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BPFCH-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure deviation approval
Scope: All customers
Input

Responsibility/Inte
raction

Activities
NONO

Defect glass from Final


inspection / Inprocess /
customer claim

YES
YES
YES

Control Document / Checkpoint

Output

YESYES

Visit to customer (if reqd )


Collection
of claimed Glass
arrange
for segregation
at FG ware house &
at customer end( if req) and replace with good
glass as a contingency measure

Production

1.E-MAIL, 2.VOC, 3.MCM report/ deviation request

Detailed report of the glass

Minutes of meeting

deviation request

1.Flow of message to the process personal & QA


inspector

Employees signature against

On the same day of the claim

witnessing the defective

QA
Detailed report /Standards
fitment trials report at
customer end / function
test report in house

Analyise the reports

CFT

Display of claim glass / information on


the shop floor & information to all
concern

Claimed glass from


recd. customer

QA

glass

QA

Raise the QACR in customer


specific format / Asahi format

Customer requireme-

1.QACR

Filled QACR for all the relevent


provisions

1.Target Date of Action Plan from the Customer

nts,

100 % Re- Inspection of the existing WIP,


QCFG & FG & Review in MCM

Type of defect

QA, PPC, FG W/H AND


PROD.

Confirm the short term containment action to


the customer

Result of segregation

Type of Claim

1.Ensuring that OK glasses are fed to customer line

Trigger off the C/M, FMEA


revision

1.C/M plan is complete within 7 days.

Revised FMEA, Review of

2.Any PPAP or similar activities involved,

Masterlist, Deep Analysis

1.Any special testing required and source identification.

Deep Analysis report

QA-MKTG

Initiate CA- PA

Remove any defective glass

2.Segregation to be completed within 48 HRS from the


receipt of claim detail.

PROD, MKTG

QA, PROD-(CFT)

Problem analysis & drive countermeasure plan & review FMEA

Type of defect

QA, SECTION HEAD-

1.Varify from PPC/FG w/h that all the existing stock is


covered

1.Analysis is done jointly, Deep Analysis/DOE reqd.

Report

Completed CA-PA form

2.Discussion with the Technical Advisor,


3.Short term corrctive actions are completed prior to
sending
4.CA-PA within 7 days/as specified by customer.

Action completed
as per target

NO

QA-PROD

1.Planned action , 2.Commited date

YES
Completed CA-PA form

Verify Effectiveness of
counter-measure

YES

Results of five
consecutive product
audit

Repetition of the
problem

QA-Mkg

1.Customer claim for the same problem

Product Audit Resut

2.Product Audit results

QA-Mkg

1.History of problem

NO

Close QACR

Weekly Reports from

PPM analysis against


targets

R.O.

QA

MKG-RO-QA- PROD

1.QACR format

1.Monthly/ Quarterly data is recd from customer or RO


regularly

Monthly customerwise PPM

2.PPM matching with finacial data

Trend graphs

3.Defect trend is catagorized in terms of bkg


& process defect

YES

Achievement of
Target or claim reoccurence

1.Monthly/ Quaterly data is recd from customer or RO


2.Reporting to MCM
MKG-RO-QA- PROD

3.Target V/s actual PPM


4.PPM matching with finacial data

NO
QACR submitted, Product

Review of counter measurement & check the


product audit result for the same model & for the
same problem .

MKG-RO-QA- PROD

1.Collect the model wise, defect wise and location wise


data to pin point the problem

Trigger off FMEA and/Control

BPFCH-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure deviation approval
Scope: All customers
Input
audit Result

Review of counter Activities


measurement & check the
product audit result for the same model & for the
same problem .

Responsibility/Inte
raction

Control Document / Checkpoint

Output

2.Collection of more detailed data model having the major


Plan updation, Review of Job
rejection from RO
Standard

3.Product Audit result


4.Review the CA/ PA

Review the Control


plan , FMEA , Job
Std

QA- CFT

Review & Update the FMEA, CP , PPAP ,


Job Std.

QA- CFT

Sending of PDI, Monthly Inspection,


Revalidation reports to customers as per
their requirements

1. Amendment plan, 2. FMEA, 3. Control Plan


4. Information to customer on amended plan

QA

Process Efficiency : Zero customer complaints & Objectives and Accountabilities.

If PPAP, submit it to customer.

1.FMEA, CP , PPAP , Job Std.

1.PDI, 2.Monthly InspectionReports.

Distributed to :1,2,3,15,22,23,29

Process Effectiveness Measure : Customer Satisfaction analysis

A
Modification Status

New Release
Modification details

1/1/2005
Checked By

Approved by

Date

BPFCH-QAD-03

Business Process Flow (Final Inspection)


Purpose: To ensure 100 % right quality of the product as per specifications to customer.
Scope: All products manufactured.
Input

Process / Activity

Products
offered for
inspection as
per process
flow chart &
Completion of
all previous
processes in
process
quality checks.

Final inspection

Final
Inspection
Result

NO

Decision

Treat As per
non-conforming
product

Resp / Interaction

Control doc / Checkpoint

Output

1)QA Inspector /
1) Production shift
supervisor/ In-charge
2) Section Head - Prod
QAPCH-QAD-01
(Procedure for
Calibration)

1) Model Specific Inspection Standard Final Inspection


2) Control Plans
Result
3) Appearance standard /
1) Proper identification of offered glass
2) Qty mentioned in the process card
3) Thickness of glass
4) Colour of Glass
5) Use of Calibrated Instruments
6) MSA Qualified Inspectors

1)QA Inspector /
1) Production shift
supervisor/ In-charge
2) Section Head - Prod
QAPCH-QAD-03
(Procedure for Handling
Non conforming Product)
QAPCH-QAD-04
(Procedure for CA/PA)

1) Model Specific Inspection Standard


2) Appearance Standard /
1) Proper identification of offered glass
2) Qty mentioned in the process card
3) Thickness of glass
4) Colour of Glass

If OK : Pallet Card
If on HOLD : Isolate
Card
If Reject : Place it on
red cart and reject
card

YES

OK Glass
Reports
Hand over OK Glass to FG
Warehouse

1) Production shift
supervisor/ In-charge
2) QA Inspector

Filled & Signed Pallet


Card

OK Glass
Stored in FG
warehouse
with pallet
card.

Product audit
result sheet
( QA/XX/CK07)

Pick on random basis OK glass from FG


warehouse for product audit/ functional testing

NOT OK
Status of product audit/
functional testing

1) Section Head - In
Process (Quality) /
1) In-charge FG
warehouse

Control Plan

Product audit result


sheet ( QA/XX/CK07)

1) Section Head - In
Control Plan
Process (Quality) /
1) FG warehouse incharge
2) Shift supervisor
QAPCH-QAD-03
(Procedure for Handling
of NC Product)
QAPCH-QAD04(Procedure for CA/PA)

Signed Off pallet card


& FG Warehouse slip
if OK
If Not OK quarantine
to isolate/ lot-out area

1) QA Inspector /
1) FG warehouse incharge

Movement of OK
Glass to FG
Warehouse.

OK
FG
Warehouse
slip

Pass the lot for despatch

Distributed to : 1,2,3,22,23,30

Process Efficiency : As per Objectives & Accountabilities.


Process Effectiveness Measure : Monitoring through In Process PPM Score.
A
Modification
Status

New Release
Modification details

1/1/2005
Checked By

Approved By

Date

BPFCH-QAD-02

Business Process Flow (In Process)


Purpose: To ensure quality of the product during manufacturing processes as per specifications.
Scope: All products manufactured.
Input

Process / Activity

Products
offered for
inspection as
per process
flow chart

Periodical Patrolling
-Inprocess Inspection

In Process
Inspection
reports

NO

Decision

Treat As per
non-conforming
product

Resp / Interaction

Control doc / Checkpoint

Output

1) QA Inspector /
2) Production shift
supervisor/ In-charge
3) Section Head/ Incharge - Prod
QAPCH-QAD-01
(Procedure for
Calibration)

1) Model Specific Inspection Standard In Process


2) Appearance standard
Inspection reports
1) Proper identification of offered glass
2) Qty mentioned in the process card
3) Thickness of glass
4) Colour of Glass
5) Use of Calibrated Instruments
6) MSA Qualified Inspectors

1) QA Inspector
1) Production shift
supervisor
2) Section Head - Prod
QAPCH-QAD-03
(Procedure for Handling
Non conforming Product)
QAPCH-QAD-04
(Procedure for CA/PA)

1) Model Specific Inspection Standard


2) Appearance Std
1) Proper identification of offered glass
2) Qty mentioned in the process card
3) Thickness of glass
4) Colour of Glass

If OK : Process Card
If on HOLD : Isolate
Card
If Reject : Place it on
red cart and reject
card

YES

Inspection and
Test Status of
previuos
process &
offering of
product to next
process

Pass to Next Operation

1) Production personnel /
1) Production shift
supervisor/ In-charge

Filled & Signed


Process Card

Distributed to : 1,2,3,22,23,30

Process Efficiency : As per Objectives & Accountabilities.


Process Effectiveness Measure : Monitoring through In Process PPM Score.

A
Modification
Status

New Release
Modification details

1/1/2005
Checked By

Approved By

Date

BPFCH-QAD-01

Business process Flow ( Incoming Quality Assurance)


Purpose: Ensure all Quality Assurance during receipt of Product Related parts.
Scope: Direct BOM items

Input
Information from stores
through phone (Lot No., Qty,
MRN No., )
Regular Production / sample

Resp /
Interaction

Process / Activity
Reject & Back to
stores

Incoming Inspector /
Stores Officer/
QAPCH-STR-01

Receipt of MRN from Stores

Control doc / checkpoint

Output

AVL / Lot no. / MRN No. on the material Verification of material at Incoming
inspection location

BPF-MAT-01
NO

Did stores
informed about
the status

NO

Is it from AVL
-

Yes
Supplier report

Inform stores/
Purchase for getting
report

Incoming Inspector

AOI/ PPAP with supplier

Incoming Inspector

Control Plan (QA/IN/CP-01) & Sampling


Plan (QA/IN/FM-03)
Calibrated instrument

Incoming Inspection report

Incoming Inspector /
QAPCH-QAD-03

Signature of Inspector by permanent


marker with date of inspection.

Signed boxes having OK material.

Incoming Inspector /
Stores Officer

Incoming Inspector Report (QA/IN/FM01)

Get OK material shifted to identified


location and get not OK material
shifted to red marked area.
OK material is issued to the concerned
deptt upon request.

Incoming Inspector /
Materials department
QAP-MAT-01

Acceptance criteria for Quality rating

Vendor Rating & suggestion for


improvements / corrective action.

Check for the receipt of supplier


report
Yes

Availability of MRN/ Lot No.


identified material at incoming
inspection location.

Carry out Incoming


Inspection

Incoming inspection report's


status

Assign Inspection status


on the material

Completion / after sign off on


the material.

Inform to stores about the status


of material
1) Consolidation of
Supplierwise Quality
performance
2) Incoming Inspection
Reports

Review of supplier performance

Process Efficiency : Clearance of Material - No stoppage due to Incoming Inspection & Objectives accountabilities
Process Effectiveness Measure : Lotwise report and report about to the supplier for corrective actions.
A
Modification Status

New Release
Modification details

1/1/2005
Checked By

Approved By

Date

Distributed to : 1,2,3,7,23,28,30

BPFCH-TPS-01

BUSINESS PROCESS FLOW FOR PRODUCT REALISATION


Purpose: To establish a procedure for a structured system of upfront product quality planning.
Scope: Applicable for all products developed & manufactured by the company.
INPUT

ACTIVITY

TIME PERIOD

RESPONSIBILITY

Finalised Time Line Chart

INTERACTION

4 WEEKS

Contract Review / LOI

Initial Preparation
for Trial

DEVELOPMENT )

Customer Main Events

STAGE - III (PROCESS DESIGN &

1.) TPS

PPC
2.) QA

PRODUCTION

1.) TPS
Prototype Control Plan

Sampling & Testing

Inspection / Job Standards

PPC
2.) QA
PRODUCTION

Tooling & Gages

CHECK POINT

CONTROL DOC.

OUT PUT

1.) Review and making of


Process Instruction.

1.) Inspection / Job Standard

2.) Inspection & Release of


Tooling & Gauges.

2.) Std. Tooling & Gauges Status.

3.) Allocated Raw-material &


consumable .
4.) Trial Dates.
5.) Review of Packaging
standards.
6.) Product / process quality
requirements
7.) Process Flow Chart .
8.) Floor plan layout .
9.) PFMEA.

3.) Technical Specs. Sheet

10.) Control plan.


11.) Homologation
requirement

10) Review of MSA & SPC.


11) Review of Packaging
Standards

1.) Specifications.
2.) Critical & Specific
characteristics control.
3.) Qty. of Samples to
produced.
4.) Type of Testing Required &
Std. specs.

4.) Standard reporting format


5.) Product / process quality review.
6.) Review of Process Flow Chart .
7.)Review of Floor plan layout .
8.)Review of PFMEA.
9.)Review of Control plan. (Prototype)

Sample Data Sheet / Report

5.) Required recording of


data.
SAMPLE EVALUATION TEAM

Standard Specs. Vs Actual


Data

Acknowledgement sign off by TPS, QA,


Concerned on Sample data sheet

1) Mode of Packing.
2) Types of Documents to be
Attached / sent.

Qty. of Samples to be send

MKTG.

Dept. Head Prdn.

Discussion over difficult case.

1.)Modification requirement(if any).

Sample Data Sheet


1. Technical Advisor(If reqd)
N.G

Sample
Evaluation
OK

1.) TPS
2.) QA

Sign Off Approval


Purchase Order
Packing Std.
Standard Formats

Submission of
Samples to
Customer

Customer Report of fitment


trial

Fitment Results

1.) TPS

STAGE - IV (TRIAL
PRODUCTION )

4 WEEKS

Customer Report for


Fitment Results

YES

Requirement
of Trial
Repeat

Head.(If reqd)

1 TPS

Production Preparation Meeting

Customer Report of fitment


trial

Concerned Section

Technical Dir. and Adv.


Concerned process Section
Person(Prod.)
Concerned process

2.)Discussion over difficult case.


3.)Toolings and gauges modification plan.

Section Person(Q.A)
PPC
Materials
Marketing

5.)Any other quality related issues.

4.)Raw Material and consumable status.

Test and Trial Schedule


(PPC format)
Production Trial date

TPS
PPC

NO

Initial Product
Validation &
Approval

2.)Q.A

'Preparation For
Pilot Lots Prod'n.

Customer Report for


fitment results

PPAP for any new item


QA
TPS

Technical Sheet

Relevant Documents submission & Sign Off.

1.) TPS

Pilot Lot Production

TPS

Homologation certificates

1) RM & consumable Requirement.


2) Information to Prod'n /PPC for Prod'n. Dates.

MATERIALS

3) Required Modifications / New Tooling.

Production deptt.

1.) Implementation of Improvement Points.


2.) Qty. of Prod'n.
3.) Variation of Actual vs Planned Process yield

SAMPLE EVALUATION TEAM

Standard Specs. Vs Actual


Data

Acknowledgement sign off by TPS, QA,


Concerned on Sample data sheet

Q.A

1) Mode of Packing.

Qty. of Samples to be send

Mktg.

2) Types of Documents to be
Attached / sent.

4 WEEKS

Sample Data Sheet

Sign Off Approval


Purchase Order
Packing Std.
Standard Formats

Customer Report of fitment


trial

STAGE - V (PILOT
PRODUCTION )

N.G.
Sample
Evaluation

1) TPS

1. Technical Advisor(If reqd)


2 Concerned Section Head(If reqd)

2) QA

OK

TPS
Submission of lot to
customer

1.) TPS

N.G
Results of Pilot Lot

2.) MKTG.

Dept. Head Prdn.


Technical Dir. and Adv.
TPS
Production Preparation Meeting

Concerned process
Section Person(Prod.)
Concerned process
Section Person(Q.A)
PPC
Materials
Marketing

1) Modification requirement if
any.

1) Effectiveness of earlier modifications

2) Raw material &


Consumables status
3) Any other quality related
issue

2) Toolings & Gauges modification plan.


3) Minutes of Meeting

INPUT

ACTIVITY

TIME PERIOD

RESPONSIBILITY

Minutes of Meeting
Production Trial Run

TPS

INTERACTION

Q.A
Prod.

CHECK POINT

OUT PUT

CONTROL DOC.

PPAP Documents ( QAP-TPS-01)


Submission of PPAP documents to customer and
their approval

Customer Specific
Requirements

PPC
Customer
( If customer wants)

1) PPAP approval file from


customer
2) Raw Material to be
included in the stocks
( PD/TP/FM-06)
3) Specific format for
defining consumables in
the system

1) PPAP for each part and


child parts.

1.) TPS
QA
Initial Preparation
for 1st Mass
Production

1) PPAP approval file from


customer
2) APQP file
3) Customer
Correspondance

QA
Transfer Meeting

4 WEEKS

STAGE - VI (MASS
PRODUCTION )

1) PPAP approval file from


customer
2) APQP file
3) Customer
Correspondance
4) Quality Planning Sign Off
Sheet

TPS

TPS

2) Prep'n. for Transfer


meeting.
3) Freezing of all
Toolings/gauges.
4) Process yield.

1) Transfer of Documents.

Prod'n

Prod'n
Final Preparation of
First Mass
Production

Raw Material & Consumables Availability

Q.A.
Mktg.

2) Quality Planning

1) RM & Consumable
availability.
2) Specific requirement
application.
3) Relevant Testing &
documentation.
4) Packing & Transportation.

1.) Process std., Job std.,


2) Inspection std. Preparation.
3) Review of process yield.

Distributed to : 1,2,3,15,22,23,28,29,30,31

Process Efficiency :
Process Effectiveness Measure :

01/01/2005

Date

A
Mod. Status

New Release as per TS

Modification details

Reviewed by

Checked by

Approved by

BPFCH-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure smooth switchover in case of enghineering changes and to clearly understand and minimise customer concerns.
Scope: All customers
Input
Doc. From TPS

Responsibility/Inte
raction

Activities

Reciept of approved PPAP along with the list of


wavier wrt drawing, wrt material specs , w.r.t
Performance specs , if any

QA/TPS

Review the documents as per List received


from TPS

QA

Doc. From TPS,


Updated Masterlist

Control Document / Checkpoint

Output

1.PSW signed off,

Update Masterlist of

2.Waivers and Correspondances in writing and

documents

customer signed.

1. PPAP Manual

Physical verification of

1. All documentation are complete

documents as per PPAP

2. Any model/part pending for approval


3. PPAP/PSW for Child Parts Completeed.

1. VOC Report/ MCM Report/E-Mail etc.

VOC Report, MCM


Report, E-Mail etc.

Draft of customer
concern

Customer Concern received through Mkg,


VOC, MCM, E- MAIL , RO , CSA, Directly
from customer.

Any Engineering
Change reqd. by
customer ?

NO

QA

1.Review of the details on the concern/information

Log in ECN/Customer

2.Desired Lead time from customer

concern

3.Acknowledgement sent to customer.

QA
Mktg/TPS

1. Review the details of concern, 2. Requirement

Customer concern/ECN/

of change in the quality system, 3. Desired Lead-

drawing

time from customer, 4. Forward to TPS in case


of any new enquiry

Yes

Customer's ECN,
Drawing

NO

Check the
feasibility of
change

QA-PROD
YES

1. Customer supplied ECN,


1. Check for the Material availability,
2. Feasibility of Tooling development,
3. Part Submission date.
4. Review to be completed within two weeks of
receipt of the concern.

Feed back to custmer & all


concerned

Verbal consensus
taken from concern
departments.

QA/MKTG

YES

Alternative
Suggested

QA/MKTG

Feedback to customer within 14 business days

Through E--Mail with mentioning


the reason why the required
change is not feasible

Through E--Mail, Telephone, Fax

NO

Close the concern

Customer communication

Issue the ECN along


with updated
documents and follow
up of ECN

Customer's ECN &


feasibility consensus

QA

QA

1. Commitment from PPC,

1. Issue the inspection Std, Job


Std.

2. Review of FMEAs and to issue the ECN,

2. Sample Inspection report

3. To inform the customer regarding the part shipment


date,
4. Dispatch the material as per the target date,
5. Sending of Inspection report to customer.

Submit the samples to


customer

New sample
Inspection Report

QA

1. Changed Inspection Std. And the Job Std.

Inspection report

1. Samples quantity, 2. Packing Condition,


3. Date of shipment as per the comittment.

Customer Communication.

Feed Back on the changed item received


through Mkg, VOC, MCM, E- MAIL , RO ,
Directly from customer.

NO

Implementation
reqd in mass
production

QA

1. VOC/MCM report, E-Mail (from Mktg/Customer),

Triggering of New ECN

2. Fitment result

QA/MKTG

1.Approval received for the sample parts submitted,


1.Availibity of Material, 2.Tooling, M/C,
3.Lead time , 4.Custmer Specific requirement for
identification, 5.Cost impact approval through mkg.

YES

Issue a new ECN for


mass production along
with committed date

-DO-

QA

1.Distribution of ECN to the reqd. area, 2.Updated


Inspection Standard,

Updation of ECN Log ,

1.Commitment from Material Dept, PPC and TPS for


tooling development

Distribution of ECN copies.

Carry out PPAP

-DO-

QA

1.Inspection Std, 2.Job Std.

Inspection Reports, Cpk

1.Change is affecting the Process Capability,

Study reports, Performance

2.Change in the Customer suppplied Dwg,

Reports

3.Inspection and Test reports, 4.Functional Testing,


NO

1.PSW, 2.Cpk Analysis and update the relevant


document.

Is PPAP
successful ?

3.Inspection Report, 4.Cpk analysis, 5.Performance


Testing Report

YES

Product validation
reports for changed
specification

Signed off PSW

Submit updated PPAP


file for PSW sign off

Update PPAP file

PRODUCT
CLAIM

1. PPAP manual

QA

Send PPAP file to customer

1. Changed documents.

QA

Updated PPAP file,


Release to Mass Production

1.Glass Model, 2.Lot Detail,


3.Defect Type, 4.Defective Qty,

BPFCH-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure smooth switchover in case of enghineering changes and to clearly understand and minimise customer concerns.
Scope: All customers
Input

Responsibility/Inte
raction

Activities
PRODUCT
CLAIM

Control Document / Checkpoint

Output

YES

Information from R.O./


Directly from customer

QA-MKTG

Collection of claimed Glass

1.E-MAIL, 2.VOC, 3.MCM report

Mangement Decision of
vising customer

Customer communication, Management


decision

Visit to customer (if reqd )


arrange for segregation at FG ware house &
at customer end( if req) and replace with good
glass as a contingency measure

Claimed glass from

Display of claim glass / information on


the shop floor & information to all
concern

recd. customer

glass to customer

QA

QA, PPC, FG W/H AND

Confirm the short term containment action to


the customer

QA, SECTION HEAD-

Employees signature against

On the same day of the claim

witnessing the defective

Filled QACR for all the relevent


provisions

1.QACR

1.Varify from PPC/FG w/h that all the existing stock is


covered

Type of Claim

1.Ensuring that OK glasses are fed to customer line

Trigger off the C/M, FMEA


revision

1.C/M plan is complete within 7 days.

Revised FMEA, Review of

2.Any PPAP or similar activities involved,

Masterlist, Deep Analysis

1.Any special testing required and source identification.

Deep Analysis report

QA-MKTG

Initiate CA- PA

Remove any defective glass

2.Segregation to be completed within 48 HRS from the


receipt of claim detail.

PROD, MKTG

QA, PROD-(CFT)

Problem analysis & drive countermeasure plan & review FMEA

Type of defect

1.Flow of message to the process personal & QA


inspector

1.Target Date of Action Plan from the Customer

PROD.

Result of segregation

Displatch of the Contingency

glass

100 % Re- Inspection of the existing WIP,


QCFG & FG & Review in MCM

Type of defect

Visitting customer,
1.Arrange man power for segregation

QA

Raise the QACR in customer


specific format / Asahi format

Customer requirements,

QA

1.Analysis is done jointly, Deep Analysis/DOE reqd.

Report

Completed CA-PA form

2.Discussion with the Technical Advisor,


3.Short term corrctive actions are completed prior to
sending
4.CA-PA within 7 days/as specified by customer.

Action completed
as per target

NO

QA-PROD

1.Planned action , 2.Commited date

YES
Completed CA-PA form

Verify Effectiveness of
counter-measure

Repetition of the
problem

YES

Results of five
consecutive product
audit

QA-Mkg

1.Customer claim for the same problem

Product Audit Resut

2.Product Audit results

QA-Mkg

1.History of problem

NO

Close QACR

Weekly Reports from

PPM analysis against


targets

R.O.

QA

MKG-RO-QA- PROD

1.QACR format

1.Monthly/ Quarterly data is recd from customer or RO


regularly

Monthly customerwise PPM

2.PPM matching with finacial data

Trend graphs

3.Defect trend is catagorized in terms of bkg


& process defect

Achievement of
Target or claim reoccurence

YES

1.Monthly/ Quaterly data is recd from customer or RO


2.Reporting to MCM
MKG-RO-QA- PROD

3.Target V/s actual PPM


4.PPM matching with finacial data

NO
QACR submitted, Product
audit Result

Review of counter measurement & check the


product audit result for the same model & for the
same problem .

MKG-RO-QA- PROD

1.Collect the model wise, defect wise and location wise


data to pin point the problem

Trigger off FMEA and/Control

2.Collection of more detailed data model having the major


Plan updation, Review of Job
rejection from RO
Standard

3.Product Audit result


4.Review the CA/ PA

Review the Control


plan , FMEA , Job
Std

QA- CFT

Review & Update the FMEA, CP , PPAP ,


Job Std.

QA- CFT

Sending of PDI, Monthly Inspection,


Revalidation reports to customers as per
their requirements

1. Amendment plan, 2. FMEA, 3. Control Plan


4. Information to customer on amended plan

QA

Process Efficiency : Zero customer complaints & Objectives and Accountabilities.

If PPAP, submit it to customer.

1.FMEA, CP , PPAP , Job Std.

1.PDI, 2.Monthly InspectionReports.

Distributed to :1,2,3,15,22,23,29

Process Effectiveness Measure : Customer Satisfaction analysis

A
Modification Status

New Release
Modification details

1/1/2005
Checked By

Approved by

Date

BPFBL-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure smooth switchover in case of enghineering changes and to clearly understand and minimise customer concerns.
Scope: All customers
Input

Responsibility/Inte
raction

Activities

Control Document / Checkpoint

Output

1. VOC Report/ MCM Report/E-Mail etc.

VOC Report, MCM


Report, E-Mail etc.

Customer Concern received through Mkg,


VOC, MCM, E- MAIL , RO , CSA, Directly
from customer.

QA

Any Engineering
Change reqd. by
customer ?

NO

Log in ECN/Customer

2.Desired Lead time from customer

concern

3.Acknowledgement sent to customer.

Draft of customer
concern

1.Review of the details on the concern/information

QA
Mktg/TPS

1. Review the details of concern, 2. Requirement

Customer concern/ECN/

of change in the quality system, 3. Desired Lead-

drawing

time from customer, 4. Forward to TPS in case


of any new enquiry

Yes

Customer's ECN,
Drawing

NO

Check the
feasibility of
change

QA-PROD
YES

1. Customer supplied ECN,


1. Check for the Material availability,
2. Feasibility of Tooling development,
3. Part Submission date.
4. Review to be completed within two weeks of
receipt of the concern.

Feed back to custmer & all


concerned

Verbal consensus
taken from concern
departments.

QA/MKTG

YES

Alternative
Suggested

QA/MKTG

Through E--Mail with mentioning


the reason why the required
change is not feasible

Through E--Mail, Telephone, Fax

NO

Close the concern

Customer communication

Issue the ECN along


with updated
documents and follow
up of ECN

Customer's ECN &


feasibility consensus

QA

QA

1. Commitment from PPC,

1. Issue the inspection Std, Job


Std.

2. Review of FMEAs and to issue the ECN,

2. Sample Inspection report

3. To inform the customer regarding the part shipment


date,
4. Dispatch the material as per the target date,
5. Sending of Inspection report to customer.

Submit the samples to


customer

New sample
Inspection Report

QA

1. Changed Inspection Std. And the Job Std.

Inspection report

1. Samples quantity, 2. Packing Condition,


3. Date of shipment as per the comittment.

Customer Communication.

Feed Back on the changed item received


through Mkg, VOC, MCM, E- MAIL , Directly
from customer.

QA

Implementation
reqd in mass
production

QA/MKTG

NO

1. VOC/MCM report, E-Mail (from Mktg/Customer),

Triggering of New ECN

2. Fitment result

1.Approval received for the sample parts submitted,


1.Availibity of Material, 2.Tooling, M/C,
3.Lead time , 4.Custmer Specific requirement for
identification, 5.Cost impact approval through mkg.

YES

Issue a new ECN for


mass production along
with committed date

-DO-

QA

1.Distribution of ECN to the reqd. area, 2.Updated


Inspection Standard,

Updation of ECN Log ,

1.Commitment from Material Dept, PPC and TPS for


tooling development

Distribution of ECN copies.

Carry out PPAP

-DO-

QA

1.Inspection Std, 2.Job Std.

Inspection Reports, Cpk

1.Change is affecting the Process Capability,

Study reports, Performance

2.Change in the Customer suppplied Dwg,

Reports

3.Inspection and Test reports, 4.Functional Testing,


NO

1.PSW, 2.Cpk Analysis and update the relevant document.

Is PPAP
successful ?

3.Inspection Report, 4.Cpk analysis, 5.Performance


Testing Report

YES

Product validation
reports for changed
specification

Signed off PSW

Submit updated PPAP


file for PSW sign off

Update PPAP file

1. PPAP manual

QA

Send PPAP file to customer

1. Changed documents.

QA

Updated PPAP file,


Release to Mass Production

1.Glass Model, 2.Lot Detail,

PRODUCT
CLAIM

3.Defect Type, 4.Defective Qty,

YES

Information from R.O./

Collection of claimed Glass

QA-MKTG

1.E-MAIL, 2.VOC, 3.MCM report

Mangement Decision of

BPFBL-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure smooth switchover in case of enghineering changes and to clearly understand and minimise customer concerns.
Scope: All customers
Input

Responsibility/Inte
raction

Activities

Collection of claimed Glass

Control Document / Checkpoint

Directly from customer

Output
vising customer

Visit to customer (if reqd )


arrange for segregation at FG ware house &
at customer end( if req) and replace with good
glass as a contingency measure

Customer communication, Management


decision

Display of claim glass / information on


the shop floor & information to all
concern

Claimed glass from


recd. customer

glass to customer

QA

QA, PPC, FG W/H AND

Confirm the short term containment action to


the customer

QA, SECTION HEAD-

Employees signature against

On the same day of the claim

witnessing the defective

Filled QACR for all the relevent


provisions

1.QACR

1.Varify from PPC/FG w/h that all the existing stock is


covered

Type of Claim

1.Ensuring that OK glasses are fed to customer line

Trigger off the C/M, FMEA


revision

1.C/M plan is complete within 7 days.

Revised FMEA, Review of

2.Any PPAP or similar activities involved,

Masterlist, Deep Analysis

1.Any special testing required and source identification.

Deep Analysis report

QA-MKTG

Initiate CA- PA

Remove any defective glass

2.Segregation to be completed within 48 HRS from the


receipt of claim detail.

PROD, MKTG

QA, PROD-(CFT)

Problem analysis & drive countermeasure plan & review FMEA

Type of defect

1.Flow of message to the process personal & QA


inspector

1.Target Date of Action Plan from the Customer

PROD.

Result of segregation

Displatch of the Contingency

glass

100 % Re- Inspection of the existing WIP,


QCFG & FG & Review in MCM

Type of defect

Visitting customer,
1.Arrange man power for segregation

QA

Raise the QACR in customer


specific format / Asahi format

Customer requirements,

QA

1.Analysis is done jointly, Deep Analysis/DOE reqd.

Report

Completed CA-PA form

2.Discussion with the Technical Advisor,


3.Short term corrctive actions are completed prior to
sending
4.CA-PA within 7 days/as specified by customer.

Action completed
as per target

NO

QA-PROD

1.Planned action , 2.Commited date

YES
Completed CA-PA form

Verify Effectiveness of
counter-measure

Repetition of the
problem

YES

Results of five
consecutive product
audit

QA-Mkg

1.Customer claim for the same problem

Product Audit Resut

2.Product Audit results

QA-Mkg

1.History of problem

NO

Close QACR

Weekly Reports from

PPM analysis against


targets

R.O.

QA

MKG-RO-QA- PROD

1.QACR format

1.Monthly/ Quarterly data is recd from customer or RO


regularly

Monthly customerwise PPM

2.PPM matching with finacial data

Trend graphs

3.Defect trend is catagorized in terms of bkg


& process defect

Achievement of
Target or claim reoccurence

YES

1.Monthly/ Quaterly data is recd from customer or RO


2.Reporting to MCM
MKG-RO-QA- PROD

3.Target V/s actual PPM


4.PPM matching with finacial data

NO
QACR submitted, Product
audit Result

Review of counter measurement & check the


product audit result for the same model & for the
same problem .

MKG-RO-QA- PROD

1.Collect the model wise, defect wise and location wise


data to pin point the problem

Trigger off FMEA and/Control

2.Collection of more detailed data model having the major


Plan updation, Review of Job
rejection from RO
Standard

3.Product Audit result


4.Review the CA/ PA

Review the Control


plan , FMEA , Job
Std

QA- CFT

Review & Update the FMEA, CP , PPAP ,


Job Std.

QA- CFT

Sending of PDI, Monthly Inspection,


Revalidation reports to customers as per
their requirements

1. Amendment plan, 2. FMEA, 3. Control Plan


4. Information to customer on amended plan

QA

Process Efficiency : Zero customer complaints & Objectives and Accountabilities.

If PPAP, submit it to customer.

1.FMEA, CP , PPAP , Job Std.

1.PDI, 2.Monthly InspectionReports.

Distributed to : 1,2,3,15,30,31

Process Effectiveness Measure : Customer Satisfaction analysis

A
Modification Status

New Release
Modification details

1/1/2005
Checked By

Approved by

Date

BPF-MKT-02

Business process Flow (Customer Satisfaction Analysis)


Purpose: To measure Customer Satisfaction Index
Scope: All OEM's and After Market Distributor's

Input

Resp /
Interaction

Activity

1) Delivery Problem
2) Quality Problem
3) New Model Development
Problem
4) Packaging Problem

CRM's / Customer
Support Executive

Prepare List of customers &


Collection of Input data

Head - Marketing

Customer wise data


Preparation of CSA Plan

Customer Satisfaction
Analysis plan

As decided - Internal
or External

Conduct Customer Satisfaction


Survey

CSA Visit reports / Surveys


Compilation of Customer feedback
& Analysis

Analysis Report

Control Doc / Checkpoint


-

Output
Compiled List of Customer
Concerns (Customer Wise)

Customer Satisfaction Analysis


plan

Audit on Supply, Quality, Packing,


CSA format dispatch / CSA Visit
Development issues
Format CSA No..MK/XX/FM-11 &
Document used by external agency

Internal - Customer
Support executive/
External agency

Analysis Report

Head - Marketing

Action Plan Report

Head - Marketing

Status of Completion of Action


Plan Report

Head - Marketing

Management Review Reports

Head - Marketing /
CRM's

Annual Consolidated Report to


evaluate Repetition.

Action Plan preparation on dissatisfaction points & improvement


plan on good points

Action Plan Report


Implementation of Action Plan

Status of Completion of
Action Plan Report
Review of results during MCM

Management Review
Reports

Monitoring of Customer feedback


for the elimination of dissatisfaction

Process Efficiency : Zero customer concerns &Objectives and accountabilities

Distributed to : 1,2,3,4,5,6,7,8,9,10,11,29,31

Process Effectiveness Measure : Customer Satisfaction Anaylsis Score.

Review

1/1/2005

New Release as per TS

1/2/2003

Modification Status

Modification details

Checked By

Approved By

Date

PJ/XX/FM-03
BPF-TPS-01

BUSINESS PROCESS FLOW FOR PRODUCT REALISATION


Purpose: To establish a procedure for a structured system of upfront product quality planning.
Scope: Applicable for all products developed & manufactured by the company.
INPUT

ACTIVITY

TIME PERIOD

RESPONSIBILITY

INTERACTION

CHECK POINT

OUT PUT

CONTROL DOC.

Inform customer through mktg.

PRE-CONTRACT PHASE
Information from
customer /mktg for new
model launch and
Development plan

NO

TPS
QA, PRODUCTION
(PROCESS),PPC,MATERIALS,
MAINTENANCE, TOP MGMT(If reqd)

(Discussed in VOC,Design Review meting)

Possibility of
Development

YES
Inform to mktg

1.) 3D- Data/Master sample.

1) Update masterlist of drawings, 3D's


Initial Information
Receiving from
MKT.

2.)Drawing.
3.)Specification.
4.)Customer System.
5) NMD Card

2) Customer Manuals
3) New Model Enquiry login sheet

MKTG

Technical Sheet
All relevant informations
available from drawing
/master sample /specs.

NOT FEASIBLE

Initial Preparation
of Technical sheet

Technical Sheet

TPS

1.)Data Provided Vs Requirement.(Deviation from


specs.)
2.)Equipment , Process & Capacity Study
(Forecast/Plan).
3.)Process capability.
4.)Review of material specs. &
Identification of SC & CC's
5.) Difficulty level Evaluation.
6.)Review of customers specific requirements, if
any.
7) VA / VE Proposals.
8.)Review of past problems in the similar model
related to design and specs.

Q.A.
Feasibility Study

1 TPS

CFT

Mktg.
Materials
PPC
All Production-Section Head

MOM with Customer

2 WEEKS

Technical Sheet

MOM with Customer

STAGE - I (FEASIBILITY REVIEW )

Top mgmt. (If reqd)

Design Review Meeting


with Customer(if reqd.)

1.)Review of clarification items with customer.

QA
MARKETING

2) VA / VE Proposals (If any)


3) Technical sheet
4) Clarification items

TPS

FEASIBLE

Finalised Technical
Sheet

Approval of
Technical Sheet

Finalised Technical

1.)Consideration of all finalised points during


feasibility study
2) VA / VE Proposals (If any)
3) Customer feedback
4) Minutes of meeting
1.)Review of final specs., Customer feedback and
yields
2) Technical sheet

TPS

Dept. Head Prod.

Sheet

POST-CONTRACT PHASE
Customer Main Events
Contract Review
Letter of Indent

TPS

CFT

1.)Customer main events Vs


Actual status.
Dept. Head Prdn.

Production
Preparation Meeting

Technical Dir. and Adv.

TPS

Concerned process
Section Person(Prod.)
Concerned process
Section Person(Q.A)
PPC

Materials
Marketing

Time Line Chart


Customer Main Events

1) Time line Chart


2) Scope of Supply (BOM)
3)Production & Test
Equipment Review

4.) Lead Time for Process &


Product Validations.
5.)* Customer specific
requirement.
6.) Sub assy items.
7.) Various Supply
Dates.

Inform customer ,if delay

12 WEEKS

Time Line Chart

STAGE - II (PLANNING/TOOL,GAUGES DEVELOPMENT)

Prepare "Time
Line Chart"

1.)Scope of supply.
2.)Lead Time for in-House
Jobs.
3.) Lead Time for Material &
Consumable Procurement for
samples & mass production.

Review of
development
schedule

TPS

Dept.Head Prod..

2.)Sampling plan for new


models.
3.)Toolings and gauges plan.

1) Time Line Chart Sign Off / MOM

2) Standard Tool Design & Actual gauge Curve

4.)Raw Material and


consumable status.
5.)Design changes in new
models.
6.)Discussion over difficult
case.
7.)Any other quality related
issues.
8.) Feedback for tool design
(Complexity of Model and the
existing tool design)
9.) General issues.
1.) Status of Tooling
Development.
2.)Status of raw-material &
consumable receiving.
3.) Sub assy status (if any).
4.) Any other changed
requirement.
5.) Homologation and other
testing requirements.
6.)Customer Project Plan.

Time Line Chart (Finalised)

PJ/XX/FM-03

INPUT

ACTIVITY

TIME PERIOD

RESPONSIBILITY

Finalised Time Line Chart

INTERACTION

4 WEEKS

Contract Review / LOI

Initial Preparation
for Trial

DEVELOPMENT )

Customer Main Events

STAGE - III (PROCESS DESIGN &

1.) TPS

PPC
2.) QA

PRODUCTION

1.) TPS
Prototype Control Plan

Sampling & Testing

Inspection / Job Standards

PPC
2.) QA
PRODUCTION

Tooling & Gages

CHECK POINT

CONTROL DOC.

OUT PUT

1.) Review and making of


Process Instruction.

1.) Inspection / Job Standard

2.) Inspection & Release of


Tooling & Gauges.

2.) Std. Tooling & Gauges Status.

3.) Allocated Raw-material &


consumable .
4.) Trial Dates.
5.) Review of Packaging
standards.
6.) Product / process quality
requirements
7.) Process Flow Chart .
8.) Floor plan layout .
9.) PFMEA.

3.) Technical Specs. Sheet

10.) Control plan.


11.) Homologation
requirement

10) Review of MSA & SPC.


11) Review of Packaging
Standards

1.) Specifications.
2.) Critical & Specific
characteristics control.
3.) Qty. of Samples to
produced.
4.) Type of Testing Required &
Std. specs.

4.) Standard reporting format


5.) Product / process quality review.
6.) Review of Process Flow Chart .
7.)Review of Floor plan layout .
8.)Review of PFMEA.
9.)Review of Control plan. (Prototype)

Sample Data Sheet / Report

5.) Required recording of


data.
SAMPLE EVALUATION TEAM

Standard Specs. Vs Actual


Data

Acknowledgement sign off by TPS, QA,


Concerned on Sample data sheet

1) Mode of Packing.
2) Types of Documents to be
Attached / sent.

Qty. of Samples to be send

MKTG.

Dept. Head Prdn.

Discussion over difficult case.

1.)Modification requirement(if any).

Sample Data Sheet


1. Technical Advisor(If reqd)
N.G

Sample
Evaluation
OK

1.) TPS
2.) QA

Sign Off Approval


Purchase Order
Packing Std.
Standard Formats

Submission of
Samples to
Customer

Customer Report of fitment


trial

Fitment Results

1.) TPS

STAGE - IV (TRIAL
PRODUCTION )

4 WEEKS

Customer Report for


Fitment Results

YES

Requirement
of Trial
Repeat

Head.(If reqd)

1 TPS

Production Preparation Meeting

Customer Report of fitment


trial

Concerned Section

Technical Dir. and Adv.


Concerned process Section
Person(Prod.)
Concerned process

2.)Discussion over difficult case.


3.)Toolings and gauges modification plan.

Section Person(Q.A)
PPC
Materials
Marketing

5.)Any other quality related issues.

4.)Raw Material and consumable status.

Test and Trial Schedule


(PPC format)
Production Trial date

TPS
PPC

NO

Initial Product
Validation &
Approval

2.)Q.A

'Preparation For
Pilot Lots Prod'n.

Customer Report for


fitment results

PPAP for any new item


QA
TPS

Technical Sheet

Relevant Documents submission & Sign Off.

1.) TPS

Pilot Lot Production

TPS

Homologation certificates

1) RM & consumable Requirement.


2) Information to Prod'n /PPC for Prod'n. Dates.

MATERIALS

3) Required Modifications / New Tooling.

Production deptt.

1.) Implementation of Improvement Points.


2.) Qty. of Prod'n.
3.) Variation of Actual vs Planned Process yield

SAMPLE EVALUATION TEAM

Standard Specs. Vs Actual


Data

Acknowledgement sign off by TPS, QA,


Concerned on Sample data sheet

Q.A

1) Mode of Packing.

Qty. of Samples to be send

Mktg.

2) Types of Documents to be
Attached / sent.

4 WEEKS

Sample Data Sheet

Sign Off Approval


Purchase Order
Packing Std.
Standard Formats

Customer Report of fitment


trial

STAGE - V (PILOT
PRODUCTION )

N.G.
Sample
Evaluation

1) TPS

1. Technical Advisor(If reqd)


2 Concerned Section Head(If reqd)

2) QA

OK

TPS
Submission of lot to
customer

1.) TPS

N.G
Results of Pilot Lot

2.) MKTG.

Dept. Head Prdn.


Technical Dir. and Adv.
TPS
Production Preparation Meeting

Minutes of Meeting
Production Trial Run

TPS

1) Modification requirement if
any.

1) Effectiveness of earlier modifications

2) Raw material &


Consumables status
3) Any other quality related
issue

2) Toolings & Gauges modification plan.


3) Minutes of Meeting

Concerned process
Section Person(Prod.)
Concerned process
Section Person(Q.A)
PPC
Materials
Marketing
Q.A
Prod.
PPC
Customer
( If customer wants)

Customer Specific
Requirements

PPAP Documents ( QAP-TPS-01)


Submission of PPAP documents to customer and
their approval

PJ/XX/FM-03

INPUT

ACTIVITY

TIME PERIOD

1) PPAP approval file from


customer
2) Raw Material to be
included in the stocks
( PD/TP/FM-06)
3) Specific format for
defining consumables in
the system

RESPONSIBILITY

INTERACTION

QA
Initial Preparation
for 1st Mass
Production

QA
Transfer Meeting

4 WEEKS

STAGE - VI (MASS
PRODUCTION )

1) PPAP approval file from


customer
2) APQP file
3) Customer
Correspondance
4) Quality Planning Sign Off
Sheet

TPS

Final Preparation of
First Mass
Production

TPS

Raw Material & Consumables Availability

2) Prep'n. for Transfer


meeting.
3) Freezing of all
Toolings/gauges.
4) Process yield.

1) Transfer of Documents.

Prod'n

Prod'n
Q.A.
Mktg.

OUT PUT

CONTROL DOC.

1) PPAP for each part and


child parts.

1.) TPS

1) PPAP approval file from


customer
2) APQP file
3) Customer
Correspondance

CHECK POINT

2) Quality Planning

1.) Process std., Job std.,

1) RM & Consumable
availability.
2) Specific requirement
application.
3) Relevant Testing &
documentation.
4) Packing & Transportation.

2) Inspection std. Preparation.


3) Review of process yield.

Distributed to : 1,2,3,4,5,7,12,13,14,15,16

Process Efficiency :
Process Effectiveness Measure :

1-Feb-03

Date

Mod. Status

New Release as per TS

Modification details

Reviewed by

Checked by

Approved by

BPF-MKT-01

Business Process Flow for Customer Related Process - ( New Model development / Existing Model modification)
Purpose: To understand customer requirements during enquiry handling & Contract Review.
Scope: All Products - OE
Input

Process/Activity

Customer Letter/mail

Receipt of customer enquiry

Resp/Interaction

Control Doc/Check Points Output

HOD-Marketing

Customer - new model

CRM

Customer credibility

Acknowledgement to customer

Product type
Volume

Regret Letter to
Customer

Checking
against AIGL
capability

No

CRM

Regret Letter to Customer

Yes
Drawings/CAD/Samples

CRM

Customer Plan

Forward drawings/CAD data/


samples to TPS with NMD
card.

Executive - Marketing

Feasibility Study-CFT

CRM

Customer specs.

Section Head-TPS

AIGL Process capability

Technical study sheet

Preparation of Quotation &


Submission to customer

Customer plan

NMD Card,Drawings/CAD/
Samples

Technical study sheet

Technical study sheet

Commercial proposal to customer

Head Marketing
Section Head-Mktg
Planning / Technical Study
Sheet for intended
requirements

Printing/Drilling

Yields
Difficulty level
Customer target

Price negotiation with customer

Competitor price

No
Customer
acceptance

Revised quotation

COO

AIS price policy

HOD - Mktg.

AIS cost

CRM

Voulume

HOD-Marketing

AIG quotation

CRM

AIG price policy

Revised Commercial proposal

AIG cost

Yes
Letter of Intent

Receipt of LOI and


customer plan

HOD-Mktg.

Price

CRM's

Payment terms
Development schedule
General terms and conditions

No

Inform customer

Acceptable/not
acceptable

HOD-Mktg.

Price

Letter to customer

CRM's

Payment terms

Contract review to TPS

Section Head-TPS

Customer Trial Plan

Development Schedule

Price

Purchase Order

Payment terms

AIG quotation

General terms and conditions

Contract Review

Price

Purchase Order

Payment terms

AIG quotation

TPS/QA

Customer development plan

Samples

Section Head - Despatch

Sample requirement

TPS/QA

Customer specs.

Customer standards

Customer plan

Pilot lot

Yes

Submision of development
schedule to customer

Purchase Order

CRM's

CRM's

Receipt of purchase order

Inform Customer

No

Acceptable/not
acceptable

HOD-Marketing

Yes

Samples submission

Resubmission of
samples

if not ok

Fitment
Approval

CRM's

ok

Pilot lot submission

TPS/QA/Despatch

Customer schedule

TPS

Result of pilot lot


submission & reveiw

Modification/specific application
requirement

Customer report

Process/Job Standards

Final Contract Review

Production
QA
PPC
Marketing

Customer Approval

Production

Commercial Production

Inspection standards

BPF-MKT-01

Business Process Flow for Customer Related Process - ( New Model development / Existing Model modification)
Purpose: To understand customer requirements during enquiry handling & Contract Review.
Scope: All Products - OE
Input

Process/Activity
Commercial Production

Resp/Interaction

Control Doc/Check Points Output


Raw material/consumable
availability

Distributed to :1, 2 , 3, 4, 5, 6

Process Efficiency : 100% execution of customer requirements ,Objectives & accountabilities.


Process Effectiveness Measure : Customer Satisfaction Analysis

A
Modification Status

New Release as per TS


Modification details

1/2/2003
Checked By

Approved By

Date

BPF-MKT-01

Business Process Flow - Customer Related Process( After Market)


Purpose: To understand customer requirements during enquiry handling & contract reviews.
Scope : All products - After Market.
Input

Resp /
Interaction

Activity

Distributorship
Agreement

Check Points

Document

Review the customer contract

- S.H. (AFM)
- Distributor agreement
for intended use.

All the contract terms

Distributorship Agreement

- Make projections for next eight months by 20th


of previous month;
- Firm plan by 6th of every month

- S.H. (AFM)
- S.H. (PPC)

- Customer schedule
- Past schedule v/s despatch
performance
- Model
- Qty.

- S&OP procedure

Order receipt at AIGL and acknowledgement of


order to customer

- S.H. (AFM)
- Customer
- S.H. (Packing)

Contract review format

S&OP sales plan

Excel sheet of sales


performance

- Customer schedule

Transfer data in excel


sheet and list of orders
to Notice Board

- Customer schedule
- AIGL price list

E - mail message to
customer/ packing
section

Order through e-mail

Order received
through e-mail

Output

Customer

- S.H. (AFM)

Decide on the acceptance


of order based on:

NoOrder acceptance

- Models
- Quantity
- Delivery requirement

- Overdue statement

- Rates/discount
- Vehicle load
Yes

- Overdue payment

Order v/s despatch


status

Change in sales plan


format
Check for any change
in sales plan

- S.H. (AFM)
Yes

Comparison of sales plan v/s


actual orders received

- Sales plan
- Customer schedule

Information to
PPC
No

Stock status at
packing

FG requisition slip
Daily requirement to PPC

- S.H. (Packing)

Check FG availability

- Warehouse issue slip

BPF-DES-01

based on FG stocks

- Stock ratio

- S.H. (Packing)
- S.H. (PPC)

Requirement received
from Packing

- Warehouse issue slip


- Stock ratio

- S.H. (Packing)

- Availability of forklift
- FG to be transferred

- Job standard for forklift


movement

FG requisition slip

Stock ratios
Issue of FG by PPC

Movement of glass to
Packing shed.

- Warehouse issue slip

Excel sheet
containing stock of
consumables

Packing and preparation of


loading plan and intimation to

- S.H. (Packing)

truck/lcv union for vehicle.

Vehicle requisition
slip

Vehicle arrangement

Compliance to:
- Packing specifications

- Packing job standards

1. Loading plan
2. Vehicle requisition
slip

- Type of vehicle required


(lcv,lp,T407)
- Availability of road permit

- S.H. (Packing)

- Type of vehicle ordered


- Condition of vehicle:

- Vehicle requisition slip

a) Tarpaulin with vehicle


b) Date/time at which
required
Loading plan

Loading plan
Loading of the vehicle

- S.H. (Packing)

- Compliance to loading plan

- Loading plan

- Sealing of material

Loading plan
Road permit

Despatch of vehicle after Invoicing

- S.H.(Despatch)

1. Loading plan details

- Rate list

2. Compliance to Govt. rules and


regulations:

Invoice
Material gate pass
GR copy
Road permit

- CST/LST applicable
- Form 38 requirement
- Road permit
2. Rates as per rate list
Movement of
vehicle to
destination.

Excel sheet of daily


despatch details

- S.H. (Despatch)
- Transporter

- Point of delivery
- Transit time

- GR copy
- Transit time standard

- S.H. (Packing)
- S.H. (AFM)

Collection of following information: - Schedule v/s despatch statement

E-mail to customer
Send despatch details to customer and HO

- Model
- Quantity
- Vehicle no.
- Date of despatch

Despatch details
Receipt confirmation of vehicle

- Customer

on GR copy by customer

- S.H. (Despatch)

- Condition of glass on

- GR copy of transporter

delivery at customer end


- Breakage/rejection report

Updation of GR record
in excel sheet

Business Process Flow - Customer Related Process( After Market)


Purpose: To understand customer requirements during enquiry handling & contract reviews.
Scope : All products - After Market.
Input

Resp /
Interaction

Activity

Check Points

Document

Output
Survey report

- Customer
Yes

Check for breakage

- S.H. (AFM)
- Insurance surveyor

- No. of broken pcs.


- Reason for breakage

- GR copy of transporter
- Breakage/rejection report
- Survey report
- Insurance claim procedure

Insurance survey to be
conducted

No

Generate monthly/weekly reports


(MCM,VOC,MD)

- S.H. (AFM)
- S.H. (Packing)

- Models
- Quantity

- Order Vs Despatch
statement

- Gross Value
- Order turnaround time
- % Execution

- Order turnaround report


- Regional sales report
- VOC agenda

- FG not available
- Rejections data
Overdue statement

Billing history
Collection of payment

- S.H. (AFM)

- Contract terms
- Overdue factor
- Breakage/rejections

- Distributorship Agreement
- Statement of accounts

END

Distributed to : 1, 2, 3, 4, 5, 6, 20

Process Efficiency : 100 % execution of customer requirements & Objectives & accountabilities.
Process Effectiveness Measure : Customer Satisfaction Analysis.
A
New release as per TS
Modification Status Modification details
Checked By

Approved By

1/2/2003
Date

BPF-MKT-01

Business Process Flow for Customer Related Process - ( Sales Planning and Execution)
Purpose: To understand customer requirements for production volumes
Scope: OEM Sales Planning, After Market Sales Planning & Exports
Input

Process / Activity

Annual Planning
1) Customer Plan,
2) Production and Sales Trend
Report,
3) NURC Report,
4) SIAM/ACMA reports,
5)Market Research Report

Resp /
Interaction

Annual Sales Plan

1) Mid Term Plan,


2) Annual Sales Plan

Not OK
Revise Plan

Output

Department Head -Marketing

1) Customer Plan /
1) New Model Launch,
2) New Customer,
3) Competitor Position, Replacement rate v/s car
parc.

Report on Market Study

1) Department Head
-Marketing /
1) Section Head - Planning,
2) CRM (North, West &
South),
3) Section Head - Aftermarket,
4) Section Head - Exports

1) Customer Plan /
1) New Model Launch,
2) Market Scenario,
3) AIGL Share of Business,
4) Govt. Regulations/Tariff's

Annual Sales Plan

Steering Committee

Future Strategy, Profitability, Strategic Implication Annual Sales Plan

Market Study

1) Report on Market Study, 2)


Customer Annual Plan, 3)
Sales plan by CRM, Section
Head

Control Doc / Checkpoint

Review by Top
Management

OK

Finalise Annual Sales Plan

Deptt Head (Mktg) , Steering


Committee / BPF-MKT-01 (OE
& AFM)

Monthly Planning
1) Annual Sales Plan,
2) Customer orders

Submission of Monthly Sales Plan by CRM's,


Section Head - After-Market and Exports

CRM, North, West &


South,Steering Committee /
BPF-MKT-01 (OE & AFM)

1) AIGL Share of Business,


Monthly Sales Plan
2) Vehicle Stock at customer end,
3) F.G. stock at regional warehouse and customer,
4) Material in transit

1) Monthly Sales Plan from


CRM's,
2) SIAM/ACMA reports,
3) Sales Report

Section Head - After Market

1) Competitor activity (domestic and imports),


2) Past trend (order v/s despatch),
3) AIGL price v/s competitor price

Monthly Sales Plan

Section Head -Exports

1) Past trend (order v/s despatch),


2) AIGL price v/s customer target,

Monthly Sales Plan

Section Head - Planning

1) Industry trend (actual prodn. v/s projection),


2) Vehicle Sales Trend,
3) Annual Projection v/s Actual

Monthly Sales Plan

Finalise Monthly Sales Plan

1) Annual Sales Plan, 2)Monthly


Sales Plan
Sales Planning Meeting

Not OK
Revise Monthly Sales Plan

Review of Industry
Scenario

1) Department Head 1) Annual Sales Plan,


Marketing /
2) Sales Trend,
1) Section Head - Planning,
3) Industry Trend (Projection v/s actual prodn.)
2) CRM's,
3) Section Head - After-Market

1) Department Head 1) Annual Sales Plan,


Marketing /
2) Sales Trend,
2) Section Head - Planning, 3) Industry Trend (Projection v/s actual prodn.)
3) CRM's,
4) Section Head - After-Market

Industry Scenario Report

Section Head - Planning

1) Customer orders,
2) Stock at customer/ regional warehouse,
3) Material in transit,
4) Inventory norms at regional warehouse,
5) New model introduction

Monthly Sales Plan (as per planning horizon)

Section Head-PPC

1) Capacity availability (BPF-PPC--01)


2) Raw material availability, (BPF-STR-01)
3) Consumables availability, (BPF-STR-01)
4)Pallets availability,
5) F.G.+WIP stocks

Production Plan

Executive - Demand
Fulfillment

1) Stock at customer and regional warehouse,


2) Material in transit,
3) Lead time for delivery

Weekly Despatch Plan

OK
1) Customer schedule,
2) Sales report,
3) Share of business report,

Submit Sales Plan to PPC

Regret to customer

1) Monthly Sales Plan (as per


planning horizon),
2) Capacity Planning Sheet

No
Review by steering committee

No

Acceptance of
Sales Plan by PPC

Yes
Weekly Planning
1) Monthly Sales Plan v/s
Actual Despatch Report,
2) Stock report,
3) Customer orders,

1) Monthly Sales Plan v/s


Actual despatch report,
2) revised customer order,

Weekly despatch plan (2 weeks rolling)

Submit Change in Sales Plan

Yes

Change in
customer
requirement

1) CRM's,
1) Increase/decrease in production at customer
2) Section Head-After-market, end,
3) Exports /
2) AIGL share of business
1) Section Head-Planning

Change in Sales Plan

No
Weekly Planning

BPF-MKT-01 SOP

Page 20

BPF-MKT-01

Business Process Flow for Customer Related Process - ( Sales Planning and Execution)
Purpose: To understand customer requirements for production volumes
Scope: OEM Sales Planning, After Market Sales Planning & Exports
Input

Resp /
Interaction

Process / Activity

1) Weekly Despatch Plan,


2)Customer orders

Daily Despatch Plan

Daily Despatch Plan


Execution of despatch plan

Control Doc / Checkpoint

Output

Executive - Demand
Fulfillment

1) Daily despatch report


2) Stocks at regional warehouse/customer end,
3) Material in transit,
4) Lead time for delivery

Daily Despatch Plan

1) Section Head - Despatch


(BPF-DES-01)
2)Section Head - Packing

1) F.G. availability,
2) Transportation availability,

Despatch from plant, Daily despatch report

Process Efficiency : 100% execution of customer orders, Objectives & accountabilities.

Distributed to : 1, 2, 3, 4, 5, 6

Process Effectiveness Measure : No premium freighting, no loss in share of business/customer orders, no raw material allocation, optimum inventory (raw material+f.g.)

A
Modification Status

New Release as per TS


Modification details

Checked By

Approved By

1/2/2003
Date

BPF-MKT-01 SOP

Page 21

Page : 22 of 57

Business process Flow ( Purchasing)


Purpose: To establish a procedure for the procurement of material and services and monitoring of performance on pereodic basis
Scope: All material procured against MPC schedules and requistions

Input

Process / Activity

Resp
/ Interaction

Control Doc ( * ) /
Checkpoint ( - )

Prepare annual savings plan

S&C
Prod.
MPC
Stores

1) Major categories of items


2) Major suppliers
3) Share of business ( value wise)

S&C
MPC
Stores

1) Major categories of items


2) Major suppliers
3) Share of business ( value wise)

Annual Activities
1) Company guidelines and target
2) Annual localization plan
3) Annual alternate sourcing plan
4) Last year procurement value item
wise
5) Annual Material requirement plan
for next FY
1) Annual MRP Sheet
2) Last year average procurement
cost
3) Annual Localization plan
4) Annual new product devlopment
plan
5) Annual savings plan
6) Issues with suppliers
1) Annual procurement budget
2) Annual savings plan
3) Last year overall rating of supplier
4) Other isuues and reasons
5) Travelling plan and schedule
6) Cost / Trip ,expected savings / trip
and issues to be discussed
7) Other expenses / section
8) Training schedule and budget

Prepare annual procurement budget for BOM


items for next FY.

Prepare Overheads budget for S&C section.

S&C
C-Planning

1) Travelling budget
2) General Budget

Quaterly Activities
Monthly results of performance of
suppliers
To conduct run periodic vendor rating for
suppliers in AVL

1) Shortlisting of suppliers for


upgradation plan as per TS-16949

S&C
Prod.
Stores

1) Procedure for vendor rating

S&C

1) Procedure for vendor rating


2) Format - MT/PU/FM-07

Feedback report to suppliers and counter


action reports

1) Countercation report on areas for


improvement
2) Plan for upgradation of quality
system as per TS-16949

1) Compare with results of last year ,quarter


and expectations

1) Clearly identify areas for improvement


and action plans

S&C

1) Compliance of schedules with plan

Monitor results of countercation plans and


schedules

Monthly Activities
1) Annual procurement budget for
BOM.
2) Annual Overheads budget for S&C
Section.
3) Variation in procurement cost as
compaired to last year average price.
4) Issues to be discussed with
suppliers

Visit suppliers in line with schedules of


Overheads and procurement budget.

Vist Report
Inform concerns sections / Dept's about the
outcomes of meeting

S&C
Stores
Prod
MPC

S&C
MPC
QA
Prod.
Stores
Mktg.
C-Planing

1) Cost reduction targets


2) Other Issues with supplier

1) Change of lead time / Supply cycle


2) Change in price / agreement / SOB
3) Change in Inventory norm
4) Certification plans
5) Other Issues

Page : 23 of 57

Business process Flow ( Purchasing)


Purpose: To establish a procedure for the procurement of material and services and monitoring of performance on pereodic basis
Scope: All material procured against MPC schedules and requistions

Input

Resp
/ Interaction

Process / Activity

Approved MRP orders ( MT/ RW / FM30) / Requisitions


Capex Approval

Clarifications from
MPC / Stores / Users
and Joint agreement
Is MRP/
Reuqitsions
adequate ?

NO

Control Doc ( * ) /
Checkpoint ( - )

S&C
MPC
QA
Prod.
Stores
TPS

MRP ( MT / RW/ FM-30)


1) Need by Date as per lead time
2) Budgeted requirement
3) Information of new Items and suppliers
4) Other Issues
Requistions
1) Approval from concern section heads
2) Need by Date as per lead time
3) Unit of measure
4) Charge Account
5) Specifications

S&C
Prod.
Mech.
Elect.
Stores

1) Agreements / Contracts with suppliers


2) Industrial directories / Internet
3) Valid ISO Certifications
4) Plan for certification

YES
Adequate MRP / requisition
Approved vendor list for BOM
(MT/PU/FM-09)
List of suppliers in oracle base

1) Identification of sources
2) Comparative quotes

Arrangemen
t of quotes if
required

NO

YES

S&C

1) Last procurement price


2) Standard rates in the market
3) Comparitive quoates
4) Budget for procurement
5) Need by date
6) Other terms and condition
7) Details to be shared & approved by
concern authorities as per lmit.
8) Regulatory concerns w.r.t EMS

S&C

1) Qty
2) Need by date
3) specification
4) Negotiated prices
5) Negotiated terms and condition
6) Requirement of inspection reports
7) Regluatory concerns , Statutory
requirements , Storage Requirement
8) Issues related to shelf life

S&C

1) Remarks of approver

S&C

Reconcilation with purchase orders

Negotiation

1) Agreement / Contract
2) Approved MRP / requisition
Creation of Orcale Order

Oracle Order
NO
Approval of
Order

YES
Approved Oracle purchase Order
Release of Orders to suppliers and get
acknowledgements from suppliers

Confirmed schedules from supplier

S&C
Accounts

1) Check payment terms


2) Check expected time of arrival
3)Check Invoice date

Release of payment as per agreed terms and


condition

Release of payment

S&C
Co-ordinate dispatches and track shipments

1) Orcale Order sheet


2) Incomming status sheet
1) Need by date / Promise date
2) Shipment documents

Page : 24 of 57

Business process Flow ( Purchasing)


Purpose: To establish a procedure for the procurement of material and services and monitoring of performance on pereodic basis
Scope: All material procured against MPC schedules and requistions

Input

Process / Activity

Shipment documents from supplier


Inform Stores / MPC about expected time of
arrival of material

Shipment documents from supplier

Resp
/ Interaction

Control Doc ( * ) /
Checkpoint ( - )

S&C
MPC
Stores
Prod.

1) All documents shall be delivered to plant.


2) Correctness of invoice and availibility of
all other related docs.

S&C
Clearance of shipment ( shipment from
Overseas suppliers)

Clearance of shipment
Receiving of material at plant

Material ready for inspection and bill


posting in sytem
Is there any discrepancies

Discrepancy report

YES
1) Information to supplier.
2) Arrangement of repalcement ( if required)
3) Arrangement of documents ( if required)

Information to supplier and clear the


discrepancy.

Receiving of material and ready for


issue

Data for monitoring and control of


procurement cost variation.

NO

Bill posting in system

Release of payment to suppliers as per


agreement.

To evaluate variation in procurement cost as


compaired to last year procurement cost.

1) Availibility of all documents required for


clearance
2) Clearance with in free period

S&C
Stores
MPC

1) Orcale Order sheet

S&C
QA
Stores
User

1) Quality
2) Quantity
3) schedule
4) Other information / document

S&C
QA

S&C
Stores

1) Item ,qty and schedule verification


against P.O
2) Physical Inspection
3) Documents with shipment

1) Complete information about the


discrepancy.
2) Arrangement of countermeasure report

1) Compare invoice with P.O

S&C
Accounts

1) Payment Terms

S&C
Accounts

1) Change in basic cost


2) Premium freighting
3) Change in other factor

Distributed to : 1,2,3,4,5,7,8,10,11,17
Process Efficiency : No stoppage of production line.
Process Effectiveness Measure : Accountabilities & Objectives

A
Modification Status

New release as per TS


Modification details

Checked By

Approved By

Page : 25 of 57

BPF-MAT-01

ess Flow ( Purchasing)

Output

Annual Savings plan

Annual procurement
budget for BOM.

Annual Overheads
budget for S&C
Section.

1) Shortlisting of
suppliers for
upgrading quality
system as per TS16949
1) Countercation
report on areas for
improvement
2) Plan for
upgradation of
quality system as
per TS-16949
1) Upgradation of
supplier

Visit Report

Inclusion of change
points in MRP / Min.Max. Norms

Page : 26 of 57

BPF-MAT-01

ess Flow ( Purchasing)

Output

Adequate MRP /
Requistion

1) Identification of
sources
2) Comparative
quoates

Agreement /
Contarct

Oracle Order

Approved Oracle
purchase Order

Confirmed
schedules from
supplier

Release of payment

Shipment
documents from
supplier

Page : 27 of 57

BPF-MAT-01

ess Flow ( Purchasing)

Output

Clearance of
shipment

Material ready for


inspection and bill
posting in sytem

Discrepancy report

Information to
supplier and clear
the discrepancy.

Receiving of
material and ready
for issue

Data for generating


periodic vendor
rating.
Data for monitoring
and control of
procurement cost
variation.
Actual variation in
procurement cost as
compaired to last
year average buying
price.

1/2/2003
Date

BPF-PPC-01

Business process Flow ( Production Planning & Control)


Purpose: To plan and control production & materials planning
Scope: For all OEM, Spares and Export Order.

Process / Activity

Input

Resp / Interaction

Control Doc / Checkpoint

Output

Annual Planning
* ACTUAL VEHICLES SALES
CATEGORY WISE TRENDS.

RECEIVING OF
ANNUAL SALES
PLAN.

* VEHICLE POPULATION CATERGORY


WISE

MKTG

* CUSTOMERS PROJECTED SCHEDULE.


- EXPORTS/AFTER MARKET REQUIREMENT.

* NEW MODELS
* MODEL WISE ALLOCATION ON
VARIOUS RESOURCES

MAKING OF
ANNUAL
PRODUCTION
PLAN

* TARGET APS,YIELDS MODEL WISE


AT EACH PROCESSES.
*ANNUAL MAINTENANCE PLAN FOR
ALL EQUIPMENTS

1.PPC
I/C PLANNING TEMPERING &
LAMINATED

ANNUAL SALES PLAN BUCKETTED


MONTHLY
FOR OEMS' AND SPARES
SEPARATELY.

* MODEL ALLOCATION TO BE DONE


CONSIDERING VARIOUS SPECIFICATIONS
TENTATIVE ANNUAL PRODUCITON
PLAN WORKCENTREWISE.

2. SECTION HEAD - ELECTRICAL./


MECHANICAL.
3. SECTION HEAD - TRIAL PRODUCITON
SECTION.

* TARGET APS,YIELDS MODEL WISE


AT EACH PROCESSES.

CAPACITY
UTILISATION WORK
CENTREWISE

* MODEL WISE ALLOCATION ON


VARIOUS RESOURCES

1.PPC
I/C PLANNING TEMPERING &
LAMINATED
2.SECTION HEAD LAMINATING./
TEMPERING.

* TARGET TIME YIELD / TACT


MODELWISE FOR EACH PROCESS.
* MODEL SPECIFICATIONS

* MAINTENANCE REQUIREMENT MUST BE


INCORPORATED IN PLAN

PROVISIONAL CAPACITY
UTILISATION SUMMARY SHEET
WORK CENTREWISE.

* CAPACITY UTILISATION MUST NOT BE > =


100% FOR ANY WORKCENTRE.

3.SECTION HEAD SUB-ASSEMBLY.


4.SECTION HEAD -TPS.

*SPECIAL PROCESSES IF ANY


*NEW MODELS

5.SECTION HEAD -PPC.

FINALISATION OF ANNUAL
PRODUCTION PLAN.

- TENTATIVE CAPACITY UTILISATION


SUMMARY SHEET WORK
CENTREWISE.

FINAL CAPACITY UTILISATION


SUMMARY SHEET WORK
CENTREWISE.

1.PPC
I/C PLANNING TEMPERING &
LAMINATED
2.SECTION HEAD -PPC.

FINAL CAPACITY UTILISATION


* CONSIDERATION OF ALL FINALIZED POINTS
SUMMARY SHEET WORK
DURING FEASIBILITY STUDY.
CENTREWISE.

- APPROVED PRODUCITON PLAN


DEPTT. HEAD PRODUCTION
APPROVAL OF
PLAN

IF NO

FINAL CAPACITY UTILISATION


SUMMARY SHEET WORK
CENTREWISE.

PREPARATION OF ANNUAL
PRODUCTION BUDGET
/TARGETS FOR
PALLETS /MANPOWER
AND POWER CONSUMPTION
AND PROCESS
YIELDS.PROJECTED
CAPACITY UTILISATION
WORKCENTREWISE.

- TARGET CONSUMABLE
CONSUMPTION
- MODELS SPECIFICATION SHEETS.
* TARGET APS,YIELDS MODEL WISE
AT EACH PROCESSES.

1.PPC
I/C PLANNING TEMPERING &
LAMINATED

YIELDS TARGETS
AVERAGE PER SHIFTS TARGET

2.SECTION HEAD -PPC.

BUDGETS:
PALLETS
CONSUMABLES.
BUDGET:
COST / SQUARE METER
BUDGET:
KWH / SQUARE METER

3.SECTION HEAD - ELECTRICAL


4.SECTION HEADS -LAM./TEMPERING.

* TARGET POWER CONSUMPTION


MODEL WISE.
* NEW MODELS

- TARGET CONSUMABLE
CONSUMPTION

BUDGET
APPROVAL

- MODELS SPECIFICATION SHEETS.


- NEW MODELS DEVLOPMENT
SCHEDULE

* REVIEW OF MODEL ALLOC.


DEPTT. HEAD PRODUCTION

APPROVED PRODUCITON
TARGETS/BUDGETS.

* REVIEW OF MANPOWER STATUS I.e.


REQUIREMENT Vs AVAILABILITY.
AVAILABILITY

IF NO

FINALISATION OF
PRODUCTION TARGETS FOR :
PROCESS YIELDS
PALLETS.
MANPOWER.
POWER CONSUMPTION.

* CONSIDERATION OF ALL FINALIZED


POINTS DISCUSSED DURING BUDGET
PREPARATION
APPROVED PRODUCITON
TARGETS/BUDGETS.

1.PPC
I/C PLANNING TEMPERING &
LAMINATED
2.SECTION HEAD -PPC.

Monthly Planning
* CUSTOMER REQUIREMENT.
* CUSTOMER SCHEDULES.

RECEIVING OF MONTHLY
SALES PLAN FOR PLANNING
HORIZON BY 6th & 21st OF
EVERY MONTH

* STOCKS AT CUSTOMER.
* ANNUAL SALES PROJECTIONS.

*SALES PLAN FOR PLANNING


HORIZON

MKTG

SALES PLAN SUBMISSION


DATES: 21st OF MONTH N0-1

SALES PLAN FOR PLANNING


HORIZON

AND
6th OF MONTH N0

PRODUCTION PLAN SUBMISSION DATES :


MAKING OF PRODUCTION
PLAN FOR MONTH M0 AND
PLANNING HOROZON

* ANNUAL MAINTENANCE SCHEDULE.

PPC
I/C PLANNING TEMPERING &
LAMINATED

* MODEL RUNS AND ALLOCATION


PROJECTED STOCKS RATION
STOCK RATION MODELWISE
*NEW MODELS

* TENTATIVE PRODUCITON PLAN FOR


MONTH M0 + HORIZON
HORIZON

APPROVAL OF
PLAN FOR MO
MONTH

SECTION HEAD -PPC

DATES: 26TH OF MONTH N0-1

* MONTHLY CAPACITY UTILIZATION


TEMPERING/LAMINATING
WORKCENTRE WISE.

AND
10th OF MONTH N0

* TENTATIVE PRODUCITON PLAN


FOR MONTH M0 + HORIZON
HORIZON

* PROJECTED STOCKS RATIO

* FINAL PRODUCITON PLAN

MUST BE WITH IN NORMS

FOR MONTH M0 + HORIZON


FINAL CAPACITY UTILISATION
SUMMARY SHEET WORK
CENTREWISE.

IF NO

FINAL CAPACITY UTILISATION


SUMMARY SHEET WORK
CENTREWISE.
*TENTATIVE PRODUCITON
TARGETS/BUDGETS FOR THE
MONTH

- TARGET CONSUMABLE
CONSUMPTION
- MODELS SPECIFICATION SHEETS.
* TARGET APS,YIELDS MODEL WISE
AT EACH PROCESSES.
* TARGET POWER CONSUMPTION
MODEL WISE.
* NEW MODELS

* CAPACITY UTILISATION SUMMARY


SHEET

PREPARATION OF TARGET
FOR M0 MONTH
FOR :
POWER CONSUMPTION.
PROCESS YIEDLS
PROJECTED CAPACITY
UTILISATION

APPROVAL OF
MONTHLY
TARGETS.

* TENTATIVE CAPACITY UTILISATION


SUMMARY SHEET PROCESS WISE
PPC
I/C PLANNING TEMPERING &
LAMINATED

-MANPOWER REQUIEMENT Vs. AVAILABILTY * FINAL PRODUCITON


TO BE CHEKCED BASED ON CU FOR EACH
TARGETS/BUDGETS FOR THE
MONTH

BPF-PPC-01

Business process Flow ( Production Planning & Control)


Purpose: To plan and control production & materials planning
Scope: For all OEM, Spares and Export Order.

Input
* NEW MODELS SCHEDULE.

Process / Activity APPROVAL OF


MONTHLY
TARGETS.

IF NO

Resp / Interaction
SECTION HEAD -PPC

Control Doc / Checkpoint


PROCESSWISE

* FINAL PRODUCITON
TARGETS/BUDGETS FOR THE MONTH

- BUDGET SHEET CONSUMABLE


WISE.

1.SECTION HEAD -PPC


FINALISATION OF
PRODUCTION
TARGETS FOR M0
MONTH

2.PPC
I/C PLANNING TEMPERING &
LAMINATED

* FIANLISED CAPACITY UTILISATION


SUMMARY SHEET PROCESS WISE.

3.SECTION HEADS - TEMPERE 1,2


TEMPERED 3,4
LAMINATED

* VARIANCE /ANALYSIS BETWEEN


PLANNED Vs.ACTUAL DISPATCHES
FOR MONTH M0-2.

1.PPC.

* SALES PLAN SUBMITTED ON 22nd


OF MONTH M0-1 FOR PLANNING
HORIZON.

MONTH.
* FIANLISED CAPACITY UTILISATION
SUMMARY SHEET PROCESS WISE.

* MAINTENANCE SCHEDULE

MONTH.

Output

SALES AND OPERATIONAL


PLANNING MEETING

* VARIANCE/ANALYSIS BETWEEN
PLANNED Vs.ACTUAL PRODUCTION
FOR MONTH M0-2.

- SUMMARY SHEET FOR VARIANCE


OF PLANNED Vs.ACTUAL
PRODUCTION .
- SUMMARY SHEET FOR VARIANCE
OF PLANNED Vs.ACTUAL
DISPATCHES.

2.SECTION HEADS -LAM./TEMPERING.

3. SECTION HEAD -MPC

* PROJECTED RM STOCKS AND


CRITICALITY'S IF ANY.

4. SECTION HEAD- MATERIALS.


5.SECTION HEAD- MKTG.
6. SECTION HEAD - DISPATCH.

Weekly Planning
* FG STOCKS RATIO .
*WEEKLY DESPATCH PLAN

MAKING OF LINEAR
PRODUCTION PLAN FOR
THE CURRENT WEEK
ACCOMODATING
VARIANCE OF PREVIOUS
WEEK.

* MAINTENANCE REQUIREMENT
*NEW MODELS SAMPLING DATES

*MONTHLY PRODN PLAN


Vs.ACTUALS.

1.PPC
I/C PLANNING TEMPERING &
LAMINATED
2. SECTION HEADLAMINATING/TEMPERING
3. SECTION HEAD - RM WAREHOUSE.
4. SECTION HEAD - TPS.
5. SECTION HEAD - DISPATCH.

*MODEL ALLOCATION

- ROLLING DESPATCH PLAN FOR 15 DAYS


FOR OEMS'S
- FIRMED UP S&OP PRODUCTION PLAN FOR
MONTH M0.
- TEST & TRIAL SCHEDULE.
- RM STOCK STATEMENT

* LINEAR WEEKLY PLAN FOR


TEMPERING
FURNACE WISE AND FOR CRITICAL
PROCESS IF ANY.
LAMINATING:
BENDING FURNACES ONLY.

- WEEKLY STOCK RATIO SHEET.

6. ACCOUNT EXECUTIVES- MKTG.

* CRITICAL MODELS SCHEDULING.


APPROVAL OF
WEEKLY PLAN

* SAMPLING DATES AND TIME


ALLOCATED FOR SAMPLING.

1.SECTION HEAD - PPC

- PREVIOUS WEEK's PRODUCTION RESULTS.

2.SECTION HEAD TEMP12,TEMP3,LAMINATED

- TIME LINING CHART FOR NEW MODELS.


*LAMINATED : WEDNBESDAY OF EVERY
WEEK

IF NO

*TEMPERED : SATURDAY OF EVERY WEEK

FINALISATION OF WEEKLY
PRODUCTION PLAN.

* WEEKLY PRODUCTION PLAN

* ROLLING DESPATCH PLAN

PLANNING CELL
MEETING

*CRITICAL FINSIHED GOODS


REQUIREMENT.
*RAW MATERIAL AVAILABILITY
STATUS FOR HORIZON BASED

* CHANGE IN SALES PLAN.

1.PPC
I/C PLANNING TEMPERING &
LAMINATED
2. SECTION HEAD -MPC
3.SECTION HEAD- MKTG.
4. SECTION HEAD - DISPATCH.
5.SECTION HEAD -PPC

S&OP PRODUCITON PLAN


* FG STOCKS AT AIS
WAREHOUSE/CUSTOMER's
END/ADVANCE WAREHOUSE

1.PPC
I/C PLANNING TEMPERING &
LAMINATED
2.SECTION HEAD -PPC
* TO BE HELD ON WEDNESDAY OF EVERY
WEEK.
- CHANGE IN SALES PLAN FORMAT.

-ROLLING DESPATCH PLAN.


-FEEDBACK SHEET FOR DESPATCH PLAN
-WEEKLY PRODUCITON PLAN -TEMPERED
AND LAMINATED.
-STOCKS RATIO SHEET TEMPERED AND
LAMIANTED.
- CHANGE IN SALES PLAN FORMAT.

MONITORING OF WEEKLY
PLANNED Vs.ACTUAL
PRODUCTION

PPC
I/C PLANNING TEMPERING &
LAMINATED

* DYNAMIC PROCESS YIELD/TIME


YIELDS
* NEW MODELS SAMPLING
SCHEDULED DATES.

- DAILY PRODUCTION RESULTS.

* CHANGE IN PRODUCITON PLAN


BASED ON ALL THESE INPUTS TO
MEET CUSTOMER

- DAILY PDCA SHEET FOR EACH SECTION.

DEMAND.

- MONTHLY PLAN Vs. ACTUAL SHEEET.


- DAILY DESPATCH PLANS.

Results Preparation
*CONTROL FILES FOR EACH PROCESS IN
SOFT.

* DAILY SHIFTWISE DATA ENTRY


INTO VARIOUS SOFT CONTROL
SHEETS , PRODUCITON SECTION
WISE RESOURCE WISE.

PREPARATION OF
PERIODICAL PRODUCTION
REPORTS

2. SECTION HEAD -MPC

- PRODUCTION RESULTS PROCESS


YIELDS,TIME YIELDS.
- TIME YIELD REPORT.

1.PPC
I/C PLANNING TEMPERING &
LAMINATED

- IRA'S REPORT.
*PROCESS OPERATION RECORDS FOR EACH - RM CONSUMPTION Vs ISSUE
PROCESSES.
TALLYING .

2.SECTION HEAD -PPC

*RE-WORK INSPECTION CARDS.

3.SECTION HEAD- MKTG.

-TARGET Vs.ACTUAL C.U.


- SUMMARY SHEET FOR TARGET Vs
ACTUAL SAVINGS IN
CONSUMABLES.

4. SECTION HEAD - DISPATCH.

- SUMMARY SHEET FOR TARGET Vs


ACTUAL POWER CONSUMPTION.

5. SECTION HEAD -MPC

- SUMMARY SHEET FOR TARGET VS


ACTUAL PRODUCTION
COST/SQUARE/METER.

FG Warehouse
*Pallets ID Number writted on Transfer
slips.
* Date and Shift of Production
* Quantity mentioned on transfer slips.

VERIFICATION &
TRANSFER OF FG
PALLETS FROM VARIOUS
PRODUCTION SECTIONS

FG W/H SHIFT SUPERVISOR

FG in lot-out not to be transferred to FG W/h.

* FG models to be transferred to W/h.

Physical quantity of pallets must match


with the quantity mentioned in transfer
slips.

* Pallets in QCFG area matching with


that mentioned in Transfer slips.

Each pallets card affixed on OK FG pallets


must be countersigned by QA Shift I/C.

*Type of pallets to be stacked

Warehouse Layout and location plan

*Model location.

Stacking of Pallets at
defined location in
warehouse

FG Shift Supervisor.
Forklift driver

Standard for Material handling/Stacking of FG


Pallets.

Finsihed Goods pallets can be


transferred to warehouse.

Finsihed Goods pallets can be


transferred and stacked properly at
their location in warehouse.

* Qty of pallets to be stacked in a


column.

Complete transactions
a) Receiving
b) Issuing
c) Sale-return

Finished Goods stocks


reporting considering receipts
and issues

FG Shift Supervisor.
FG Warehouse I/c.

Finished Goods trnasfer slips.


Daily despatch plan from Despatch Section.

Daily FG Stock Statement

BPF-PPC-01

Business process Flow ( Production Planning & Control)


Purpose: To plan and control production & materials planning
Scope: For all OEM, Spares and Export Order.

Process / Activity

Input
*Despatch Quantity.
* FG material transfer slip from W/h to
Despatch.
*Daily FG Stock Statement
*Quantity requested for issue from
W/h.

Resp / Interaction
Despatch Sec

Receipt of Despatch
Plan from despatch
section & isuue of FG
pallets to PDI area.

FG Warehouse I/c.
FG Shift Supervisor

FG transfer slip form Wh to despatch.

Control Doc / Checkpoint


*Despatch Quantity.
Pallets No.'s of palltes to be isuued to be
mentioned on transfer slips only.
*Quantity requested for issue from W/h.
Warehouse Layout and location plan

Output
* Schedule for FG issue from W/h.

*FG pallets number and location of pallets.


Pallet wise tracking file of FG.
FIFO system to be followed pallet Number
wise.
FG transfer slip form Wh to despatch.

Checking of stocks working files for FG


received & issued in models where
differences found.

*Defined location of models stacked

Physical Stock take


Model wise and
compilation.

* Models Code/name.
* No of pallets stacked
* Qty in pallets

FG Warehouse I/c.
FG Shift Supervisor

*Net physical stocks


*System stocks files

IF NG

Physcial Fg stocks, Invoices and Transfer slips Complied model wise physical stocks
statement.
Warehouse layout and location plan
Format for stock tacking

FG Warehouse I/c.

Comparison of
system and
physical stocks

*Final Finished Goods Stocks


Statement for Planning only
Monhtly & Bi - Monthly. AND
Interim FG stocks report
statement for EXCISE
reconcilation.
IF OK

*Final Finished Goods Stocks


Statement for Planning only
Monhtly & Bi - Monthly.

Interim FG
Stocks report
statement

Checking of stocks working files for


FG received & issued in models
where difference found
*Physcial stocks statement
*Excise records.

FG Warehouse I/c.

IF OK
FG Warehouse I/c.

Reconcillation with
Excise Stocks

* Documents related for receiving and

Concerned person from


excise deptt

Issuing of material

*Physcial stocks take format


* RG1 register
* Fg transfer slips
* Fg material issue books
* Pre-despatch check sheet

IF OK
Results
Model Wise

FG Warehouse I/c.
Section head-excise

IF NG

*Entries in excise records

Variations in finsihed goods stocks


modelwise.

* Finished goods Invoices


* Receiving and issuing documents
* Finished Goods Gate pass

IF OK
Finilisation of FG Stock
report

FG Warehouse I/c.

Reconcilled stock statement

Finalised FG stock statement

Distributed to :
1,2,3,4,5,6,7,10,11,12,13,14,15,16

LEGENDS:

RM===> RAW MATERIAL.


FG===> FINISHED GOODS.
C.U.===> CAPACITY UTILIZATION.
kWh/Sq.Mtr.==> KILO WATT HOUR/SQUARE METER.
M0===> CURRENT MONTH UNDER PLANNING CONSIDERATION.
M0+1==> REFERS TO MONTH AFTER CURRENT MONTH I.e. IF CURRENT MONTH IS SEPTEMBER THAN M0+1 MONTH
WILL BE OCTOBER.
M0-2==> REFERS TO MONTH BEFORE CURRENT MONTH I.e. IF CURRENT MONTH IS SEPTEMBER THAN M0-1 MONTH
WILL BE JULY.
S&OP===>SALES & OPERATIONAL PLANNING.
Process Efficiency : 100% execution of customer orders, Objectives & accountabilities.
Process Effectiveness Measure : No premium freighting, no loss in share of business/customer orders, no raw material allocation, optimum inventory (raw material+f.g.)

A
Modification Status

New Release as per TS


Modification details

Checked By

Approved By

1/2/2003
Date

BPF-TPS-02

Business Process Flow ( Tooling Management)


Purpose: To establish flow for Tool Management & to ensure proper maintenance and manufacturing methodology
for all the tools / gauges.
Scope :For all process tools / gauges developed & manufactured in tooling section.

Input

Resp / Interaction

Control Doc / Checkpoint

Trial Production
Section
BPF-TPS-01

APQP Time line chart

Process / Activity

APQP Time
line chart
(PD/TP/FM-05)

Receipt of Tool Development


Request

Tool
development
Schedule

Develop Gauge / Tool development


Time line plan

Review of
Resources

Develop Gauge Design &


Finalise

Gauge Design

Output

Trial Production Sectio Tool Development Timeline Pl Tool development


Schedule

Trial Production Sectio Masterlist of designs / Tool


Design

NA
Return to vendor

Final Gauge
Design( PD/TP/CK15)

TPS / MAT / STORES

Material Indent in System


Oracle

TPS / MAT / STORES

Incoming Inspection report / Inspection report


Tool Design & Material Specs

Raise Indent for Procurement of


Gauge / Tool RM

P.O. Approval

Tool development
Schedule

P.O. Approval

Insp. Of

Gauge /
Tool RM

Accepted
Inspection
report

Start Mfg of Gauge / Tool

Gauge / Tool
Fail
Corrective Action

Gauge /Tool
Inspection
Report
( PD/TP/FM21)
(PD / TP / CK10)

Insp. Of
Gauge /
Tool

Pass

Fail
Corrective Action

Trial of
Tool

Trial Production Sectio Work Instructions / Job


standards

Gauge /Tool

Trial Production
Section
Gage R&R Studies

Gauge /Tool
Inspection Report
( PD/TP/FM-21)
(PD / TP / CK-10)

Gauge & Tool Inspection


report / Checksheet

TPS / QA / PPC /
Component Inspection
Concerned Sec Head Report / Check Sheet
(Prod)
(PD / TP/ FM-21)
Is PPAP to trigger
here?

Product as per
Drawing / CAD

TPS / Concerned
Section Head (Prod)

1) Masterlist of Tools
2) Identification list
3) Tool history card

Masterilst of
Gauges
(PD/TP/FM-18)

TPS / QA /
Concerned Sec
Head (Prod)

Component Inspection
Report & Sign Of

Component
Inspection Report
( PD/TP/FM-21)

TPS / Concerned
Section Head ( Prod)

Tool Maintenance Charter /


Tool Checklist
PPAP trigger for major
change

Annual gauge
Revalidation
Schedule
( PD/TP/FM-23)

Pass
Gauge / Tool
with
identification

Identification & Update master list of


Gauges

Tool Handover to Manufacturing

Gauge / Tool
Break down

Gauge / Tool Maintenance Charter

Process Efficiency : 100% OK Tool, Gage & Objectives & Accountablities

Distributed to : 1,2,4,5,12,13,14,15,17

Process Effectiveness Measure :Number of tools made OK first time.

A
Modification
Status

New Release as per TS


Modification details

1/2/2003
Checked By

Approved By

Date

BPF-DES-01

Business Process Flow - Customer Related Process ( Dispatch)


Purpose: Ensure dispatch of Finished Goods to the customers
Scope: Dispatches made to OEM's and After Market

Input

Resp /
Interaction

Process / Activity

1) Dispatch Plan through email.

Section Head Dispatch

Receipt of Dispatch Plan from Mktg


H.O.

Masterlist of Parts

Section Head Dispatch / Officer - FG


Warehouse

Verification of
finished part
availability at
W/H

NO

Meeting with PPC

Control Doc / Checkpoint

Output
Masterlist of Parts / Transfer data
to Notice Board

FG stock statement from


Warehouse

Yes

Availability of
trailer

NO

Inform Marketing

Transfer data of notice board

Officer Dispatch /
Marketing Deptt. - HO

Trailer Movement Board

Trailer Movement Record

Officer-dispatch

Despatch plan of H.O. for model


parts.

Excel sheet of daily dispatch plan.

Yes
Preparation of daily despatch plan

Excel sheet of daily


dispatch plan.

Officer-dispatch /
Marketing H.O.

Inform to H.O. confirmed dispatch


plan

Excel sheet of daily


dispatch plan.

Officer - Dispatch /
Officer - FG
Warehouse

Requisition to FG Warehouse

Requisition slip
acknowldegement from
FG warehouse

Forwarded Excel sheet

Dispatch Plan

Officer - Dispatch /
Officer - FG
Warehouse

Receipt of Information about


allocation of FG Material

Physical verification of shifting of


material.
-

Officer - Dispatch /
Officer - FG
Warehouse

Allocation of Material
Preparation of loading plan

Loading Plan

FG Requisition Slip

Loading Plan
-

PDI Inspector
NO

Hold the
material

PDI Checksheet

Ofer for
Pre
dispatch

PDI Checksheet

Yes

PDI Inspector

Quantity & Model

Physical verification of material

PDI Inspector
BPF-QAD-03

Physical Condition of Trailer

Status of trailers on the


checksheet.

PDI Inspector
BPF-QAD-03

Physical Condition of Pallet

Status of pallets on the


checksheet.

Shift SupervisorDispatch

Dispatch Plan from Marketing H.O.

Material Gate Pass


PDI reports as per Customer
Requirements

Section Head
(Dispatch)

Gate Pass
Glass Model
Quantity
Vehicle No.

Daily Dispatch Details status sheet

Section Head
(Dispatch)

Location of trailer

Swipe Machine Print Output

Section Head
(Dispatch)

Any information on GR Copy

GR Record

Section Head
(Dispatch)

Time taken (w.r.t the norms) Trailer


Movement board

Checking of material against


loading plan

Trailer Maintenance
Checksheet

NOT OK
Trailer not loaded

Check
condition
of trailer
OK

Pallet checksheet
Inform Pallet Section

Not OK

Check
condition
of pallets
OK

Daily Dispatch Plan

Dispatch of Material

Excel sheet of daily


dispatch details.

Information to H O

Swipe Card
Tracking of Trailer Movement

GR document
Receipt of GR

Transportation Bill
GR Record

Submission of Bill

GR Record
Transporter Bill

Section Head
(Dispatch)

Amount by Section Head (dispatch)


based on Customer and Warehouse
Reports

Release of Payment.

Payment to Transportation

Process Efficiency : No stoppage of customer line and Objectives & accountabilities.

Distributed to : 1,2,3,4,5,6, 20

Process Effectiveness Measure : Delivery Rating from the customer on monthly basis & Delivery Performance Monitoring
A
Modification Status

New Release as per TS


Modification details
Checked By

1/2/2003
Approved By

Date

BUSINESS PROCESS FLOW FOR UPKEEP OF PLANT & MACHINERY.


Responsibility /
Interaction

Activities

Control Doc / Checkpoint

Output

Maintenance

Unplanned
Maintenance

Maint. Of Prod
Equipments &
Predictive Maint

A
A

Section Head Maint.


Section Head PPC

Monthly maintenance
Plan

Section Head Maint

Take dates & shifts for


maint. from PPC Dept.

Section Head Maint


Section Head PPC

Weekly production plan

Up dation of Monthly maint. plan


MN/ME/FM - 22

Pre preperation of Periodical


Maintenance Execution plan

Section Head Maint

a)Replacement,Repair,Checking freq.
b)M/C. History Card
c)Prod. Maint. Req. slip items
d)Adequate manpower availability
e)Required material availability in store
f)Arrangement of fabricated items
g)Patrol Check sheet of machine
h) Improvement plans

a)Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

Process Incharge
(E & M)

a) Time taken for execution.


b) Adherence to Periodical maint. plan
c) Time taken for execution.

Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

All Critical Items should covered

Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

Execution of maint. plan

Are all
points
executed

No
Carry
Forward to
next NO
maint.

YES

Driving Test

Removal of
abnormality
Is driving
test is
normal

NO

Section Head Maint

Break Down Trend of m/c.

Annual maint. Plan :MN/ME/FM-06

Preperation of
Annual maint. plan

Monthly Maint. Plan :MN/ME/FM -22

Section Head Prod.


Section Head maint.

Process Incharge /
Shift Incharge
(E+M+P)

Process Incharge /
Shift Incharge
(E+M+P)

Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

Running M/C checking


parameters like noise
vibration & movement

Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

Size ,Curvature,Fragmentaion
Grinding & washing quality,

Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

YES
Start Production
Removal of
abnormality

NO

Is product
quality
parameter are
within
Standards

Process Incharge /
Shift Incharge
(E+M+P)
Process Incharge /
Shift Incharge
(E+M+P+Q)

YES
Hand over to Prod.
Deptt.

Updating of Maintenance
Charter
End

Shift Incharge (E+M)

Process Incharge
(E+M)

Updation of Periodical Maintenance


Execution Plan :-MN/ME/FM-07

Periodical Maint. Execution plan


Improvement plan
Production request slip

Up dation of Annual Maintenance plan &


execution details: MN/ME/FM-18 &
Periodical Maint. Execution Plan :
MN/ME/FM-07

BPF-MNT-01

Business Process Flow ( Mechanical Maintenance)


Purpose: Business process flow for quality, predictive & preventive maintenance of equipments to ensure health of equipment and safety of operation.
Scope : All manufacturing & production equipments.
Input

Responsibility / Interactions

Activities

Cont.Doc/Checking
Point

Output

B
(1) Verbal Information of
Break down or by pressing
alram by production worker

(1) Fault tree diagram

Information of equip.B/D
maint. Deptt.

to

Section Head
Process Incharge
Shift Incharge

Testing Of
M/c

(1) Machine history card

Weekly Analysis
of Break Down

(1) Machine history card

(1) Countermeasure effec-tiveness sheet

Shift Incharge

Implement
Countermeasure
Check effectiveness of
countermeasure
Countermeasure

Problem
Again
Repeat

M/c Manual

Section Head
Process Incharge
Shift Incharge

Hand Over to
Concerned Dept.
Problem discription in
History Card

Update Machine
History card(for time & m/c.)

Section Head
Process Incharge
Shift Incharge

Take Corrective Action

(1) Machine History card

Prod. Shift I/C


Prod.worker

Time Consumed,
Spare Used

Updation of M/C History


Card : MN/ME/FM-01

Dept. Head
Section Head
Process Incharge

a) Freq. Of problem M/C History Card updation for


b) Time consumed countermeasure:MN/ME/FM-01

Section Head
Process Incharge

(a) MRA schedule


(b) Job change
schedule

Signature in M/C History Card


MN/ME/FM-01

Dept. Head
Section Head
Process Incharge

MachineHistory
card

Updation ofCountermeasure
effectiveness sheet :MN/ME/FM-23

Section Head
Process Incharge

MachineHistory
card

Updation of history card for


countermaesure implementation

Yes

No
(1) Master list of machinery

Implement Same Countermeasure


on similar M/C.
End

Process Efficiency : Zero Breadown and Objectives & Accountabilities


Distributed to : 1, 2, 4, 5, 11, 16
Process Effectiveness Measure : Graphical trend of breakdown time.

New release as per TS

Modificatio Modification details


n Status

1/2/2003
Checked By

Approved By

Date

Update history
card
Weekly Analysis
Implement
Counter Measure

BPF-MNT-02

Business Process Flow ( Electrical Maintenance)


Purpose: Business process flow for quality, predictive & preventive maintenance of equipments to ensure health of equipment and safety of operation.
Scope : All manufacturing & production equipments.

INPUT

RESP./INTERACTI CHECKING POINT /


CONTROL DOC
ON.

ACTIVITIES

Meeting

Maint. Of Prod
Equipments &
Predictive
Maint.

Maint. Of
Equipments which
require power shut
down
B

PM meeting

OUTPUT

Section Head
Process I/C
Shift I/C

Pending Jobs From Previous day


Previous day B/D's
Routine jobs

Trouble shooting reports :- MN/EL/FL-51


Monthly maintenance plan :- MN/EL/FM-06

Section Head

Frequency

Annual maint. Plan :- MN/EL/FM-08


Monthly Maint. Plan :- MN/EL/FM -06
PM meeting Record :- MN/EL/FM -01

A
A

( 1 ) Master list of Machine


( 2 ) Manufacturer manuals

Preperation of Annual
maint. plan

Monthly Maint. Plan :- MN/EL/FM -06

Annual maint. Plan :- MN/EL/FM-08

Annual maint. Plan :- MN/EL/FM-08

Taking tentative Maint.


Date from PPC.

Section Head

Monthly Maint. Plan :- MN/EL/FM -06

Display of monthly
maintenance Plan

Section Head

a) Monthly maint. Plan


Ref :- MN/EL/FM - 06

Pre preperation of Periodical


Maintenance Execution plan

Monthly Maint. Plan :- MN/EL/FM -06

Section Head (E & M) M/C maint. Frequency


Section Head PPC

Section Head

a)Preventive maintenance items.


b)Pending items from previous
maintenance.
c)Prod. Maint. Req. slip items
d)Adequate manpower availability

a) P.M Meeting Record :- MN/EL/FL - 01


b)Maint. check sheet :- MN/EL/CK-40

e)Required material availability in


store
f)Arrangement of material req.to be
fabricated.
Weekly prod. Plan :- PD/PP/FM-08

Confirmation of dates & shifts in


weekly prod. plan by PPC

Periodical maint. Execution plan

Execution of maint. plan

NO

Are all
points
executed

Carry
Forward to
next maint.

Process Incharge
(E & M)

Weekly production plan

Weekly prod. Plan :- PD/PP/FM-08

a) Time taken for execution.


b) Adherance to maint. plan
as per check sheet.
c) Time taken for execution.
d)Job Standards,

b)Maint. check sheet :- MN/EL/CK-40

Section Head

a) Maint. check sheet :- MN/EL/CK-40


b) Prod. request slip

YES

Driving Test

YES

Section Head

Is driving
test is
normal

Process Incharge /
Shift Incharge
(E+M+P)

Process Incharge /
Shift Incharge
(E+M+P)

Running M/C checking parameters Maint. Check sheet :- MN/EL/CK-40


like noise, viberation & mpovement Job standard
Inspection check sheet :- MN/EL/FL-55

NO
Removal of
abnormality

Hand over to Prod. Deptt.

Process Incharge /
Shift Incharge
(E+M+P)

Hand over to Prod.Deptt.


Day / Shift Incharge

Maint. Check sheet :- MN/EL/CK-40

Updating of history card

Inspection check sheet :- MN/EL/FL-55

Process Incharge /

Maint. Check sheet :- MN/EL/CK-40

(E+M+P)

Job standard
Inspection check sheet :- MN/EL/FL-55

End

B
Making of list of activities
& schedule in month of
April

Pre preperation of
activities

Information of personnel
& security deptt.

Execution plan.

Section head

Section head

Section head

Dates of holidays

Annual maint. Plan :- MN/EL/FM-08

a)Adequate manpower availability

List of activities

b)Required material availability in


store
c)Arrangement of material req.to
be fabricated.

BPF-MNT-02

Business Process Flow ( Electrical Maintenance)


Purpose: Business process flow for quality, predictive & preventive maintenance of equipments to ensure health of equipment and safety of operation.
Scope : All manufacturing & production equipments.

INPUT

RESP./INTERACTI CHECKING POINT /


CONTROL DOC
ON.

ACTIVITIES
Execution plan.

OUTPUT

Section head

Annual maint. Plan :- MN/EL/FM-08

All jobs
completed
Section head
OK

Add to next
maint.

END

C
Section head
Process Incharge /

Collection of Data

Shift Incharge
Analysis of problem

Section head &


Shift Incharge
Section head

Setting up counter
measure plan

Process Head

Execution plan.

Section head

Review of trouble shooting record. Trouble shooting record file.


MN/EL/FL - 51
Setting up of resp. & target dates

PM meeting file :- MN/EL/FL - 01

5S, safety, job standards

5S Manual
Safety Mannual
Job Standard

All jobs
completed

Section head

NOT
Equipment
failure data

OK
Record Update

END

Process Efficiency : Zero Breadown & Objectives & Accountabilities

Distributed to : 1, 2, 4, 5, 10, 16

Process Effectiveness Measure : Graphical trend of breakdown time.


A
Modification Status

New Release as per TS


Modification details

Checked By

Approved By

1/2/2003
Date

BPF-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure customer requirements are clearly understood and to minimize customer concerns.
Scope: All customers
Input
Doc. From TPS

Responsibility/Inte
raction

Activities
Reciept of approved PPAP along with the list of
wavier wrt drawing, wrt material specs , w.r.t
Performance specs

QA/TPS

Review the documents as per List received


from TPS

QA

Doc. From TPS,


Updated Masterlist

Control Document / Checkpoint

Output

1.PSW signed off,

Update Masterlist of

2.Waivers and Correspondances in writing and

documents

customer signed.

1. PPAP Manual

Physical verification of

1. All documentation are complete

documents as per PPAP

2. Any model/part pending for approval


3. PPAP/PSW for Child Parts Completeed.

1. VOC Report/ MCM Report/E-Mail etc.

VOC Report, MCM


Report, E-Mail etc.

Draft of customer
concern

Customer's ECN,
Drawing

Customer Concern received through Mkg,


VOC, MCM, E- MAIL , RO , CSA, Directly
from customer.

Any Engineering
Change reqd. by
customer ?

NO

NO

Check the
feasibility of
change

QA

1.Review of the details on the concern/information

Log in ECN/Customer

2.Desired Lead time from customer

concern

3.Acknowledgement sent to customer.

QA
Mktg/TPS

1. Review the details of concern, 2. Requirement

Customer concern/ECN/

of change in the quality system, 3. Desired Lead-

drawing

time from customer, 4. Forward to TPS in case


of any new enquiry

QA-PROD
YES

1. Customer supplied ECN,


1. Check for the Material availability,
2. Feasibility of Tooling development,
3. Part Submission date.
4. Review to be completed within two weeks of
receipt of the concern.

Feed back to custmer & all


concerned

Verbal consensus
taken from concern
departments.

Alternative
Suggested

QA/MKTG

YES

QA/MKTG

Through E--Mail with mentioning


the reason why the required
change is not feasible

Through E--Mail, Telephone, Fax

NO

Close the concern

Customer communication

Issue the ECN along


with updated
documents and follow
up of ECN

Customer's ECN &


feasibility consensus

QA

QA

1. Commitment from PPC,

1. Issue the inspection Std, Job


Std.

2. Review of FMEAs and to issue the ECN,

2. Sample Inspection report

3. To inform the customer regarding the part shipment


date,
4. Dispatch the material as per the target date,
5. Sending of Inspection report to customer.

Submit the samples to


customer

New sample
Inspection Report

QA

1. Changed Inspection Std. And the Job Std.

Inspection report

1. Samples quantity, 2. Packing Condition,


3. Date of shipment as per the comittment.

Customer Communication.

Feed Back on the changed item received


through Mkg, VOC, MCM, E- MAIL , RO ,
Directly from customer.

Implementation
reqd in mass
production

NO

QA

1. VOC/MCM report, E-Mail (from Mktg/Customer),

Triggering of New ECN

2. Fitment result

QA/MKTG

1.Approval received for the sample parts submitted,


1.Availibity of Material, 2.Tooling, M/C,
3.Lead time , 4.Custmer Specific requirement for
identification, 5.Cost impact approval through mkg.

YES

Issue a new ECN for


mass production along
with committed date

-DO-

QA

1.Distribution of ECN to the reqd. area, 2.Updated


Inspection Standard,

Updation of ECN Log ,

1.Commitment from Material Dept, PPC and TPS for


tooling development

Distribution of ECN copies.

Carry out PPAP

-DO-

QA

1.Inspection Std, 2.Job Std.

Inspection Reports, Cpk

1.Change is affecting the Process Capability,

Study reports, Performance

2.Change in the Customer suppplied Dwg,

Reports

3.Inspection and Test reports, 4.Functional Testing,


NO

1.PSW, 2.Cpk Analysis and update the relevant


document.

Is PPAP
successful ?

3.Inspection Report, 4.Cpk analysis, 5.Performance


Testing Report

YES

Product validation
reports for changed
specification

Signed off PSW

Submit updated PPAP


file for PSW sign off

Update PPAP file

1. PPAP manual

QA

Send PPAP file to customer

1. Changed documents.

QA

Updated PPAP file,


Release to Mass Production

1.Glass Model, 2.Lot Detail,

PRODUCT
CLAIM

3.Defect Type, 4.Defective Qty,

YES

Information from R.O./


Directly from customer

Collection of claimed Glass

1.E-MAIL, 2.VOC, 3.MCM report

Mangement Decision of
vising customer

Customer communication, Management


decision

Visit to customer (if reqd )


arrange for segregation at FG ware house &
at customer end( if req) and replace with good
glass as a contingency measure

Claimed glass from

Display of claim glass / information on


the shop floor & information to all
concern

recd. customer

QA-MKTG

QA

Visitting customer,
1.Arrange man power for segregation

Displatch of the Contingency


glass to customer

QA

1.Flow of message to the process personal & QA


inspector

Employees signature against

On the same day of the claim

witnessing the defective


glass

BPF-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE


Purpose: To ensure customer requirements are clearly understood and to minimize customer concerns.
Scope: All customers
Input

Responsibility/Inte
raction

Activities

QA

Raise the QACR in customer


specific format / Asahi format

Customer requirements,

QA, PPC, FG W/H AND


PROD.

Confirm the short term containment action to


the customer

Result of segregation

QA, SECTION HEAD-

Filled QACR for all the relevent


provisions

1.QACR

1.Varify from PPC/FG w/h that all the existing stock is


covered

Type of Claim

1.Ensuring that OK glasses are fed to customer line

Trigger off the C/M, FMEA revision

1.C/M plan is complete within 7 days.

Revised FMEA, Review of

2.Any PPAP or similar activities involved,

Masterlist, Deep Analysis

1.Any special testing required and source identification.

Deep Analysis report

QA-MKTG

Initiate CA- PA

Remove any defective glass

2.Segregation to be completed within 48 HRS from the


receipt of claim detail.

PROD, MKTG

QA, PROD-(CFT)

Problem analysis & drive countermeasure plan & review FMEA

Type of defect

Output

1.Target Date of Action Plan from the Customer

100 % Re- Inspection of the existing WIP,


QCFG & FG & Review in MCM

Type of defect

Control Document / Checkpoint

1.Analysis is done jointly, Deep Analysis/DOE reqd.

Report

Completed CA-PA form

2.Discussion with the Technical Advisor,


3.Short term corrctive actions are completed prior to
sending
4.CA-PA within 7 days/as specified by customer.

Action completed
as per target

NO

QA-PROD

1.Planned action , 2.Commited date

YES
Completed CA-PA form

Verify Effectiveness of
counter-measure

Repetition of the
problem

YES

Results of five
consecutive product
audit

QA-Mkg

1.Customer claim for the same problem

Product Audit Resut

2.Product Audit results

QA-Mkg

1.History of problem

NO

Close QACR

Weekly Reports from

PPM analysis against


targets

R.O.

QA

MKG-RO-QA- PROD

1.QACR format

1.Monthly/ Quarterly data is recd from customer or RO


regularly

Monthly customerwise PPM

2.PPM matching with finacial data

Trend graphs

3.Defect trend is catagorized in terms of bkg


& process defect

Achievement of
Target or claim reoccurence

YES

1.Monthly/ Quaterly data is recd from customer or RO


2.Reporting to MCM
MKG-RO-QA- PROD

3.Target V/s actual PPM


4.PPM matching with finacial data

NO

Review of counter measurement & check the


product audit result for the same model & for the
same problem .

QACR submitted, Product


audit Result

MKG-RO-QA- PROD

1.Collect the model wise, defect wise and location wise


data to pin point the problem

Trigger off FMEA and/Control

2.Collection of more detailed data model having the major


Plan updation, Review of Job
rejection from RO
Standard

3.Product Audit result


4.Review the CA/ PA

Review the Control


plan , FMEA , Job
Std

NO

QA- CFT

1. Amendment plan, 2. FMEA, 3. Control Plan


4. Information to customer on amended plan

YES

Review & Update the FMEA, CP , PPAP ,


Job Std.

Sending of PDI, Monthly Inspection,


Revalidation reports to customers.

QA- CFT

QA

Process Efficiency : Zero customer complaints & Objectives and Accountabilities.

If PPAP, submit it to customer.

1.FMEA, CP , PPAP , Job Std.

1.PDI, 2.Monthly InspectionReports.

Distributed to :1,2,3,4,5,6

Process Effectiveness Measure : Customer Satisfaction analysis

A
Modification Status

New Release as per TS


Modification details

1/2/2003
Checked By

Approved by

Date

BPF-STR-01

Business Process Flow ( Material Planning & Control)


Purpose: To establish a procedure for planning & managing Raw material, BOM items,Spare Parts and other consumable inventories so as to ensure that stock levels are optimum.
Scope: Raw material, BOM items, Spare parts and other consumables.

Input

Resp /
Interaction

Process / Activity

Control Doc / Checkpoint

Output

Annual Planning
1) MTP for the Year
2) TPS Sheet for New Items
3) BOM consumables allocations,
yield.
4) RM Yields (MT/RW/FM-23)
5) Model allocations on suppliers
6) Lead time of supplies
7) Share of business

MPC/SIC

1) Supply Cycle with major vendors


2) Production schedule at Suppliers
3) Last year budget

MPC/SIC

1) Inventory norms - RM, BOM &


1) Inventory budget for RM,BOM
Spares for last year (MT/RW/FM-19).
items, Spare parts and other
2) Inventory holding in days for last
consumables.
year (MT/RW/FM-19).
3) Share of business for last year &
current year
4) Inventory ageing (MT/RW/FM-26)for
last year
5) Slow moving trend (MT/RW/FM27)for last year
6) RM allocations (MT/RW/FM-28)for
last year
7) Capacity assesment for Warehouse

MPC / SIC

1) Planned vs actual production.


2) Planned vs actual allocations.
3) Warehouse/ storage assessment.
4) Planned inventory holdings vs
actual inventories.
4) Planned inventory turnover vs
actual inventory turnover.

1) Revised annual MRPs.


2) Revised inventory budgets.

MPC/SIC

1) Shortages and allocations.


2) Material requirement dates.
3) Lot size per supplier
4) Production constarints and supplier
prefrences.
5) Shipment schedules.

1) MRP Sheet - RM & BOM


(MT/RW/FM-20 for Imported
RGL,MT/RW/FM-21 for Domestic
RGL, MT/RW/Fm-22 for PVB &
MT/RW/FM-30 for BOM)
2) Oracle requisitions for Spare
parts and other consumables

MPC/SIC

1)
2)
3)
4)
5)
6)
7)

1) MRP workings (MT/RW/FM-20 for


Imported RGL,MT/RW/FM-21 for
Domestic RGL, MT/RW/Fm-22 for PVB
& MT/RW/FM-30 for BOM)
2) Prodcution Oder / dispatch Order
Imported RGL Orders: MT/PU/FM-21
Domestic RGL Orders:MT/PU/FM-22
PVB Orders :MT/PU/FM-23
3) Approved requistions.

S&C/ RMP

1) MRP Sheet for RM & BOM


(MT/RW/FM-20 for Imported
RGL,MT/RW/FM-21 for Domestic RGL,
MT/RW/Fm-22 for PVB & MT/RW/FM30 for BOM)
2) Shipping schedules.
3) Indenting guidelines to buyer.

1) Production Orders /Forecasts


Imported RGL Orders: MT/PU/FM21
Domestic RGL Orders:MT/PU/FM22
PVB Orders :MT/PU/FM-23
2) Dispatch orders
3) Purchase orders/releases

MPC

1) Customer Wise Despatch


Schedules
2) Material Availability against
requirement

1) Corrections in MRP workings


2) Plan Allocations
3) Minutes of meeting

MPC/SIC

1) Action plan for Slow Moving &


1) Inventory Turnover (MT/RW/FM-03) Ageing Inventory (MT/RW/FM-27)
2) Slow moving inventories
(MT/RW/FM-27)
3) Age of inventories (MT/RW/FM-26)
4) Allocation loss in sqmtr/value
(MT/RW/FM-28)
5) RM turnover consumption
6) RM, BOM & Spares inventory trend
7) Inventory record accuracy

Prepare Annual Material Requirement


Plan for RM and BOM items.

1) Annual MRP sheet


2) Supply cycles and lead times
3) Updated min-max norms
Prepare Inventory Budget for next fiscal
year for RM, BOM items , Spare parts
and other consumables.

1) Annual MRP sheet

Quarterly Planning
1) Change of lead time / supply
cycle
2) Change in price
agreement/share of business
3) Change in product mix
4) Change in customer plans
5) Change in sources of supply
6) Change of Min - Max norms

Review of Annual
Requirements and
Inventory Budgets.

Not Achieved

Update and amend annual


requirements and inventory
budgets.

Achieved

Monthly Planning
1) Monthly sales plan and
production plan (PP/PP/FM-08).
2) Annual Requirement Plan.
3) RM defect %age.
4) BOM items yields/ life.
5) AIG stocks(MT/RW/FM-16)
6)BOM stocks (MT/ST/FM-25)
7) Supplier stocks (MT/PU/FM-24)
8) Production/dispatch schedule
9) Oracle database(Min-Max
reports)
10) Production Yields (MT/RW/FM23)

Working out material requirement:


MRP for RM, BOM items.
Requistions for Spare parts and
other consumables.

1) MRP Sheet - RM & BOM


(MT/RW/FM-20 for Imported
RGL,MT/RW/FM-21 for Domestic
RGL, MT/RW/Fm-22 for PVB &
MT/RW/FM-30 for BOM)
2) Oracle requisitions for Spare
parts and other consumables

Not OK

Approval of
material
requirement
output and
requisitions.

Procurement Budget
Share of business
Default organisations
Item Category
Vendor Checks
Minimum Ordering Qty
Ordering Schedules

OK
1) Approved MRP Order / Oracle
requisitions
Initiation of procurement process

Weekly Planning
1) MRP workings (MT/RW/FM-20 for
Imported RGL,MT/RW/FM-21 for
Domestic RGL, MT/RW/Fm-22 for
PVB & MT/RW/FM-30 for BOM)
2) Prodcution oder / dispatch order
Imported RGL Orders: MT/PU/FM-21
Domestic RGL Orders:MT/PU/FM-22
PVB Orders :MT/PU/FM-23
3) Min-Max

Planning Cell Meeting

1) Oracle inventory MIS


No

Action plan for Slow Moving &


Ageing stocks
1) Consumption Statement
(MT/RW/FM-13)
2) Statement of slow moving,dead
stocks (MT/RW/FM-27)
3) Allocation Loss (MT/RW/FM-28)
4) Age of Inventory (MT/RW/FM-26)
5) Inventory turnover reports
(MT/RW/FM-03)
6) Critical item list

Is Inventory inline
with the targets?

Yes

Department meeting,
MCM , TG Meeting

1) Minutes of Meeting
2) Suppliers instructions
3) Sales quotations

Sale of rejected /Scrap Stocks

MPC/SIC/RMP/ 1) Pending points


S&C
2) Agenda
3) Accuracy of reports
4) Critical issues

Minutes of Meeting

MPC/SIC/RMP/ 1) Oracle std reports


Diversion of Material
S&C
2) ED records and manual
3) Books value and market value of
stocks
4) Excise impact on the sale of stocks

Daily Planning
1) Dispatch order
2) Incoming material status
reports:
Imported shipment status :
MT/PU/FM-26
Domestic shipment status : MT/PU/
FM-27
Model Wise Delay Status
(Domestic) : MT/PU/FM-28
3) Advance set of shipment docs

MPC/SIC
Planning for Receipts

1) Approved PO
1) Allocation of facilities and
2) Job std for receiving (MT/RW/JS-05) manpower

BPF-STR-01

Business Process Flow ( Material Planning & Control)


Purpose: To establish a procedure for planning & managing Raw material, BOM items,Spare Parts and other consumable inventories so as to ensure that stock levels are optimum.
Scope: Raw material, BOM items, Spare parts and other consumables.

Input

Resp /
Interaction

Process / Activity

1) Bill / Invoices from Suppliers

Not OK

Output

MPC/SIC

1) Approved PO
2) Completeness of documents Invoice/ GRN/Challans

1) Gate Entry
2) Material receipt Note

MPC/SIC

1) PO number.
2) Technical specification sheet
3) Job standard for receiving
(MT/RW/JS-05)
4) Not returnable gate pass.

1) Incoming inspection Report

MPC/SIC

1)
2)
3)
4)

1) Updated location on locator grid


2) Updated FIFO boards
3) Updated stocks statement

MPC/SIC

1) Availability as per stock statement


2) Requisition slip (MT/RW/FM-09)
work order number.
3) Issues as per allocated stocks
statement
4) Issues as per FIFO
5)Correct Lot nos.

Gate entry - Generation of MRN


Nos.

1) Material Receipt Note

Control Doc / Checkpoint

Physical Inspection &


receipt of Material

Store in reject Area

Return to Vendor
1) OK Material
2)Incoming Inspection Report

Storage of Material.

1) Requisition slip from Plant


(MT/RW/FM-09)
Issue of Material

1) Return Slip (MT/RW/FM-10)

Production/MP 1) Physical condition of the material


C/SIC
2) Quantity on Return Slip
(MT/RW/FM-10)

Return of material from Production

1) Updated stocks net of returns


(MT/RW/FM-16 & MT/ST/FM-25)
2) Revised Sales & Production Plan

Take corrective
action

MPC
Review MRPs for RM, Bom items
and Min-max for Spare parts and
other consumables.

Process Efficiency : No stoppage of production line.

MPC= Material planning and control


SIC= Stores inventory control
RMP= Raw material procurement
S&C= Spares and consumables procurement
Raw Material: At AIG there are two raw materials i.e. Float Glass and PVB.
Bill of material: specifies all subcomponent items required to manufacture an end product.
For the purpose of planning and control BOM is categorised into following categories:
Direct BOM Items: All material that becomes a part of final product Eg. Mirror Buttons,Terminals, Inks etc.
Indirect BOM Items: Consumables the requirement of which can be determined from the production plans using input/output
ratios. Eg. Bevelling wheel, Core- drill seamers etc.
Spare Parts: Parts used to support maintenance, repair and operation of fleets and facilities.
Other consuambles: Consumables the requirement of which can not be ascertained directly from the end product to be
produced.

Modification Status

New Release as per TS


Modification details

1) Shortages and allocations.


2) Material requirement dates.
3) Lot size per supplier
4) Production constarints and supplier
prefrences.
5) Shipment schedules.

Distributed to : 1,2,4,5,7,16,18

Process Effectiveness Measure :Accountabilities and Objectives of MPC, SIC.

Type of Material
Area of utilisation / Cost Centre
Location grid
FIFO boards

1/2/2003
Checked By

Approved By

Date

1) Updated Stock Statement


(MT/RW/FM-16 & MT/ST/FM-25)
2) Updated Bin Cards, FIFO
Boards, Locator Grids
3) Updated location file

1) Updated Stock Statement


(MT/RW/FM-16 & MT/ST/FM-25)
2) Updated Bin Cards, FIFO
Boards, Locator Grids
3) Updated location file
1) MRP Sheet - RM & BOM
(MT/RW/FM-20 for Imported
RGL,MT/RW/FM-21 for Domestic
RGL, MT/RW/Fm-22 for PVB &
MT/RW/FM-30 for BOM)
2) Oracle requisitions for Spare
parts and other consumables

BPF-MAT-01

Business Process Flow ( Raw Material Procurement)


Purpose: To establish a procedure for procurement of Raw Glass and PVB as per required quality and delivery standards at optimal cost.
Scope: Raw Glass and PVB
Input

Resp /
Interaction

Process / Activity

Control Doc / Checkpoint

Output

Annual Planning
- Sales Plan / Production Plan
(PP/PP/FM-08)

Annual Budget Sheet

2) Define annual defect targets and


prepare improvement plan with
suppliers to reduce gap between
current and target.

- New Models requirement (PD/TP/FM-06)

Annual improvement plans agreed


with Suppliers

3) New source identification &


development

- Result of current F.Y (Budgets V/s Actuals)

1) Prepare annual budget (Procurement


& Overheads) for next F.Y for RGL and
PVB

- Annual MRP from MPC


MT/RW/FM-20, MT/RW/FM21
- Supplier Contracts

RMP

- Model Allocation on
suppliers from Production

- Process flow for Budgeting and Review


(Annexure I)

-Supply Cycle agreed with


Suppliers
(production and dispatch
schedules)
-Defect Targets from Suppliers

- Previous audit sheets


1) Plan Quality audits of vendors

- Defect Trend

RMP / QA

- Audit check sheet

QAP-MAT-01

- Approved Vendor List

RMP / QA

- Sales Plan / Production Plan


(PP/PP/FM-08)

Supplier audit report

Monthly Planning

Not Ok

- Change
agreements

in

Supplier

- Change in Model Allocation


on suppliers
- Change in Supply Cycle with
Suppliers
(production and dispatch
schedules)

Budget review and revised projections

- Plan for new Models


(PD/TP/FM-06)
1) Make contingency plan to meet
requirement and maintain cost
2) Review annual countermeasure
plan

1) Review annual budget against


actual procurement and latest
MRP
2) Review defect target v/s actual
defect
3) Reviee status and effectiveness
of countermeasure plan

- Results of last F.Y

-Annual budget sheet for current F.Y

- Process flow for Budgeting and Review


(Annexure I)

-Defect Targets, Actual Trend


- Annual Countermeasure Plan

Ok

- Defect Report from QA

- Exceptional rejection / QACR


(QA/XX/FM-23)

RMP

- Supplier agreements

Defect Claim report

- Factor for landed cost Calculation

Defect claim to supplier / Exceptional


reporting

- Inspection reports
- Defect trend

- Defect Claim Report

RMP

Reconcialiation of Claime with supplier

Settle defect claims with supplier.

- Supplier agreements

Defect claim status sheet


Credit note

Delivery history

Vendor Evaluation Sheet

Vendor Rating

Ageing stocks at supplier end

Campaign Plan sheet

Stocks net of previous dispatches (MIP)


Overseas supplier: MT/PU/FM/24
Domestic Supplier: MT/PU/FM/25

Supplier stock status sheet


1) Overseas supplier: MT/PU/FM/24
2) Domestic Supplier: MT/PU/FM/25

Vendor Rating as per system to


suppliers
Vendor feed back on the rating

Comparative cost
Management system

RMP

Improvement Activities
Techinal Support

Defect Trend & Settlement


Fortnightly /
Monthly Planning
- Stock statements
Overseas
MT/PU/FM/24
Domestic
MT/PU/FM/25

Send production schedules, Stock


details, RM defect % to MPC

supplier:
Supplier:

- Defect report

Incomming Material Status


report
Shipment Status (Imported):
MT/PU/FM/26, Shipment
Status (Domestic):
T/PU/FM/27, Model wise
Incomming Material Status
(Domestic): MT/PU/FM/28

RMP

Incoming Material Status report


Shipment Status (Imported): MT/PU/FM/26,
Shipment Status (Domestic): T/PU/FM/27,
Model wise Incoming Material Status
(Domestic): MT/PU/FM/28

Pending production

- Fortnightly MRP
MT/RW/FM-20, MT/RW/FM21
- Supplier agreements

RMP

Not Ok
Return to MPC for review

Check fortnightly
MRP received
from MPC

- Supply Cycle with Suppliers


(production and dispatch
schedules)

- Model Allocation on suppliers

- Defect percentage considered for MRP


calculations
- Revision in RM sizes

N
o
t
O
k

- Supply cycle with supplier

Order Sheets
1) Imported RGL: MT/PU/FM/21
2) Domestic RGL: MT/PU/FM/22
3) PVB: MT/PU/FM/23

BPF-MAT-01

Business Process Flow ( Raw Material Procurement)


Purpose: To establish a procedure for procurement of Raw Glass and PVB as per required quality and delivery standards at optimal cost.
Scope: Raw Glass and PVB

N
o
t

Input

Process / Activity

O
k

Production / Despatch Order


Sheet

Resp /
Interaction
Ok

RMP

Control Doc / Checkpoint


- Order Sheet Format

Output
Purchase Order

- Process Flow for Order Processing

Send order to supplier/s

- Approved Vendor List


- Suppliers agreement
- Terms & Conditions of PO as appropraite.
( MSDS, AOI, QMS, Process Qualification)

- Supply Cycle with Suppliers


RMP

Receive acknowledgement and dispatch


schedule from supplier

- Need by date for the material

Communication to supplier if required


on change in delivery schedule

- Order sheet sent to the supplier


Imported RGL: MT/PU/FM/21
Domestic RGL: MT/PU/FM/22
PVB: MT/PU/FM/23

- Shippling line schedules

- Process Flow for Order Processing

- Order sheet sent to the


supplier

Creation & Approval of system


agreement / Order / Release

Compensation shipments / Hold


release

Standard Oracle Procedure for


Purchasing

RMP

System Releases and Agreements

- Process Flow for Order Processing

- Dispatch
supplier

Statement

Incoming material Status report


1) Shipment Status (Imported):
MT/PU/FM/26,
2) Shipment Status (Domestic):
MT/PU/FM/27,
3) Model wise Incoming Material Status
(Domestic): MT/PU/FM/28

by

RMP

- Need by date for the material

Co-ordinate Dispatches /Track


shipments

- Order sheet sent to the supplier


- Process Flow for Order Processing
- Process Flow for Import Clearance

- Order sheet sent to the


supplier
Imported
RGL:
MT/PU/FM/21
Domestic
RGL:
MT/PU/FM/22
PVB: MT/PU/FM/23

Landing Charges Report

RMP
- Dispatch
supplier

Statement

by

- Process Flow for Order Processing

Receiving advance documents &


arranging for clearance (For
Imports/Documents through bank
shipments only)

- Process Flow for Import Clearance

- Supplier agreements

RMP
Take corrective
action

- Material invoice

- Payment terms with Suppliers

Tracking vendor payments,


Reconcilation of accounts & statutory
documents

- Statement of accounts

DEPB consumption sheet

- Payment track sheet

- Status of any pending claims


- Monitoring of premium frieghts.

Quality rating Sheet


Delivery performance sheet or
any customer disruptions

QAP-MAT-01 (Procedure for Vendor Selection


Vendor Evaluation report
& evaluation)
Periodical Vendor Evaluation

RMP
QA

QAP-MAT-01 (Procedure for Vendor Selection


& evaluation)
Vendor
evaluation
within
acceptance
criteria

NO

1st

2nd

3rd

DELETE

RMP

Vendor Evaluation report

OK
Continue in Approved Vendor List

Process Efficiency : On time availability of Raw Material for Production & Accountabilities and Objectives
Distributed to : 1,2,3,4,5,7,8,10,11,17
Process Effectiveness Measure :Vendor rating

A
Modification Status

New release as per TS

Modification details

Checked By

Approved By

1/2/2003
Date

Process Flow for Budgeting and Review : Raw Material Procurement


Annexure I
Activity

Responsibility / Interaction

Preparation of Gross
Annual requirement Plan

Section Head - RMP

Product Portfolio of Supplier


Suppier Constraint
- Volumes
- Price
- Quality
Logistics
Regulatory requirements
[Statutatory requirements]

NOT OK

OK
Plan Trials of a Large Sample

Inform supplier for


correctives
Evaluate Trial
resullts &
compare with
existing
suppliers

NOT OK

Section Head - RMP

RM Specifications

RM Specifications

Inspection reports

Section Head - Incomming Material

Actual v/s Inspection reports

QA Head
Production Head
Depart Head Materials

Rejection Levels

RM Specification
Customer specific
requirement
Rejection Trend of existing
suppliers

Section Head - RMP

Market Trends
Comparative price
Rejection Targets
Initiate process for PPAPs
Check QS / ISO certification / Plan

Not Okay

Section Head - RMP

Okay

Customer specific
requirements

Size / Thickness
Trial Lot

Plan Commercial trials with new


supplier & invite initial Quotation
from New Supplier

Approval of plan
by HOD

Samples from Suppliers


Comparasion of Technical
specification

Government Regulations

Section Head - RMP


Section Head - Incomming Material
QA Head
Production Head
Deptt Head Materials
Section Head - RMP

OK

Plan and cost / sourcing


options for Raw Material

(PP/PP/FM-08)
(PD/TP/FM-06)

Previous contracts
Market Trends
Need for development of a new
source

Section Head - Incomming Material


Initial
assessement of
New supplier

Standards

Annual Production Plans


New Model
RM Preferences / Model allocation
Defect Trends

Section Head - RMP


Inviting Quotations from
existing
suppliers

Identification of New Raw


Material Source / New
Product

Check Points

Market trends
(Demand Supply situation)
Vendor Agreements
RM Preferences / Model allocation
Supply Cycle with Vendors

Section Head - MPC

RM Preferences / Model Allocation


Production Schedules at Supplier
Supply Cycle with Vendors

Section Head - RMP

Production Schedules at Supplier


Lead Times
Supplier Constrains

Section Head - RMP

Review of current Year's Budget


Historical Data
Projections from Supplier
DEPB Premium / Adv. Licence
Import Cost
Projected SOB
Supply Cycle

Section Head - RMP


Section Head Incomming Material
Production Head
QA Head
HOD Materials

Supply Cycle
Vendor Agreements
Defect Trends & Claims settlement

Section Head - RMP


HOD Materials

Last Contracts
Payment term
Supply Cycle / Delivery term
Comparative price
Rejection Targets
Annual Countermeasure Plans
Agreement of Inspection (AOI)

Section Head - RMP


HOD Materials

Raw Material requirement


Exchange Rates
Vendor Contracts
Last FY Budget

Section Head - RMP

Supplier wise details


Tint wise / Thickness wise details

Section Head - RMP


Buyer - RMP
Purchase Assistant

CIF Per Sq Mtrs


Duty Structure
DEPB Premium / Discount Rate
Import cost (Landing Charges)
Oracle Agreements

Section Head - RMP

Market Trends
Prices, Product Mix & SOB
Change in Pdn Plans / Sales Plan
DEPB Premium
Import Cost (Landing Charges)
Exchange Rate
Order Processing
(Annexure II)

Section Head - RMP


Section Head - MPC
Production Head
QA Head

Market trends
Supplier Constrains
Supply Cycles
RM Preferences
Comparative price
Order Processing
(Annexure II)

Create monthly MRP based on


palnned sourcing options for RM

Existing contracts

Contracts

Not Okay

Check
Monthly
MRP
Okay
Prepare detailed cost benefit for
planned sourcing options for RM

Not Okay
Discuss & validate
the sourcing
options with
Production & QA

Budget Sheet
Vendor agreements
Approved Vendor List

Ok

Finalize contract with RM


Suppliers

Prepare RM procurement
budget

Not Okay

Prepare Travel & overhead


budget

Contract Sheet

Approval
HOD
-Materials

Send Overhead budget to


Corporate Planning

Send Share of business


details to corporate
planning, MPC, QA,
Prodn

Create Oracle
Agreements

Review budgeted v/s


actual
procurement and
overhead
cost on a monthly basis

Contracts
Customs Tariff / Notification

Not Okay

Discuss counter action


with MPC, Production and
QA

Contracts / Agreements
with Supplier
Approved Vendor list

Order Processing
Annexure II
Responsibility
Interaction

Activities

Release PO / DO on the basis of


MRP received from MPC

/
Check Points

Standards

Buyer

Price

1.MRP from MPC


MT/RW/FM-20, MT/RW/FM-21

Planner

Supplier stocks
Overseas supplier: MT/PU/FM/24
Domestic Supplier: MT/PU/FM/25

2.Contracts

Supply cycle
Lead times
Need by date

3.Order Sheets
Imported RGL: MT/PU/FM/21
Domestic RGL: MT/PU/FM/22
PVB: MT/PU/FM/23

OVERSEAS RGL SUPPLIERS

Receive confirmation of order from


supplier

Send ammended
FCL to supplier

Buyer

Material requirement
MT/RW/FM-20, MT/RW/FM-21

1.Purchase order
2.Material requirement sheet from MPC
MT/RW/FM-20, MT/RW/FM-21
3.Order Sheets
Imported RGL: MT/PU/FM/21
Domestic RGL: MT/PU/FM/22
PVB: MT/PU/FM/23

Not Recieved

Not OK
Receive &
Check FCL
details

OK

Purchaes Co-ordinator

Check size, price, Quantity & total invoice value 1.Agreement with supplier
2.Purchase order
3.FCL

Purchase Co-ordinator

Check if any item needs to be added or defined 1.Oracle Purchasing Module


Check Sq Mtrs calculations in PI & Purchase
Order
Check the Division

Inform supplier about


any discrepancy

Get PI / Order
confirmation from the
supplier & Check the
same

PVB S/ment

Initiate process to make oracle


releases

Not OK

OK

1. Receive shipment schedule from


the supplier & follow up for advance
set of documents

Domestic S/ment

Buyer

ETD (From point of origin & point of trans


shipment
Supply Cycle as per Norm
Shipping Line
Purchase order

2. Receive despatch status from


domestic suppliers
Stock statements (MIP)
Overseas supplier: MT/PU/FM/24
Buyer / Purchase Co-ordinator Domestic Supplier: MT/PU/FM/25

Supply Cycle with suppliers

Incomming Material Status report


Shipment Status (Imported): MT/PU/FM/26,
Shipment Status (Domestic): T/PU/FM/27,
Model wise Incomming Material Status
(Domestic): MT/PU/FM/28
Lead times
Provide Stocks net off Despatch
orderes to Planners (MIP)
Provide weekly Incoming material
status report

Imported S/ment
Inform supplier about any
discrepancies & follow up

Buyer / Purchase Co-ordinator Check Size & quqntity


Price & invoice value

Check if invoice against Claims


Check the B/L terms as per agreements
Check B/L date

Check
advance set of
Documents
Not OK

OK

Agreements with supplier


PI
Purchase order / FCL confirmation
Imported RGL: MT/PU/FM/21
Domestic RGL: MT/PU/FM/22
PVB: MT/PU/FM/23

Purchase Co-ordinator

Update Landing Charges

Landing Charges track sheet

Lead Buyer / Buyer

Balance in Advance Licence


Balance for Duty Drawback
DEPB availability & Premium
DEPB usage status at Customs

Advance Licence
Drawback request sheet from Mktg.

Lead Buyer / Buyer

Check for balance DEPB with CHA

Standard DEPB File


Standard Imported S/ment tracking format
Customs tarrif

Send advance set of Docs to CHA


& W/H

Advance Licence / Drawback


Check whether the
s/ment is to be cleared
against DEPB, Advance,
Licence or Duty
Drawback

DEPB
Ascertain DEPB requirment

Followup with supplier for


the original set of
documents

Check the status of


Original docs. from
supplier / Bank when
S/ment reaches
Mumbai

Buyer / Purchase Co-ordinator Check size, Qty


Price & Invoice value
Invoice against Claims
Is B/L terms as per agreements
Standard docs. Set

Not Recieved

Recieved
Page 49 of 57

Agreements
Purchase order / FCL
Advance set of documents
Documents set - Standard

Order Processing
Annexure II
Responsibility
Interaction

Activities

Recieved

Send original set of documents to


CHA along with f-38

Send Inspection report to QA

Check Points

Endorsement by bank
Balance f-38 with CHA
Division

F-38 record register


Purchase order / FCL confirmation

Buyer

Check status of PO in Oracle


ETA at ICD
Check list received from CHA
Shipping Line
Usage of DEPB or Duty Drawback or Advance
Licence

Customs Tarrif
Agreement with CHA
Agreement with S/Line
Duty & S/Line request format

Buyer / Purchase Co-ordinator Check ETD as in PO


Congesation at Nava Sheva
Usage Period

No Railment

Standards

Purchase Co-ordinator

Give duty request to the accounts


along with S/line charges when
s/ment reaches M'bai

Follow up with CHA &


S/Line for s/ment
Status

Supply Cycle as per Norms


Purchase order
Shipment track format

Railment
Give the DEPBs A/L to CHA

Buyer

Railment of s/ment from Mumbai


Check the status of Local IGM with CHA

Purchase Co-ordinator

Check the status of the S/ment


Check the debiting of DEPB
Original documents & f-38 with CHA

Pass duty to CHA

Not Cleared
Follow up for
clearance with
CHA

Followup the reasons


for delay in clearance
& confirm the exact
date of clearance

Purchase Co-ordinator

Check the reasons for non clearance / delay if


any
Demurrage free Period
Check Demurrage free days
Supply Cycle as per Norm
Check Ussage / ETA as per Supply

Cleared
Purchase Co-ordinator
Provide clearance / despatch details
to Warehouse / Planners
(Inci\omming material status report)

Recipt of the Exchange control copy ,


Modvat copy & TR6 Challan

Incomming Material Status report


Shipment Status (Imported): MT/PU/FM/26,
Shipment Status (Domestic): MT/PU/FM/27,
Model wise Incomming Material Status
(Domestic): MT/PU/FM/28

Send Modvat copy & TR6 to Excise & Exchange control copy to
the Bank

Reciept of material in oracle system.


Generation of MRN

Purchase Co-ordinator

Check the details of the B/E & TR6 Challan


Agreement with supplier
Payment request from Bank
Agreement with CHA
Payment terms with supplier
Variation in Clearance & reciept of Statutory
Docs.

MPC

Oracle Release Number


Check received Sq Mtrs V/s Released
MRN Pending List

Buyer

Checking Bills
Agreement with CHA
Check for variance in Clearance & reciept of
Bills
Check docs (Copy) - Invoice, BE

Initiate process to make oracle


releases

Receiving bills from service provider

Oracle Purchasing Module

All charges as per Agreement with service


Buyer / Purchase Co-ordinator provider
1.Agreement with CHA
Any extra charges levied
2. Agreement with S/Line
Demurrage paid
Toll tax recipt
Original Bill of S/line

Check Bills & make entry

Buyer

Check Demurrage on the s/ment


Check Detention charged by S/Line
Reasons

Standard demurrage free period


Agreements with S/Line

Buyer

Check Oracle Po for approval


Delay (if any) in clearance of Bills

Agreement with CHA

Check for Demurrage & Detention

Analyse the reasons for Demurrage


& detention & take corrective actions
for future s/ments

Pass bills to accounts & follow up for


payments

Check arrival of s/ment at W/H

Excess received / MRN Pending

Page 50 of 57

BPF-QAD-03

Business Process Flow (Process control)


Purpose: To manufacture the product as per customer requirements under controlled conditions
Scope: All products manufactured.
Input

Process / Activity

Monthly Plan
Receipt of Monthly PPC Plan and
review of WIP

Weekly Plan
Weekly Plan

Requisition
Slip
Requisition for RM (BOM items)

Daily Plan

Resp / Interaction

Control doc / Checkpoint

Output

Section Head (Prod) /


1) PPC Plan Formats /
Section Head PPC
1) Stock ratio
BPF-PPC-01 (Procedure 2) Maintenance Plan
for Production Planning
& control)
BPF-MNT-01, 02
(Procedure for Mech &
Elect respectively)

Weekly Plan

Section Head (Prod) /


Section Head (PPC)
Section Head (Elect /
Mech)
BPF-MNT-01, 02 (Mech
& Elect respectively)

1) PPC Plan Formats /


1) Stock ratio
2) Maintenance Plan

Daily Plan

1) Section Head - Prod


2) Process Engineer /
1) Section Head (Stores)
2) Officer (RG
Warehouse)

RM Requisition slip /
1) Thickness of Glass
2) Colour of Glass
3) Size of glass

Issued physical RG &


BOM item

Section Head (Prod) /


Process Engineers

1) Daily Production
2) Scheduling Board

Shift Plan

Shift Supervisor

Hourly plan format /


Hourly Plan
1) Manpower Requirement
2) tooling Requirement & Maintenance

1) Supervisor
2) Machine Operator
3) Process Shift Incharge
QAP-QAD-01 (Procedure
for Calibration)
QAP-QAD-02, 03 & 04
( Procedure for Statistical
Techniques, NC & CAPA)
QAP-PRD-01
( Procedure for
Identification &
Traceability)
QAP-PRD-02 (Procedure
for Inspection & Test
Status)

1) BPF-QAD-02
2) PPAP file /
1) Operation record formats
2) Machine checksheets
3) Inspection Standards
4) Job Set up verifications
5) Job standards
6) Appearance Standards
7) Limit samples
8) Process Qualification records
9) Skill Matrix
10) Safety precautions

Daily Plan

Shift Plan
Shift Plan

Hourly Plan
Processing & Appropraite
Inprocess inspection at respective
stages

Operation
records

Report

Operation
Checksheets ..

1) Machine Operator
2) Process Shift Incharge

Defects analysis
sheet
Time Yield Analysis
Daily IRA Sheet
RM Reconciliation
sheet

Defects
analysis sheet
Time Yield
Analysis
Daily IRA
Sheet
RM
Reconciliation
sheet

Review of Plan
vs actual

1) Section Head ( Prod) / 1)Production Quantity


1) Process Engineer
2) Rejection rate
3) Rework percentage
4) Down time
5) Job Change Time
6) Cpk
7) Design Yield
8) IRA Checking
9) Absenteeism.

Updated Plan vs
Actual sheet

Distributed to : 1,2,4,5,12,13,14,

Process Efficiency : Targeted Yield As per Objectives & Accountabilities.


Process Effectiveness Measure : Monitoring through APS, .
A
Modification
Status

New Release as per TS


Modification details

1/2/2003
Checked By

Approved By

Date

BPF-DES-01

Business process Flow


Purpose:Annual Planning
Scope:

Input
1) Comapny's Vision 2) Comapny's
Mission 3)Goals of company 4)Themes
of MD annual policy 5) Enviornmental
factors - Growth in national and
international economy 7) Fiscal
enviornment - interest and exchange
rates 8) Growth trend of Automobile
sector 8) Previous year reuslts operational and financials 9) Targets in
annual plan - operational and financials

Jet Airway Indian Airli Sahara


7025
6725

Process / Activity

Resp /
Interaction
Planning dept

Work out sales plan based on


inputs

Control Doc / Checkpoint


1. Last updated MTP 2. Vehicle
production trend for diferent
segments 3. Govt Budget for fiscal
year 4 Customer projections 5. MD
Annual policy 6. Foreign currency
trend 7. Previous year financial
results and analysis 8. Annual plan

Output
1. Five year plans highlighting
Cost Rs / Sqm of diferent cost
elements, financial parameters 2.
Equipment deployment - utlisation
and improvement 3. Manpower
status and release plan 4. Funds
requirment 5. Share of business

BPF-MRO-01

Business process Flow


Purpose: Resource Planning
Scope: Planning for Machines - Production Equipments

Input

Resp /
Interaction

Process / Activity

1) Demand forecast as in annual plan and


MTP

Control Doc / Checkpoint

Output

PPC

Model wise sales plan

Capacity utilisation of machines

CFT

1. Latest technology available at


global level
2 Cost of operation of production
equipments
3. Specifications of glass
requirement
4. Quotations from vendors
5) plant Layout

1) Cost caparison of production


equiment
2) Proposals for selection of
machine and vendor comaprison
stating negotiated capital and
running cost and services to be
rendered
3) Revised Plant Layout

Capacilty Utilisation Study

No

Gap between
requirement vs
availability

Review if demand rises by 10%


more than budget
Yes
1) Technology update
2) Product profile
3) Operations Update - cost comaprison
of different production equipment
4) Cost of prodcution equipment ,
technical specifications and scope of work
from different vendors

Assessment of production
equipment and selection

Capex approval form with negotiated


cost and cost benifit analysis

MD / COO
Capex approval authority - upto Rs
25 Lacs by COO and more than Rs
25 Lacs by MD & CEO

Approval form MD /COO

If queries raised
OK

1) Approved purchase order,


2) Delivery schedule form vendor,
3)Plant layout

Materials

Time schedule for procurement


and installation of schedule

Procurement of machinery

Mechanical,
Electrical ,Project
Dept

Installation of machinery

Mechanical,
Electrical ,Project
Dept

Installation of Mahine
Trial runs on machine

If not ok

Installation of Mahine
Specification sheet

Supplier's Agreement

OK

1 Projects dept /
1 Vendor,
2 Production head ,
3 Concerned Section
head

Training to operators and


engineers

Mass production on machine

Montoring of KPIs

1 Production head / Technical sheet


Concerned Section
head

1 Production head / Cost benefit document


Concerned Section
head

Distributed to : 1,2,3,4,5,8

Process Efficiency : Optimum utilisation of resources.


Process Effectiveness Measure : Review reports.
A
Modification Status

New Release as per TS


Modification details

1/2/2003
Approved By

Checked Date

Budget Vs Actuals

BPF-MRO-01

Business Process Flow


Purpose: Resource Planning
Scope: Planning for Machines - Infra Structure Equipments/ capex items

Input

Process / Activity

1) Budgeted capex items in annual plan


2) improvement plans

Discussion on cost benefit of


capex additions proposed

1)Cost of capex item , technical


specifications and scope of work from
different vendors

Assessment of capex item required


and selection

Capex approval form with negotiated


cost and cost benifit analysis

Resp /
Interaction
COO, /
Concerned dept
head

1 Materials/
1 Concerned dept
2 Project dept

MD / COO

Control Doc / Checkpoint

Output

1) Purpose of capex item - currently Cost benefit of a capex item


how operations are carried out
whereever it is available
without item suggested

1 Quotations from vendors

1) Vendor selection based on


negotiated rates and services to
be rendered

Capex approval authority - upto Rs


25 Lacs by COO and more than Rs
25 Lacs by MD & CEO

Approval form MD /COO

If queries suggested
OK

Approved purchase order, Delivery


schedule

Time schedule for procurement


and installation of schedule

Material dept
Procurement of capex item

Item is put to use

Concerned dept ,
Electrical, Mech ( if
required)

Budget vs Actual as in Cost benefit


sheet

Concerned dept
KPIs are monitored

Process Efficiency : Optimum utilisation of resources.


Process Effectiveness Measure : Review reports.

A
Modification Status

New Release as per TS


Modification details

Distributed to : 1,2,3,4,5,8

Checked By

Approved By

1/2/2003
Date

BPF-MRO-01

Business process Flow


Purpose: To identify and plan resources and their deployment and its review mechanism for effectiveness
Scope: Annual Planning of Capex items, infrastructure and production equipments.

Input

Process / Activity

1) Themes of MD annual policy


2) Projection of vehicle production and
SOB
3) Targets at model level for Raw
material procurement ,Production
Yield, Customer rejections in PPM,
Power usage
4) Budgets on Repairs &
maintenance, overheads by all
departments.
5) Manpower requirement
6) Expneses on capital additions and
improvement plans

Resp /
Interaction

Planning dept

1. Previous year financial results 2 1) Variance of Budget vs Last year


Actual KPI trend of previous year
Actuals, 2) Savings or loss as
compared to last year
achievements. 3) Highlights on
cost factors where budgeted cost
rate is higher than previous year

Comapre budgeted KPIs and


finacial results of previous year

All departments /
Contingency Plan

Discuss budgets with departments 1. budgeted cost


is higher than actuals and work out alternate solutions
to bring down cost where ever possible 2. KPIs of
machines - deployments of equipments

Planning dept

1) Budget summary and targets of


departments

Output

1. MD Annual policy 2. Budgets


from departments

Compile and Value qunatitative


data to work out KPI parameters
Profit & loss statement and
Balance sheet

1) Previous year data of KPI , cost,


Proft &loss and Balance sheet ,
Variance analysis

Control Doc / Checkpoint

Planning dept

1. Annual plan highlighting Cost


Rs / Sqm of diferent cost
elements, capacity utilisation of
machines , manpower
productivity, funds requirement
2. Customer profitability

Annual plan summary of cost and KPIs 1) Cost benefit of new equipment
required to meet production
requirement and reduce cost
2) New equipment required for
technology upgradation
3) Alternate source plan for
procurement of inputs
4) Revised Profit & Loss statement
and balance Sheet
1 Plans to incoporate changes
suggested by depts.
2 Revised Annual plan presentation
document

Suggestions from top mangement


for changes to be done in plan

Submit annual plan to top


mangement for approval
Steering Commettee
Top management
suggest changes
OK
Original budget plan with monthly
breakup

Feed back of approved budgets

1) Actual vehicle production and SOB


for period.
2) S&OP plan from marketing dept
3) Significant change is any input
which impacts profits

1. Vehicle production report based


on SIAM data
2. S&OP report
3. Exchange rate report
4. Fuel rates trend

Workout rolling budget based


actual sales and changes in P&L
for rest of the period

Revised proft & Loss account and


reconciliation statement of orignal
budget vs revised rolling budget

Variance analysis report for all


cost elements

1) Profit & Loss statement and


Balance sheet of the period under
review
2) Actual KPIs achieved by
departments.
comaprison of Actual results with
revised budgets

MIS reports from departments

Contents of monthly MIS folder

Monthly MIS folder.

Minutes of meeting of review


meeting by top mangement

1. List of corrective actions to be


taken. 2)
Improvement/countermeasure
plan

Reports to top mangement and


feedback to departments in
MCM and TG for actual
performance and its financial
impact

Feedback from top


management for monthly
performance and "area of
concern " as discussed in
review meeting by steering
committee
Minutes of meeting of review
meeting by top mangement

Information passed on to
concerned dept for
countermeasure /correction
plans or specific report
requirements
Improvement / Countermeasure
plan

Countermeasure plans for "area


of concern" gets incorporated in
next month MIS folder or at at
next review meeting and close
monitoring is done

Distributed to : 1,2,3,4,5,8

Process Efficiency : Optimum utilisation of resources.


Process Effectiveness Measure : Review reports.
A
Modification Status

New Release as per TS


Modification details Checked by

1/2/2003
Approved By

Date

Jet Airway Indian Airli Sahara


7025
6725

BPF-MRO-01

Business Process Flow (Product Homologation)


Purpose: To get product homologated as per ECE regulations
Scope: All safety Glasses manufactured.

Input

Process / Activity

Information from TPS / QA (Customer


Service Section) through E mail.

Receipt of information from TPS /


QA (Customer Service)

E mail to Homologation agency


Scrutiny of data by the
homologation agency

Feedback to
TPS/customer and
asking for
clarification

Feedback from homologation agency


through fax / e mail.

NOT OK

E Mail stating the type of tests from


homologation agency.
On site testing of glass

Approval documents as per


requirements.

Preparation of documents

Send documents to homologation


agency

Receipt of homologation
certificates

Section Head
1.
(Product
2.
Homologation) /
3.
1. Section Head
4.
(TPS)
5.
2. Section Head
6.
( Customer Service - 7.
QA)
8.

Modification Status

E mail to homologation agency.

1) Grouping of windscreens
2) R point Coordinates
3) Adequacy of documents

Feedback from homologation


agency through fax / e mail.

External Agency /
Section Head
(Product
Homologation)

Type of test as per grouping of


windscreens

E Mail stating the type of tests


from homologation agency.

Section Head
(Product
Homologation) /
External agency

ECE reference standard latest


version /
1. Number of test pieces required
2. Acceptance criteria as per laid
down standards.

Approval documents as per


requirements.

Section Head
(Product
Homologation)

1.
2.
3.
4.

Approval documents as per


requirements.

Section Head
(Product
Homologation) /
Administration
department

Confirmation
List of windscreens
Technical Specifications
Annexure

Section Head
(Product
Homologation) /
External agency

1/2/2003
Checked By

Approved By

1. Approval stamp on the


Homologation Certificates.
certificates and or papers
2. Contents mentioned on the
certification vis a vis documentation
sent

Distributed to : 1,2,3,4,5,8

New Release as per TS


Modification details

Customer Name
Glass model name
FG Size of Glass
Height of Segment
Minimum Radius
Installation Angle
Seat Back Angle
R point Co-ordinates

Output

External Agency /
Section Head
(Product
Homologation)

Process Efficiency :
Process Effectiveness Measure : First time through

Control Doc / Checkpoint

OK

Confirmation on the tests required


to be done

Approval documents as per


requirements.

Resp /
Interaction

Date