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QUALITY GROWTH SERVICES PVT LTD.MANUFACTURING EXCELLENCE-DIAGNOSTIC STUDY

Sl No Information Required

1 Name of the Organization

2 Full Address

3 Tel. No.

4 e mail id

5 Key Contact Person(s)

6 Phone No. of Key Contact Person(s)7 Nature of Business

8 Key product(s) for TMTL

9 Year of commencement

10 Daily running hours

11 Number of employees

• Sr Management :

• Technical:

• Commercial:

• Workmen:

12 Existing Management System (ISO 9001/TS 16949 etc.)

13 Any existing improvement program(s): Lean/Kaizen/TPM etc.

14 Company maintains defined business plan

15 What are the key business performance issues, company

wants to solve (on priority)

16 Attach Process Flow Chart of Products supplied to TMTL

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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

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Sr. No.

Sr. No. Contact Person

A General

A1 Brief details of manufacturing equipments

B Performance data analysis Score

B1 Availability and Analysis of Cycle time data for all products/ Op. 1B2 Availability and Analysis of Productivity data 3

B3 Availability and Analysis of Set up time/ change over time data 1

B5 Availability and Analysis of Equipment Breakdown data 2

B6 Availability and Analysis of Setup scrap data 1

B7 Availability and Analysis of Production Scrap data 1

B8 Availability and Analysis of Quality scrap data 2

B9 Availability and Analysis of Rework data 2

B10 Availability and Analysis of Production Consumables data 1

B11 Availability and Analysis of WIP Inventory data 1

B12 Availability and Analysis of Plan vs Production data 2

B13 Availability and Analysis of OEE data 1

B14 Availability and Analysis of Process Capability data 2

B15 Availability and Analysis of Incoming quality ppm data 2

B16 Availability and Analysis of Shop quality ppm for BOP 2

B17 Availability and Analysis of Customer complaint data/ppm 3

B18 Availability and Analysis of BOP/ RM Inventory data 2

B19 Availability and Analysis of Finished product Inventory 2

B20 Availability and Analysis of Inventory Turn Over ratio 3

B21

B22

C PracticesC1 Availability of Control Plan 3

C2 Availability of PFMEA 3

C3 Availability of Process Control Sheet/ Work standard at work stati 3

C4 Availability of Setup Instruction 2

C5 5S conditions and Audit system 2

C6 Availability of data driven disciplined Root Cause Analysis 2

C7 Poka Yoke monitoring and identification system 2

C8 Operator Competence Matrix 1

C9 Are the staff trained on the following Tools 2

C9.1 Problem solving 3

C9.2 FMEA 2

C9.3 MSA 1

C9.4 SPC 1

C9.5 Error Proofing Techniques 2

C9.6 Employee Suggestion Scheme 1

C9.7 Lean Tools 2

C9.8 TPM Tools 2

C9.9 Process Validation 2

Name of Organizatio

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C10 Compliance of Control Plan 2

C11 Compliance of Work Standard 2

C12 Function wise performance goals and analysis system 2

C13 Availability and Analysis of Preventive Maintenance 2

C14 Availability and Analysis of Predictive Maintenance 2

C15 Availability and Analysis of Autonomous maintenance 2

C16 Analysis of Cost of Poor Quality 1C17 Use of Control Charts 1

C18 Identification of Special Processes (Give Details) 1

C19 Manufacturing Process Validation System 1

C20 System for verification of Process Layout 1

C21 1st

piece/Set up verification 1

C22 Tooling/ Die control (Drg, History card, life monitoring) 1

C23 Product Identification for status at each stage 1

C24 Availability and Analysis of Process Audit system 2

C25 Availability and Analysis of Product Audit system 2

C26 Availability and Analysis ofNC product control system 2

C27 Availability and Analysis of Contingency Plan 1

C28 Morning meeting practices 2

C29 Area Information Board 2

C30 Staff and Operator trg. (Hrs/ Year) 1

C31 No. of Kaizens in the year 2

C32 Laid down stores layout 2

C33 Dedicated place for each item in stores and its adherence 2

C34 Inventory norms (Min, Max etc…) for each item established 2

C35 Monitoring of stores against inventory norms 1

C36 Analysis of Inventory norms in ordering/ scheduling 1

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STATUS/COMMENT

Not AvailableData Available

Not Available

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Score Performance

0 No data1 Limited data, no analysis

2 Data available, Limited trend analysed

3 Data available, trend analysed, un

structured causal analysis and action

4 Data available, trend analysed,

structured causal analysis,action,

effectiveness verification

5 Process standardized, Complete

Analysis, action, effectiveness

verification, horizontal deployment

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Practices

No activityNot 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