MACE Formats 1

7/30/2019 MACE Formats 1

1/46

Training Topic Vs Name

S.no Name of Perso Designation Level 5s TS Positive att 7QC Tools

1 Ram oper oper Y N Y Y2 Shyam mgr top N Y Y Y

3 Ghanshyam supp. middle Y Y Y Y

4 Sonu oper oper Y Y N N

5 monu mgr top Y Y N N

6 Bhavesh mgr top N Y N N

7 Pintu engg middle N Y N N

8 Tinku engg middle Y Y N N

9 ratiram mgr top Y N N N

10 rajaram am top Y N Y Y11 ratanlal am top Y N Y Y

12 joshi dm top N Y Y Y

13 pk dm top N Y N Y

14 rajeev oper oper N Y N N

15 mandal oper oper N Y Y Y

16 miglani supp. middle N Y Y Y

17 parveen supp. middle N N Y Y

18 jangra ae middle N N N Y

19 vikasbh oper oper Y N Y Y

20 vabhav engg middle Y Y N N

21 anil engg middle Y Y Y N

22 ajit am top Y Y N Y

23 kky dm top Y Y Y Y

24 ashok am top Y Y N Y

25 teeka oper oper Y N Y N


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Kaizan

Y

N

Y

Y

Y

N

N

Y

YY

N

N

N

N

N

N

Y

Y

N

N

N

Y

Y

Y


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AA A B CMkt

gEngg Dev

2 Pre-Feasibility O O O O O

5 Cost Estimation O O O O O

10 BOM O O O O

17 Process FMEA O O O O O O O

18 Productivity Goals O O O O O

Work Instruction for Resposibility(APQP)

Purpose : To define the rank of new product for development & activities & responsibiliti

process change of existing items.

Scope : This WI is applicable for development of new product,Engg change and any Pr

Method : Description,Rank of Development and responsibility is defined as below

S.No Description

Development Respo

1 Reciept of drawing along with spec drg/ref.sample O O O O

3 Clarification from customer for incomplete info O O O O O O

4 Technical feasibility. O O O O O

6 Reciept of LOI from customer O O O O O

7 Preparation of PDF O O O O

8 Preparation of Timing Chart O O O O O

9 Process Flow Chart O O O O

11 Passed History Study O O O

12 Component Drawing O O O O

13 Drawing Review O O O O

14 Review of Process Flow chart O O O

15 Listing of special Characteristics O O O O O

16Evaluation of Regulatory/Statutory requirements,

environmental Health & Safety IssuesO O O O


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22 Tool Manufacturing O O O O

23 Gauge Testing Equipment O O O O

24 Sourcing Raw Material/BOPs O O O O O25 Sample Trial Run O O O O O O

26 Follow-Up Results during Product Development O O O O O

27 Review with Customer O O O O

28 Layout Plan O O

29 Component Procurement O O O O O

30 Ppk Study Plan O O O O

31 Operator Process Instruction O O O O

32 Logistic Study O O O O

33 Packaging Specifications O34 Pre-Launch control Plan O O

35 MSA Plan O O O O

36 Production Trail Run,Pilot Lot O O O O O

37 Process Product Validation O O O O O

38 Process Capability Evaluation O O O O O

39 MSA study O O O O

40 PPAP O O O

41 Customer Approval O O O O O

43 Production control Plan O O O O O

44 Production Source Approval O O O

Rank

AA

Legend

42 Feedback Analysis & Corrective Action O O O O O O

That whenever the Environment (Containing comtaminants like Metallic Chips,Dust) or

and the safety contents

Development Rank:

Details

BThat Whenever there happens to be a Minor Deviation in the Component produced so f

CThat whenever there happens to be extremely minor change in details related to the co

becomes non mandatory(It becomes more of checks in regard to monitoring of the poin

Absolutely new component : no Experience of Production so farA That the part happens to be similar to what had been produced so far but there happen

material,Machining Methodology,In the structure or in the function.

A component similar to the component produced so far but there happens to be

That whenever there happens to be changed in production site

That whenever the place/country of development happens to be different from the place

Review Required/Important from discussion

(Blank)

LEGENDS:

For Development Rank

Definition

Point to be Implemented


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Legend Definition

For Responsibility

Prime Responsibility

Co-Responsibility

00' New Issue

Rev.No. Description


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QA Prod Matls

O

O

Document No.

es for product development , Engg change and any

cess change of existing items.

nsibility

RemarksDocument

Reference

O O

O

O

O

O

O


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O O O

O O

OO O

O

O

O

O O

O O

O O O

O

O O

O

O

O

O

lse the degree of Moisture,Temperature,Pressure

O O O

ar(To implement only for inspection of initial product)

ponent ,so much so that even the inspection

s of variation in regard to 4M

to be large scale difference in raw

/country of production

oint of view


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19/8/2004

Date


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Advanced Product Quality Planning DateStatus Report Review No.:

Diamond Point:

Supplier Program

Location Model Year

Supplier Code Lead Part No.Risk Assessment Part Name

New: Site X Technology Process Eng. Level

Other Risks User Plant(s)

Team Members Company/Title E-Mail Phone/Fax

Build Level IPD Into Plant Status GYR Quantity Concurred P.I.S.T. P.I.P.C.

Date (MRD) Present History No. SC's No. CC's % %

G G

1Risks: 1 = No Risk 3 = medium Risk (PSW part submission date can still be achieved - Special effort necessary) 5 = high (PSW part submission date endangered)

APQP Elements GYR Risk Program Supplier Closed Resp. Remarks or

Status Evaluation Need Timing Date Engineer Assistance Required

Present History per Element Date Date Initials

1 Customer Input Requirements G G 4/15/2005 4/13/2005 4/14/2005 OW2 Agreed GQA G Y 4/15/2005 4/13/2005 TF

3 Product Feasibility G G 4/15/2005 4/13/2005 4/14/2005 AZ

4 Sourcing Decision G G 4/15/2005 4/13/2005 4/14/2005 OW

5 Change Management G G 5/20/2005 5/18/2005 AZ

6 Environmental-Management/ IMDS/ ELV G G 6/3/2005 6/1/2005 5/22/2005 TF

7 Prototype Build Control Plan G G 5/20/2005 5/18/2005 5/18/2005 TF

8 Design Verification Plan G G 4/29/2005 4/27/2005 4/27/2005 AZ

9* Facilities, Tools, Gauges G G 6/10/2005 6/8/2005 AZ

10* Design FMEA R R 5/13/2005 5/11/2005 AZ11* DFMA @ Customer level G G 5/20/2005 5/18/2005 5/18/2005 AZ

12* Drawings and Specifications (Design Freeze) G G 5/20/2005 5/18/2005 5/18/2005 AZ

13 Information about Subcontractors G G 4/22/2005 4/20/2005 4/20/2005 OW

14* Logistic Concept G G 4/29/2005 4/27/2005 4/28/2005 UE

15* Packaging Specification (Serial & Spare Parts) G G 5/20/2005 5/18/2005 5/2/2005 UE

16* Design Validation @ Supplier Level G G 5/13/2005 5/11/2005 5/11/2005 AZ

17* Design Validation @ Customer Level G G 5/20/2005 5/18/2005 5/18/2005 AZ

18* Measurement Syst. Analysis/ Measuring Agreem. G G 5/20/2005 5/18/2005 5/18/2005 TF

19 Definition of Team for Serial Support G G 6/3/2005 6/1/2005 6/1/2005 OW

20 Definition of Quality Reporting G G 6/3/2005 6/1/2005 6/1/2005 TF

21 Prelaunch Control Plan G G 4/29/2005 4/27/2005 4/27/2005 TF

1

1

1

3 In negociation

2 Points to be cleared

1

1 1 Gauge may be unnecessary

1

1

1

1

5 see below1

1

1

1

1

1

1

1

1


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Part Name:

Part Number

Clause No.1.3

Implementati

on date

TGR / TGW (PDCA Format)

Defect / Problem Incharge Action Taken Target Date


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Status

1st 2nd 3rd OK/NG

Effectiveness of Checking

Remarks


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Part Name __________________________________ Model _______________ Station _________________

Part Number________________________________ Customer _____________________________________________

Start date of Initial Supply Control ________________________________________________________________________

End Date of Initial Supply Control ________________________________________________________________________

Remarks.

___________________________________________________________________________________________________

___________________________________________________________________________________________________

___________________________________________________________________________________________________

Incharge ( Product Development)

Extended upto (If required) ______________________________________________________________________________

Reason for Extention _________________________________________________________________________________

Incharge ( Product Development)

INTIAL SUPPLY CONTROL


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Clause No.2.7


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________

________

_________

_________

__________

__________

__________

_________

___________


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Implemented Not Implemented

1 Is the assembly line, stage under "ICP" is identified

clearly --- "Under Initial Control Period" ?

YES

2 Are additional check points given in Supervisor

check sheet for " ICP" ?

YES

3 Are additional check points given in Operator check

sheet for " ICP" ?

YES

4 Are additional points in check sheet / WI for ICPclearly highlighted or is special identification of these

additional points done ( Star mark etc) ?

YES

5 Are the Operators and respective Initial Flow Incharge

aware of their / his responsibilities?

YES

6 Is the timing plan made detailing all the activities ? YES

7 Is follow up of respective activities being done as per

Timing Plan and is review status being updated in

Timing Plan and are remarks for any delay or

rescheduling recorded ?

YES

8 Is PDCA Approach followed for problem solving

during ICP ? ( Rejection Analysis , rejection trend , To

fillup the CM Sheet , to decide the actions and

YES

9 Is Process FMEA carried out ? YES

10 Is cut off limit of RPN decided for taking actions on

the basis of FMEA ?

YES

11 Is evaluation of Process capability done ?( Once in 3 months)

YES

12 Is supplier audit planned and is carried out at decided

frequency?

YES

13 Are operators being trained for the work they are

performing ? ( training record / training plan / Skill

matrix)

YES

14 Are Managers and Supervisors clear about their

added responsibilities ?

YES

15 Is problem solving technique used for the faced

problems ( inhouse , customer line rejection)

( See Counter Measure sheet History of possible

YES

Status

CHECK SHEET FOR " INITIAL CONTROL PHASE"

1) NAME OF THE PRODUCT UNDER " Production Preparation Phase" --- WASHER ASSY. WINDSHIELD (YC-5)

2) NAME OF THE CUSTOMER :--- MARUTI SUZUKI INDIA LIMITED

3) PART NUMBER :- 38400M68K00/K10

4) DATE OF STARTING OF " ICP" :-

5) TERMINATION DATE OF " ICP" ( Period for Initial Control ) :-

6) PROJECT LEADER / CFT LEADER :-

S No Points to be Implemented / Reviewed


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17 Are identification tags used to identify initial products

from the changed process and is the identification

controlled through out the subsequent supplier

process till despatch ?

18 Is Initial product supplied to customer with necessary

inspection reports and with FPP tag ?

19 Are all the instruments calibrated ?

20 Are all the fixtures validated ? ( Is Drawing available?

)

21 Is MSA study carried out ?

22 Are Breakdown trend maintained and is action plan

made to reduce breakdown ?

YES

Signature of Initial Flow Incharge :-


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Responsibility /Remarks


19/46


20/46

Implemented

1 Are all the problems occuring before SOP are

resolved ans a recheck done to confirm that they

remain solved ?

2 Is any new problem arising in Initial Control Period

resolved ? ( Verify the concerned records)

3 Is cross verification of all the additional check

points given in Supervisor check / Operator check

sheet and Work Instructions sheet for " ICP" done ?Is

there still a need for these additional points ?

Are these documents revised before terminating the

ICP?

4 Is Cpk > 1.67 ( If not , is action decided to increase

the Cpk value? ) ( Verify from the SPC records)

5 Is ICP at supplier's end over. Are all the incomingparts related to ICP product OK ?

6 Are Acceptance Standard revised ( Remove the extra

check points -- if there is no quality issue during ICP )

7 Is History of all the problem faced during ICP

maintained ( CM , rejection trends , History of

possible reasons etc)

8 Are Control Plan , FMEA rocess Flow Diagram ,Work Instructions. Operator and Supervisor Check

sheets have been updated ( Highlight the marks

related to Customer Complaint , Customer Line

rejection or related to Critical Process)

9 Is the skill matrix of Operators and their Competency

records updated ?

10 Are the necessary Limit samples , Sketches available

on all the required stages as per Control Plan

11 Are all the jigs and fixtures suitable for their respective

CHECK SHEET FOR " TERMINATION OF INITIAL

1) NAME OF THE PRODUCT UNDER " Production Preparation Phase" ---

2) NAME OF THE CUSTOMER :---

3) PART NUMBER :-

4) DATE OF STARTING OF " ICP" :-

5) TERMINATION DATE OF " ICP" :-

6) PROJECT LEADER / CFT LEADER :-

S No Points to be Implemented / Reviewed St


21/46

12 Are all the jigs and fixtures validated at regular

interval ?

13 Is History sheet of all the machines maintained ?14 Is time study carried out ? Are action taken for line

balancing ?

15 Is OEE carried out for this line ? Is the line capable of

meeting Customers requirements ?

16 Is MSA records updated as per Control Plan?

17 Is there any repeated Breakdown ?

18 Are all the machines suitable for their respective

usage ?

19 Are Production trial and Mass Production trial records

available ? ( Verify the records)

Signature of CFT Members :-


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Not Implemented

CONTROL PHASE"

atus Responsibility /Remarks


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24/46

Part Number _____________________ Part Name _

Control duration : From ___________________ To ________

Extension (if any) _________________________________

Reason of extension _________________________________

Details of initial supply control :

New component (Model) ___________________________

Design change (ECN number) ______________________

Process change :

Process parameter change Su

Tool/Die/Machine/Equipment change O

Layout change Re

S.No. Control Item UOM

Specificat

ion

R

c

1 Customer complaints numbers 0

2 Inprocess rejection ppm 30

3 Incoming rejection ppm 30

4 Cpk value 1.67

5

Result of c'measure taken

aginst problems during

production preparation

current vs

previous Effective

6

Result of c'measure taken

aginst problems during initial

supply control

current vs

previous Effective

7 Any other

Result of Initial Supply Control NG

Initial control checks can be terminated NO

Initial supply control period extended by da

Ap

C

INITIAL SUPPLY CONTROL SIGN O


25/46

__________________

__________________

_________________

pplier change

erator change

located plant

esult at end of

ontrol duration Remarks

OK

YES

ys

proved by (Devp Incharge)

FF


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Part Name

Part Number

Reason of IPP

Date of Production

Inspected by

Signature

Clause No.

IPP Tags

Initial Part Product Tag


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3.2


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Sect ion / Department

List of Activities performed by Operator 1

Are the operator verification sheets completed daily by all shifts ?

Are the tagging procedures being followed?

Are the Non conforming rejection are located in the specified area.

Procedure for carrying activities done as per the Operation standard

Clause No.11

If Rating < 03, Operator counselling required, Training to be give

OBSERVANCE OF OPERATOR

Operator Name


29/46

2 3 4 5

Rating Criteria

to Operator.


30/46

SI NO.DATE OF

OCCURRENCEPART NAME

MODEL/

CUSTOMERDEFECT REPEAT NO

PLAN


31/46


32/46

ROOT CAUSE ANALYSIS ACTION TO BE TAKENTAR

DATE

ACTUAL

CLOSURE

DATE

RESP.

CUSTOMER COMPLAINTS VERIFICATION CHECKSHEET

DO


33/46


34/46

1 2 3 4 5 6 FMEACONTRO

L PLAN

INSPECTI

ON STD

WORK

INSTRUCTIO

NS

QUALITY

ALERT

FOLLOW UP / DATESHorizontal

Deployme

nt

INSTITUTIONALISE THE PROBLEM WITH UPDA

CHECK ACT


35/46


36/46

LESSON

LEARNTREMARKS

ION OF FOLLOWINGS


37/46


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1 6

2 7

3 8

4 9

5 10

1 2 3 4 5 6 7 8 9 10

End Point

Unloading of Raw MaterialLoading of Finish

Goods

PART NAME:-

PART NO:-

MODEL:-

Team Menber

DEFECT POSSIBILITIES

Orientation

Proper Seating

Damage

Missing

Starting Point

Safety

Identification

Operation Missing

Reverse

Double

Wrong parts (different parts)

Date:-

Process Precision Check

OBSERVATIONSSl.No PROCESS STEPSDefect Possibilities

STATUSACTION RESPONSIBILITYTARGET

DATE


39/46

Clause No 13

MAKE A PLAN FOR PRECISION PRECISION


40/46

S.NOPARAMETER TO

CHECK1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 REMARKS

X

CHECKED BY

OK AFTER CORRECTION APPROVED BY

VERIFIED BY

OKLEGAND NG

DAILY INSPECTION OF INSTRUMENT / EQUIPMENT / MACHINE

MONTH:-

INSTRUMENT / EQUIPMENT / MACHINE NAME:-

CONTROL NO:-


41/46

QA Production

Date Date

Time Time

Note: Retension period :

In Charge Prod. In Charge QA

Part Name

Part No

Model

QUALITY ALERT / FLASH NOTE

(Customer / In-house / Warranty / Supplier)

DEFECTS:-

PHOTO/SKETCH:-

ACTION REQUIRED:-


42/46

Apr. May Jun Jul Aug Sep Oct Nov Dec Jan Feb

P

A

P

A

P

A

P

AP

A

P

A

P

A

P

A

P

A

S.No Topic Date

Month

YEAR Prepared By Verified By Approve

HigherMgt.

MiddleMg

t

Operatorlevel

ANNUAL TRAINING PLAN Vs ACHIEVEMENTNo. of

Persons

Faculit

yDurationTopicCat.

Next Date Sign.

Sign.

Total

Date

Reasion for Delay

Plan/

Actu

al

DepartmentFacilities


43/46

Mar

By


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Parameter

No

Pr.

No

1 6

2 7

3 8

4 9

5 10

Parameter

No1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1

2

3

4

5

7

9

10

Opr. Sign.

Sup. Sign.

LEGAND X

Date Sketch (if any)Abnormality Action Taken Impl. Date Resp.

Prepared By Approved By

DAILY STARTUP CHECK SHEET(for Equipment/ Machine/ Instrument etc)

Name:- No:- Deptt./Section:- Last Call/ Maint. Date:- Call/ Maint. Due Date:- Resp.:-

Month

Parameter Specification Check Method Freq.Parameter Specification Check Method Freq.

OK AFTER CORRECTION APPROVED BYOK NG


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S.No Parameter to Check 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1

2

3

4

5

7

9

10

Opr. Sign.

Sup. Sign.

LEGAND X

Date

OK NG

Abnormality Action Taken Impl. Date Resp.

OK AFTER CORRECTION APPROVED BY

Sketch (if any)

DAILY STARTUP CHECK SHEET(for Equipment/ Machine/ Instrument etc)

Deptt./Section:- Resp.:-Control No:-Inst/Equi.Name:-


46/46

1 2 3 4 5 6 7 8 9 10

Remarks

4 7

TOPIC

S.No EMP.NO PHOTO EMP.NAMECan work under supervision

Plan

Can handle independently

Actual

Can train other

SKILL MATRIX

Minium no.of person req. for skill level



Revised on:

De

cember

Ja

nuary

Fe

bruary

M

arch

Basic Knowledge only


Year

April

May

June

July

A

ugust

September

O

ctober

No

vember

1 A

2 B

3 C

DATE REASION FOR DELAY

4 D

NEW DATENAME

SIGN.

DATE

Documents

MACE Formats 1