Download - plant perform.1
Supplier Inhouse Customer end Total
Cost ofPoor
quality( %)
Totalprod.Qty.
TotalRej.Qty.
Rejectionppm
(inhouse)
TotalRej.Qty.
Rejectionppm
(Supplier)
Rejection Cost - (sell value)
TotalDisp. Qty.
Rej. PPM, SELL & COPQMonth - Jan.2015
Sr.No
Part No
Inhouse Supplier Customer End
value/ piece Total SellProd qty.
(sell value) Totaldisp.
Rej.Qty.
Rejectionppm
(cust. End)
Total
Prepared by : Reviewed By:
Sr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status
DAILY REJECTION - INWORD,INHOUSE , FINAL STAGE
Jan.2015
Reviewed By:Prepared By:
Sr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status
Sr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status
Sr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status
Sr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status
DAILY REJECTION - Major NC ( Top Five defects)Jan.2015
Total
Total
Total
TotalSr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status
Prepared By: Reviewed By:
Total
Total
SrNo NC Total
rej.REJ % CF %
1
2
3
4
5
REJECTION PARATO Jan2015 - Major NC
0.00
0.20
0.40
0.60
0.80
1.00
1.20
REJ
% &
CF%
REJ.PARATO
REJ %
#REF!
Series3
5
TOTAL
Prepared By: Reviewed By:
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target ( PPM)
Company Level PPM
Trend Chart-Company Level PPM (Rejection)
4000
5000
Company Level PPM Target ( PPM) Linear (Company Level PPM)
Prepared By: Reviewed By:
0
1000
2000
3000
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
( PPM
)
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Total Rej Qty
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0
SCRAP NOTE
Jan.2015
Sr.No
DefectPart No & Qty.
15 0
16 0
17 0
18 0
19 0
20 0
21 0
22 0
23 0
24 0
25 0
26 0
27 0
28 0
29 0
30 0
31 0
32 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Production Incharge QA Incharge Store Incharge Plant Incharge MD
Total
Production Incharge QA Incharge Store Incharge Plant Incharge MD
Complaintrec. Via.
Complaint Summary
Month : Jan.2015
Sr.No.
Date Part No. Part Name Customer Part No.Customer
NameProblem Description
ComplaintRaised By
Prepared By: Reviewed By:
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target (Total max. Complaints) (Nous.) 2 2 2 2 2 2 2 2 2 2 2 2
No. of Complaints Received (Nous.)
Target (Repeat Complaints) (Nous.) 0 0 0 0 0 0 0 0 0 0 0 0
No. of Repeat Complaints Received(Nous.)
Target (Field Failure) (Nous.) 0 0 0 0 0 0 0 0 0 0 0 0
No. of Incidences of Field Failure (Nous.)
Trend Chart-Customer Complaint Details
No. of Complaints Received (Nous.) No. of Repeat Complaints Received (Nous.) No. of Incidences of Field Failure (Nous.)
Target (Total max. Complaints) (Nous.) Target (Repeat Complaints) (Nous.) Target (Field Failure) (Nous.)
Updated By: Reviewed By (Head-QA):
0
1
2
3
4
5
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target (Total max. Complaints) (Nous.) Target (Repeat Complaints) (Nous.) Target (Field Failure) (Nous.)
Nou
s.
Updated By: Reviewed By (Head-QA):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target ( PPM )
Customer PPM
Trend Chart-Customer PPM (Rejection)
1600
1800
2000
Customer PPM Target ( PPM ) Linear (Customer PPM)
Prepared By: Reviewed By:
0
200
400
600
800
1000
1200
1400
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
PPM
Prepared By: Reviewed By:
Cost of Poor QualityJan.2015 to jul.2015
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00%
% Cost of poor quality
Month Jan.2015 Feb.2015 Mar.2015 Apr.2015 May.2015 Jun.2015 Jul.2015
Cost of scrap
Cost of customerDissatisfaction
0 0 0 0 0 0 0
#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Reviewed By:
Sr. No.
1
2
Total
Sales(Rs.)
Cost of poor quality %
Prepared By:
0.00 0.00 0.00 0.000.00
0.00 0.000.00
0.50
Jan.
201
5
Feb.
201
5
Mar
.201
5
Apr
.201
5
May
.201
5
Jun.
201
5
Jul.2
015
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target ( %)
Delivery Performance [%]
Trend Chart-Delivery Performance (%)
Delivery Performance [%] Target ( %) Linear (Delivery Performance [%])
Prepared By: Reviewed By:
0
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Prepared By: Reviewed By:
Sr.No.
Name of Customer Unit Jan'15 Feb'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 sept'15 Oct'15 Nov'15 Dec'15
PPM
Grade
Rating
PPM
Grade
Rating
Customer Feedback
Mar'15
1
2 Grade
Rating
2
Colour Code for Unit:
Customer PPM Customer Grade Customer Rating
Prepared By (Manager-QA): Reviewed By (Plant Head):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Machines Planned (Nos.)
Machines Completed ( Nos.)
Target [%]
Plan Adherence [ % ]
Trend Chart-Preventive Maintenance Plan Adherence
90.00
100.00
Plan Adherence [ % ] Target [%] Linear (Plan Adherence [ % ])
Prepared By (Manager-Maintenance): Reviewed By (Plant Head):
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Prepared By (Manager-Maintenance): Reviewed By (Plant Head):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target ( %)
Actual MDT Factor ( % )
CNC
Hobbing
Press
Shaping
Shaving
Milling
Broaching
Grinding
VMC
HMC
Trend Chart-Machine Downtime Factor
HMC
General
Total ( Hours.) 0 0 0 0 0 0 0 0 0 0 0 0
0.00
0.50
1.00
1.50
2.00
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Actual MDT Factor ( % ) Target ( %) Linear (Actual MDT Factor ( % ))
0 0 0 0 0 0 0 0 0 0 0 00
50
100
150
200
250
300
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
%H
ours
.
Prepared By (Manager-Maintenance): Reviewed By (Plant Head):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sept'15 Oct'15 Nov'15 Dec'15
Incidences of Downtime( Nos.)
Trend Chart-Downtime Due to Non-Availability of Toolings
1Incidences of Downtime ( Nos.)
Prepared By (Engineer-Toolings): Reviewed By (Head-Production):
0
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sept'15 Oct'15 Nov'15 Dec'15
Nos
.
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
PA Planned ( Nos.)
PA Completed ( Nos.)
Not in Production ( Nos.)
Target ( % )
PA Plan Adherence ( % ) #DIV/0! #DIV/0! #DIV/0! #DIV/0!
No. of NCs
Trend Chart-Product Audit Data
60.00
70.00
80.00
90.00
100.00
110.00 PA Plan Adherence ( % ) Target ( % ) Linear (PA Plan Adherence ( % ))
%
Prepared By (Incharge-QA): Reviewed By (Head-QA):
0.0
0
0.0
0
0.0
0
0.0
0
0.00
10.00
20.00
30.00
40.00
50.00
60.00
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
0
1
2
3
4
5
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
No. of NCs
Nos
.%
Prepared By (Incharge-QA): Reviewed By (Head-QA):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Audits Planned
Audits Completed
Target (%)
Adherence (%)
Major NC's (NC1)
Minor NC's (NC2)
OFIs
Total 0 0 0
Trend Chart-Manufacturing Process Audit Data
Adherence (%) Target (%) Linear (Adherence (%))
0.00
20.00
40.00
60.00
80.00
100.00
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
0
10
20
30
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Major NC's (NC1) Minor NC's (NC2) OFIs
Prepared By (Executive-QMS): Reviewed By (Head-Production):
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Minor Injuries (Nos.)
Target (Nos.)
Major Injuries ( Nos.)
Trend Chart-Incidences of Injury
4
5
6
Major Injuries ( Nos.) Minor Injuries (Nos.)
Prepared By (Executive - HR): Reviewed By (Plant Head):
0
1
2
3
4
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Nos
.
Prepared By (Executive - HR): Reviewed By (Plant Head):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Target %
Plan Adherence %
Trend Chart-Training Plan Adherence
80
90
100
110
Plan Adherence % Target % Linear (Plan Adherence %)
Prepared By (Executive-HR): Reviewed By (Plant Head):
0
10
20
30
40
50
60
70
80
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
%
Prepared By (Executive-HR): Reviewed By (Plant Head):
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Inquiries Received
Inquiries Quoted
Received PO
Trend Chart-Inquiry Status
1
1
Prepared By: Reviewed By:
0
0
0
1
1
Inquiries Received Inquiries Quoted Received PO
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Prepared By: Reviewed By:
Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
New Received
Under Development
Development Completed
Trend Chart-Development Status
20
25
New Received Under Development Development Completed
Prepared By (Engineer-PED): Reviewed By (Head-PED):
0
5
10
15
20
Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15
Prepared By (Engineer-PED): Reviewed By (Head-PED):
Month Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'15 Feb'15 Mar'15
Sample Submission Plan
Samples Submitted(as per Timeline)
Samples Delayed
Target (%)
Plan Adherence (%)
Trend Chart-Sample Submission Plan Adherence
110.00
Plan Adherence (%) Target (%) Linear (Plan Adherence (%))
Prepared By (Engineer-PED): Reviewed By (Head-PED):
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'15 Feb'15 Mar'15
Prepared By (Engineer-PED): Reviewed By (Head-PED):