SOP & check
sheet put NC tag &
hold the supply
CAP-D Register & 5
Rule Sheet

TOTAL MAN WORKING HOURS

30 Min.
12 HRS &
45 MIN.

Deputy Quality Custodian

Sr.no.

Role, Responsibility & Authorities

What

To check inspection data

To ensure complete & proper inspection
of all stage
(F.I.,
and testing of product before release to
PDI, Lab & Quality
Customer.
Gates)

Product / process / System Audit based

on 32 Attribute Sheet & QAV-2 Audit.

To initiate action to prevent the

occurrence of any non-conformity
related to product, process and quality
system & stop production to correct
quality, if required.

Where

When

QA Room

Daily
(10AM to
11AM)

Who

How

Dy. Quality
Custodian

By Countersign on FIR, PDI

& Quality Register & Cross
Check Reports on sampling
basis

Plant audit on 32
Attribute Points

In all Processes

25th of every
month

Dy. Quality
Custodian

By doing audit as per 32

Attribute Points

PQCS audit

All Processes of
related product

As per m/c
loading plan

Dy. Quality
Custodian

By doing audit as per

PQCS points

Daily Quality DWM

PPC Room

2.30~3.00 PM

Dy. Quality
Custodian

Discuss Product,Process &

System related issues with
process team to avoid NC

Check effectiveness of
action taken

QA Room

9~10 AM

By monitoring the Rejection

Deputy Quality
data, 6 months monitoring
Custodian
on 5 Rule sheet

To analyes the NC &

make CAPA

PPC Room

2.30~3.00 PM

Dy. Quality
Custodian

Analyes the problem on 5

Rule sheet with related
process operator

11~12 AM

Dy. Quality
Custodian/
Process
Operator

Final Inspection & Quality

Gate Rejection data, Daily
Plant PPM, Cap-D Register

Check daily NC data &

communicate to process Concerned
operator & Put in CAP-D Process
register of Process

To identify and record any problems

related to the product,process and
quality system.

Initiate, recommended or provide

solutions through designated channels
To ensure that
through monthly presentation / FMEA (s) recommended solution
/ CA(s) PA(s) / Continuous
are being done
improvements.

Verify implementation of solutions & help To check effectiveness

confirm effectiveness of the same in his of the implemented
area of operation.
solution

Concerned
Process

Dy. Quality
On the Target Custodian/
Date
Process
Operator

Process & FI
Stage

Final Inspection & Quality

Gate Rejection data, Daily
Deputy Quality
12~12.30 PM
Plant PPM &
6
Custodian
Month tracking of each 5
Rule sheet

FMEA Diarectory,
5 Rule Sheet, PokaYoke

Control further processing, delivery or

installation of non-conforming products
until the deficiency or unsatisfactory
condition has been rectified / correctedthrough control of non-conformities and
enforcement of quality system in his
area of operation.

Put NC material on hold

Concerned
till the necessary action
Process
is initiated

Represent the needs of Customer in

internal functions selection of special
characteristics training. Corrective &
preventive actions, product development
by participation in these activities.

Establishment of CTQ
Parameters, SPC Study,
Concerned
PPAP Documets,
Process
Problem Solving
Technique

To attend Customer on regular basis.

Visit the Customer

10

Submission of DOL document.

1~2 PM

Dy. Quality
Custodian/
Process
Operator

As per
Requirement

Training on Quality, CTQ

Deputy Quality parameters Board,
Custodian /
Customer PPM Traget,
Engineering
External & Internal quality
feedback board

At Customer end. Regularly

Make & Submit the DOL

HMCL
Documents

Every Month

NC data, Material
Segregation, Material
Rework, CAP-D Register,
Analysis on 5 Rule sheet

Attend Customer to
Deputy Quality
understand the problem &
Custodian
eleminate the problem.
Take the Dashboard
parameter sheet from
Deputy Quality
HMCL,file all required
Custodian
documents & submit to
HMCL
TOTAL MAN WORKING HOURS

Man Hours

1 Hrs.

1 Day

12 HRS &
45 MIN.

Lab Assistant
Sr.
No

Roles & Responsibility

What

Where

Thread Laps Checking (In

Process)

Lab

To ensure the correct results are

Thread Laps Checking (In
conveyed to internal / external
Process)
Customers &all testing as per laid
down procedure for products
pertaining to his area of function is
complete before product is
released for packing
Metallurgical Check of
Heat Treatment Lines

Lab Report of Material

despatched to Customer

Stop N/c Material &

PDI shall have authority to stop the
Communicate to
dispatch of non-conforming
Metallurgist & Dy. Quality
material to customer.
Custodian
Lab assistant will communicate to
Metallurgist & Dy.Quality Custodian
Sign. On PDI Cap-D
for needful corrective & preventive
Register
actions of non-conforming
products.

Lab

Lab

Lab

Std. Lab

Lab

When

Who

How

Per Shift ( 02 Times of

Hard Rolling(12.9 &
By Mould and Record
Lab Assistant
10.9 Grade) & 01 Time
Generation
Soft Rolling(8.8))

5 Pcs /Bins of Hard

Rolling (12.9 Grade)

By Acid Pickling ,Check In

Lab Assistant Zoom Sterioscope and
Record Generation

Daily (Each Shift, each

By Mould , UTS, & Hardness
Lab Assistant
Line)
Test and Record Generation

Daily (After Final

Inspection)

Daily

(During
PDI)

9.00 AM Daily

Generation of Material cum

Lab Assistant Plating evaluation Report (As
per Sampling Plan)

If material not ok as per SOP

Lab Assistant & check sheet put NC tag &
hold the supply

Lab Assistant

CAP-D Register & 5 Rule

Sheet

Metallurgist
Sr.
No
1

Roles & Responsibility

To Ensure Proper Working Of
Laboratory Facilities

Where

When

Who

How

Man
Hours

Proper Working of Lab

Instruments

Lab

Daily

Metallurgist

By Using daily check sheet of

Instruments

20 Min.

Thread Laps Checking (In

Process)

Lab

Daily( 06 Times of
Hard Rolling & 02
Time Soft Rolling)

Metallurgist

By Mould & Image Analyser

and Record Generation

13 Hrs

Lab

Daily (Each Shift,

each Line)

By Mould & Image Analyser,

Metallurgist UTS, & Hardness Test and
Record Generation

1 Hr

Lab

Daily (After Final

Inspection)

Generation of Material cum

Metallurgist Plating evaluation Report (As
per Sampling Plan)

21 Hrs.

Check availability of Color

Metallurgist Code, Wire Dia, &
Identification Tags

15 Min.

What

To ensure the correct results are

conveyed to internal / external
Customers &all testing as per laid Metallurgical Check of
down procedure for products
Heat Treatment Lines
pertaining to his area of function is
complete before product is
released for packing
Lab Report of Material
despatched to Customer
Receiving of RM of Job
Work Items (Gzb Plant
RM) & Locating at
specified places

To ensure that proper testing of

raw material is done and no
unauthorized use of nonconforming raw material is done.

R.M. Super
Market

Daily

In-coming RM Inspection
(Msr Plant Raw Material)

R.M. Super
Market and Lab

Daily (After
Receipt of RM )

Check Availability of Mill TC,

Supplier & Third Party Report
and check Color Code, Wire
Dia,Macro,Cold
Upsetting,Micro
2 Hrs.
Metallurgist Structure,Grain Size,
30
Hardness In HRB,TS,RA &
Min.
Hardenbility and Record
Generation
(As per RM Standard &
PQCS)

R.M. Supplier's
End

Once in a week

Metallurgist

Lab

Daily

To ensure testing is done as per

laid down standards only

RM Supplier's Audit

To ensure calibration is done as

per Requirements.

Calibration/ Verification of
Instruments

RM Inventory Check, &

Checking of Macro,
Microstructure, Upsetting,
T.S. Hardness & R.A.

Verification of Hardness
Metallurgist Tester by Master Block, &
U.T.M. By Dial Zero Setting

6 Hrs

10 Min.

TOTAL MAN WORKING HOURS

38 HRS &
15
MIN.

Daily Work Management

Name:

Emp. Code:Period

Date

Avtivities

Starting
Time

Completion
Time

Remarks

TOTAL MAN WORKING HOURS

Man
Hours