100PPM & SQ MarkVENKATESWARAA INSULATIONACHIEVE 100PPM / SQ MARK - CHECK LISTSl.NoActivity Description / Action PlanResponsibilityTarget DateStatus1)Visual Control & Disciplinary Activities1Shop Floor CleanlinessFree From Mud, Oil, Dust, Scrap, etc.,2Wall Painting & Floor Painting3Clear Gangway & Pathway4Process Flow(I/P-Process-O/P)- Layout For Entire Factorywith Optimum Distance Between Each Process.5No Back & Forth Movement of Goods Against ProcessFlow Layout6Process Location Identiification7Working Tables Should be Clean & No Rust8Working Height to be Maintained between 750-850mm.9"ACHIEVE SQ MARK / 100 PPM" Display in Key Areas.10Uniform Dresses & Shoes for All Workers11A3 & A4 Transparent Leafs to be replaced with AcrylicBoards12Performance Trend Charts to be Displayed in Key Area13Conference / Training Hall Layout to be Done14Utilities Such as Air & Water Lines are Properly Installed.15Unused Goods are removed & Kept far away from WorkPlace15Organization's Performance with Product Display Case3Testing Facilities1Universal Testing Machine (UTM)2Shore 00 Hardness Durometer3Density/GSM Tester4Compression Set Apparatus5Temperature Sensor Gun6Colour Matching Cabinet3)Rejection Control1In-Coming, In-Process & Customer Rejection DataCollection2Rejection Analysis, Action Plan with EffectivenessMonitoring and linkage with Improvement.3Separate area for Receipt materials inspection4Quarantine Area for incoming, In-process & FinalInspection5Rejected materials identification with Red Tag6Separate Area for Rework and Rejection Storage & Separate Table Allocation for Rework7History of NC Part Occurrence incoming/In-Process/FinalInspection8Scrap Yard to be Created with Defined Frequency Disposal.9Scrap Register to be Maintained4)Machine Maintenance1Daily, Weekly, Monthly, Quarterly, Half-Yearly and Annual Preventive Maintenance Plan.2Machine History Card3Critical Spares Stock Register / Display Board4Critical Spares Stock Storage Rack5Machine History Card5)Tool/Die Maintenance1List of Punching Dies2Tool/Die Validation in Fixed Frequecy3Tool History Card (No of Shots)4Punching Die Identification in sequence with respective material Selection5Tool/Die Storage Layout to be made6Tools/Dies will be stored customer wise.7Sufficient Racks to be made for Tools./Dies Storage

6)Display Board With Table On Each Machines1Display Board Quote Receipt & Order Finalization2My Machine3Machine Specifications4Work Instructions - English & Tamil (With Photos)5Annual Preventive Maintenance check List6Daily/Weekly/Quarterly/Half-yearly M/c Check Sheet7Job Card8First-Off & Last-Off Samples Display7)First-Off&Last-Off Samples Identification & Storage Rack1First-Off & Last-Off Samples Storage at Racks2(With 1 Weeks Retention) with batch Identification8)QA Laboratory1Master Samples Storage with Identification in Racks2Master Accepted & Rejected Samples to be Stored inQA Lab with Lock & Key.3QA Lab Layout with Identification4Inspection Standardsa) Incoming Inspectionb) In-Process Inspectionc) Final Inspection5Customer Complaints' Status Board (Red Colour) to bedisplayed at Factory To monitor the Effective Closure.6Appropriate Selection, Master List, and Calibration of Monitoring & Measuring Equipments.7Part Identification Tag for Identification & TraceabilityPurpose which reveals RM Lot, Work Order, Operator, Mfg Date & Part Details.8Manufacturing / Work Standard (With Important ControlPoints)a) Pre-Production / Sheet Cuttingb) Semi-Automatic Adhesive Coating Machinec) Die Punching Machine I,II & III.d) Slicing Machinee) Slitting Machinef) Pouch Sealing Machine I, II & III.g) Simultaneous Sealing & Cutting Machineh) Lamination Machinei) Packingj) Raw Material Inventory Controlk) Finished Goods Inventory Control9)Training1Skill Matrix & Job Responsibility to be Displayed ineach processa) Pre-Production / Sheet Cuttingb) Semi-Automatic Adhesive Coating Machinec) Die Punching Machine I,II & III.d) Slicing Machinee) Slitting Machinef) Pouch Sealing Machine I, II & III.g) Simultaneous Sealing & Cutting Machineh) Lamination Machinei) Incoming / In-process & Final Inspectionj) Packingk) Raw material Storage FIFO Controll) Finished Goods Storage FIFO Control10RM, WIP & FG Storage & Control1Raw Material GRN Identification2RM Storage as per material/Weight/Colour/Thickness3Raw Material Stock Staus Board with FIFO Control4Raw Material Storage Rack Identification5Raw material Stores Layout6Stores Stock Report - Review Meeting7Stores Issue / Receipt Register8Max. Level to be marked in RM Storage area9Material Lifting & Movementof weight between 20-500 Kgs Fork Lift to be Purchased10Finished Goods to be Stored Customerwise at Racks11Finished Goods Stock Report to be maintained.12Max. Level to be marked in FG Storage area13WIP-Standards has to be defined and implemented1411PSW/AOI & Revalidation Requirements1Customer Wise PPAP File Indexing while initial Submission2As per AOI/PSW, performing External Lab Testing3Revalidation Plan4Revalidation Reports as per Customer Schedule12Customer Satisfaction1Customer PPM Monitoring, Analysis & Action Plan2Customer Complaints' closure effectiveness3Positive Feedback Collection and Analysis for Improvement13Health & Safety Measures1List of Personnel Protective Equipments (PPE)2PPEs at each machines For OperatorsGloves, Shoes etc.,3Shelf Life of Receipt Chemicals & Adhesives4Pressure Vessel to be calibrated5Entire Electrical wirings to be properly routed.6No Electrical outlets near Material Storage area.7Necessary Fire Extinguishers in Place8No Oil Spillage near Hydraulic Units9Min & Max to be Marked in all Pressure Gauges10In/Out Identification to be Marked in All Pipe Lines.11Colour Identification to be Introduced for Air & WaterPipe Lines12Entire EB Panel Boards to be Fenced for Safety13Separate Area for Safe Assembly Point in case of Emergencies14Safety Posters and Safety Guards in Equipments.

14Improvement1Task Force Team For Improvement Activities2Cost Saving Projects Without Affecting Quality3Poka-Yoke implementation to Avoid Manual Errors.4Document Back Up Procedure to be implemented5Rewritable DVDs/External Hard Disk Procurement

15Inspection & Packing Tables1Final Inspection Table with sufficient lights to be made.2Final Inspection Layout to be created with sufficientInspection Lines.3Skill Matrix for Inspectors to be Displayed at Final Inspection AreaPacking Standard with Photos to be Displayed atFinal Inspection & Packing Table.

16Supplier Control1Supplier PPAP/ISAR/PSW Collection2Supplier RM Master/Limit Samples3Incoming Inspection Register4Incoming Rejection Analysis5Test Certificate for Incoming Materials6Supplier Quality Assurance-Procedure to be Documented.7Supplier Audit Check List / Auditing in Certain Frequency.8Supplier Parts Revalidation as required.9Identification & Traceability of Supplier Materials.10Supplier Complaint Register11Supplier Non-conformance Report & Counter Measures.12Supplier Complaint Closures - Review in MRM.17Production1Capacity Planning For Each Machine / Product / Men2Understanding the Present Capacity Utilization & Upgrading for Increased Capacity3Job Card For Each Process / Machines

18Management Systems Implementation1ISO/TS 16949:2009 Quality Management Systems for Particular to Automotive Requirements2ISO 14000:2004 Environmental Management Systems

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