1st MRM Minutes Dated 20th Nov 09

S.No Topics Action Plan Responsibility Target Date Remarks

1 MR Discussed

2 Review of Objectives

a Customer complaints

COO Closed

b Production Volumes

c Inprocess rejections

d Ontime delivery

3 Internal Quality Audit

Marketing 2 NC & 1 obs

Management Responsibility - Nil Nil

MR - Nil NIL

Human Resource - Nil NIl

PPC - 1 NC 1 NC closed

Production Drilling - 1NC 1 NC pending

Production Tempering - 2NC 2 NC closed

Production Lami - 1 NC 1 NC closed

Production DGU - 1 Nc , 1 Obs

Dispatch - 1 NC 1 NC Pending

Quality Assurance - 1 NC 1 NC Closed

Maintenance - 1 NC 1 NC closed

Stores - 2 NC 1 NC closed & 1 NC pending

Purchase - 1 NC 1 NC Closed

Note : Final review by MR is pending for all the NCs & will be completed by 28th Nov 09 , Targets dates for completion are given in NCR re

Glasstech Industries (India) Pvt Ltd.

MANAGEMENT REVIEW MEETING MINUTES

MRM No.: 1 Date : 20th Nov 09

ISO Num :F / MR/ MRMMOMVER :1.0

Status as on 20th Nov 09

Pending points of previous MRM meeting.

This is the 1st MRM meeting as per ISO 9001:2008 standards , however last MRM's points were discussed & reviwed , These points also will be taken into consideration in the next MRM agenda meeting .

The objectives set in Aug 09 were reviewed & were found in line with the targets set ( Refer annexure for the results of 4 objectives set)

From Aug 09 to Oct 09

In the Internal Quality Audit conducted on 7th & 9th Nov 09 - Total 14 NC & 2 obs were found ( Refer the Annexure of Audt summary )

1 NC & 1 OBS closed & 1 NC Pending

1 NC closed & 1 obs pending

4 Process performance QC Manger Upto Oct 09 Closed

QC Manger Upto Oct 09 Closed



DGU Dessicant Test - Total 56 test done - 56 test pass QC Manger Upto Oct 09 Closed

DGU shore A Hardnesss - Total 58 Test done - 58 Test pass QC Manger Upto Oct 09 Closed

Lamination : Boil Test 15 Test done & 15 test pass QC Manger Upto Oct 09 Closed


5 Product confirmity QC Manger Upto Oct 09 Closed

6 Up to Oct 09 Closed

7 Oct-09 Closed

8 Training Closed

a Regular training For 1st Quarter Sessions planned - 12 , Sessions Actual- 8 Till Oct 09 Closed

b Safety training Session Plan - 1 , Session Actual- 1 HR Admin Till Oct 09 Closed

c Fire fighting training Session Plan - 1 , Session Actual- 0 HR Admin Till Oct 09 Closed

d First Aid training Session Plan - 1 , Session Actual- 1 HR Admin Till Oct 09 Closed

Temepred /HS Glass - 107 test done - 106 pass , 1 fial (approx 30 glasses were retempered job num 905 )

Roller wave test : 76 Test done - 76 test pass - Max value of Avg dept found to be 0.19 mm in Job num 812 & 900 against the Target of 0.2 mm .

DGU Potlife Test - Total 64 Test done - 63 test pass - 1 fail due to more fast curing time ( resetting done & made ok) .

DGU Butter fly - Total 60 Test done , 58 test pass - 2 fail ( resetting done )

Room Conditions - Daily basis 2 times reading taken , All found Below 30 Deg c

Based on the inprocess & Random Test inspection reports Dimensions : From last 3 months the data recorded for sizes found with max +/- 1 mm

CA PA customer complaints

From last 3 moths for the complaints accepted by Glasstech 6 Corrective action have been taken & are closed ,Most of the colours for Master colour samples are ready ,few samples are pending as till date order has been not placed for them

Marketing Head & QC Manger

CA PA Inprocess rejections

From the past 3 months data , in 3 areas corrective action were taken ,Viz Grinding machine, Tempering Machine , Handling Breakage in all deptts & have been started implenting .

QC Manager & CFT Team

It was decided to meet the Planned the trainning session & individual deptts head to speed up & regularise tranning progamms.

Plant Manger/HR

Admin

By Next review meeting

Concerned Deptt Heads

9

7] Enlarged area for stores planned in the new shade .

10 Plant Manager Oct-09 Closed

11 Customer Feed Back Oct-09 Discussed

12 No Issues MR Oct-09 Closed

13Resource needs to any

Plant Manager By Nov09 end Inprocess

Plant Manager By Jan 09 end Inprocess

Prepared by Checked By Approved by

MR COO

Summary of Continuous Improvements Planned & achieved ( BY Plant Manager & QA )

1] To Set Min Max Consumables list by each process / Deptt ( Benefit : Inventory cost will reduce , Stock problems will decrease as minimium stock will be mainted by Stores & Purchase )

Production Head / QC manger


This being the first MRM , improvements are planned & completion, implementation will be reviewed in next meeting.

2] Control plan in details to be made for controlling the process at micro level. Detailed training to be provided to the workers for same .



3] Exsisting machine check list are not detailed one , hence there are chances of missing the checks before start up of machine . Detailed machine checklist to be made & introduced.



4] The ideas coming from the suggestions schemes to be implemented & results to be monitored for the benefits getting to the company.



5] Pls for re-training of all the operators & incharges for Tempering, DGU & Lamination line by machine supplier.



6] Introduction of format for recording , control & traceability of Incoming farmas & Out going farmas





8] Exsisting ceramic printing supplier to be discontinued , once the New ceramic printing line is installed & commissioned .



Devaitions /Consession forms & details

From Aug 09 to Till date , 5 Devaitions have been recorded for minor issues related to asthetics looks & till date no complaints received for those deviations sent.

Prior to Aug 09 ,Total 12 feedbacks received & 1 form had negative feecback form for delivery concern, From Aug 09 to Oct 09 Total 5 feedback forms received ,& no negative feed back received .

Mr Anoop ( Marketing)

Changes in SOP & QSM

It is planned to have a Manual grinding team on contract Basis for grinding work of edge polishing & minor repair works like scratches

3 nos fresh Diploma electronics enggs needed in all 3shifts for machine manitenance team to handle the sophesticated CNC Based machines

Glasstech Industries India Pvt Ltd ( Objectives ) Year 09-10

Area1st Quarter

April.09

1 % NA 2% 4.46

Average 4.8

2 % NA 3% 6

Average 6.4

3 Customer complaints Registered Nos NA NA 4

Customer complaints Accepted Nos 4

No of orders Nos NA NA 88

% NA 2% 4.55

Average 4.44 Production Volumes

Tempered Production FG SQM NA 25000 15988DGU Production FG SQM NA 9000 7223Laminated Production FG SQM NA 1833 0Total Production Volumes FG SQM NA 35833 23211

Average 21312Tempered Rejection SQM NA NA 406.1DGU Rejection SQM NA NA 398.2Laminated Rejection SQM NA NA 0.0% Rejection Tempered % NA 0.50% 2.5

Average 3.6% Rejection DGU % NA 0.20% 5.5

Sr. No.

Unit of Measure

mentLast Year

data 08-09Avg Target

for this year 09-10

Inprocess rejections ( Excluding RM & Dispatch ,Transport Breakage

Total Rejections ( Customer complaints + Dispatch & Transit breakage+RM defects +Inprocess rejections)

3nos /month

% Accpeted complaints on Order basis

Average 4.7% Rejection Laminated % NA 1% 0.0

Average 0.05 Ontime Delivery

Total orders Nos NA NA ,-Total Delivery on time Nos NA NA ,-% On time Delivery % Na 80% ,-

Average ,-


1st Quarter 2nd Quarter 3rd Quarter 4th Quarter

May.09 June.09 July.09 Aug.09 Sept.09 Oct.09 Nov.09 Dec.09 Jan.10

2.46 7.54 2.78 2.95 2.11 1.33

4.8 2.6 1.3 #DIV/0!

2.9 10.4 3.2 4 3.2 2.9

6.4 3.5 2.9 #DIV/0!

4 7 5 2 4 9

4 6 4 1 2 2

106 126 195 154 216 173

3.77 4.76 2.05 0.65 0.93 1.16 #DIV/0! #DIV/0! ###

4.4 1.2 #DIV/0! #DIV/0!

17849 10346 14434 13401 16003 191948180 4349 4274 4581 4058 5686

0 0 0 1246 1963 185426029 14695 18708 19228 22024 26734 0 0 0

21312 19987 8911 0445.5 588.3 196.7 136.0 141.6 122.131.6 362.6 79.2 36.1 32.5 43.00.0 0.0 0.0 27.8 62.4 26.22.5 5.7 1.4 1.0 0.9 0.6 #DIV/0! #DIV/0! ###

3.6 1.1 #DIV/0! #DIV/0!0.4 8.3 1.9 0.8 0.8 0.8 #DIV/0! #DIV/0! ###

4.7 1.1 #DIV/0! #DIV/0!0.0 0.0 0.0 2.2 3.2 1.4 #DIV/0! #DIV/0! ###

0.0 1.8 #DIV/0! #DIV/0!

,- ,- 0 154 216 173,- ,- 0 118 179 141,- ,- 0 77 83 82 #DIV/0! #DIV/0! ###

,- 53 #DIV/0! #DIV/0!


4th Quarter Remarks

Feb.10

3.4

#DIV/0! #DIV/0!

4.7

#DIV/0! #DIV/0!

3.3

### ###

#DIV/0! #DIV/0!

15316.4

5478.7

723.3

0 0

0 12552.4

### ###

#DIV/0! 2.3

### ###

Actual Avg 09-10March.1

0

#DIV/0! 2.9

### ###

#DIV/0! 0.9

### ###

#DIV/0! 53.2

Customer complaints analysis

Month

Break up

April.09 4 4 100 0 0 4 0

May.09 4 4 100 0 0 4 0

June.09 7 6 86 1 0 5 1

July.09 5 4 80 1 0 4 0

Aug.09 2 1 50 1 0 1 0

Sept.09 4 2 50 2 0 2 0

Oct.09 9 2 22 7 0 2 0

Nov.09 #DIV/0!

Dec.09 #DIV/0!

Jan.10 #DIV/0!

Feb.10 #DIV/0!

March.10 #DIV/0!

Total 35 23 66 ###12 0 22 1April .10 #DIV/0!

May.10 #DIV/0!

June.10 #DIV/0!

July.10 #DIV/0!

Aug.10 #DIV/0!

Sept.10 #DIV/0!

Oct.10 #DIV/0!

Nov.10 #DIV/0!

Dec.10 #DIV/0!

Jan.11 #DIV/0!

Feb.11 #DIV/0!

March.11 #DIV/0!

Total 0 0 ###### 0 0 0 0

Quater1 Aug 09 ~oct 09 Target Actual Avg

Aug-09 1

2Sep-09 2

Oct-09 3

Total no of complaints registered

Total no of complaints accepted

% Accepted Customer

errorNot an

complaintProduction

errorextra short

Nov 09 Corrective actions : No Actions taken as results are with the targets

3nos /month

Quater2 Nov 09 ~ Jan10 Target Actual Avg

Nov-09 5

4Dec-09 5

Jan-10 3

Quater3 Feb 0 ~ April 10 Target Actual Avg

Feb-10 3

9Mar-10 17

Apr-10 8

Quater4 May10~July 10 Target Actual Avg

May-10 12

9Jun-10 9

Jul-10 6

Feb 10 Corrective actions : Dec-09 , complaint number 48 was later on found as customer error as he didn’t give the orientation pattern & complaint 50 was know to us , but sent with the intention that it will go inside the fitting.

No corrective actions were planned as in some cases only cleaning & chipping issue was observed but verbal strict instructions were given to respective process owners for avoiding such issues in future.

3nos /month

May 10 Corrective actions : Due to heavy production load & year ending completion work , errors increased to an Avg 9 , against an target of 3 .During heavy load exsisting people make mistakes in basic things.COO informed all the take necessary actions against the respective operators , make them aware about loss to company interms of money for each replacement & discussed about about putting new fresh diploma holders in each process & informed HR Admin to call for Biodatas .Also discussed to put final inspection team at dispatch stage after 1~2 months to control rejections if rejection rate continues.COO planned to meet individual process owners to discuss about the inprocess rejections as well.Discussed to start an internal mistake register for all deptts with 1 ~2 months , same to submit to Quality deptt , final summary will be made & necessary action will be taken on respective process owners.

3 nos /month

Aug 09 Corrective actions : In july 2010 , Final inspection team deputed in Dispatch stage , effective from 9th july 2010In july 2010 fresh Diploma engineers were appointed & training started.Mistake register started from 22nd of July 2010Rejection from may 10 was decreasing as all process were being monitored for control of rejections for basic reasons.To make aware to all incharges about loss in comany in terms of moneyHence no corrective action were taken for this quater , only monitoting of the data & discussion with respective process owers is planned.

2 nos /month

Customer complaints analysis

Break up Break up

0 0 4 1 3

0 0 4 4

0 0 5 2 2

0 0 4 3

0 0 1

0 0 2

0 0 2 1 1

0

0

0

0 0 22 1 3 0 5 5 3 0 00

0

0

0

0

0

0

0

0

0

0

0

0 0 0 0 0 0 0 0 0 0 0

Production error

Head office error

Labelling issue

Size error

Drilling error

Coating damage

Visual defect error

wrong coating

side

DGU error

Tempering error

Cerami

crror

Nov 09 Corrective actions : No Actions taken as results are with the targets

Feb 10 Corrective actions : Dec-09 , complaint number 48 was later on found as customer error as he didn’t give the orientation pattern & complaint 50 was know to us , but sent with the intention that it will go inside the fitting.

No corrective actions were planned as in some cases only cleaning & chipping issue was observed but verbal strict instructions were given to respective process owners for avoiding such issues in future.

May 10 Corrective actions : Due to heavy production load & year ending completion work , errors increased to an Avg 9 , against an target of 3 .During heavy load exsisting people make mistakes in basic things.COO informed all the take necessary actions against the respective operators , make them aware about loss to company interms of money for each replacement & discussed about about putting new fresh diploma holders in each process & informed HR Admin to call for Biodatas .Also discussed to put final inspection team at dispatch stage after 1~2 months to control rejections if rejection rate continues.COO planned to meet individual process owners to discuss about the inprocess rejections as well.Discussed to start an internal mistake register for all deptts with 1 ~2 months , same to submit to Quality deptt , final summary will be made & necessary action will be taken on respective process owners.

Aug 09 Corrective actions : In july 2010 , Final inspection team deputed in Dispatch stage , effective from 9th july 2010In july 2010 fresh Diploma engineers were appointed & training started.Mistake register started from 22nd of July 2010Rejection from may 10 was decreasing as all process were being monitored for control of rejections for basic reasons.To make aware to all incharges about loss in comany in terms of moneyHence no corrective action were taken for this quater , only monitoting of the data & discussion with respective process owers is

Break up

1

1

1

1 1

0 1 1 1 1 1 0 0

0 0 0 0 0 0 0 0

DGU condensa

tion

Delamination

Chiiping, spots / scratch

Fragments not as per

std

Automatic glass bkg

Wrong order /

PI

Waviness

packing/

loading

Replacement Analysis Year 09~10 ( Only Process Rejection Exculding Dispatch & RM Defects )

ProcessCutting Grinding Drilling Edge Deletion

QTY SQM QTY SQM QTY SQM QTY

April.09 0 0 34 75.65 8 12.61 11

May.09 1 1.13 27 60.42 2 2.54 3

June.09 8 11.04 17 42.58 4 6.36 10

July.09 55 67.6 12 22.4 8 16.68 4

Aug.09 29 49.51 58 115.87 10 17.63 9

Sept.09 14 26.26 75 122.98 21 41.87 1

Oct.09 16 34.26 48 109.4 6 15.2 2

Nov.09

Dec.09

Jan.10

Feb.10

March.10

Total 123 189.8 271 549.3 59 112.89 40


Edge Deletion Ceramic Tempering Insulating Lamination

SQM QTY SQM QTY SQM QTY SQM QTY

24.26 54 118.28 184 406.08 223 398.2 0

10.23 29 50.23 223 445.54 14 31.56 0

12.6 8 17.25 374 588.279 209 362.563 0

14.54 26 44.55 85 196.68 32 79.2 17

22.71 70 140.48 67 136.04 30 36.12 17

3.29 4 8.9 78 141.59 16 32.45 23

3.19 0 0 63 122.12 21 42.96 11

90.82 191 379.69 1074 2036.3 545 983.05 68


Lamination Sub Total

SQM QTY SQM QTY SQM Tem+DGU+Lam

0 0 0 514 1035.08 23211

0 20 37.61 319 639.26 26029

0 33 67.06 663 1107.73 14695

47.57 19 31.77 258 520.99 18708

27.78 10 21.61 300 567.75 19228

62.38 9 24.79 241 464.51 22024

26.15 2 3.48 169 356.76 26734

0 0

0 0

0 0

0 0

0 0

Others (HO ,Site ,washing

)

Production In SQM

163.88 93 186.32 2464 4692.1

% Rejection

4.46

2.46

7.54

2.78

2.95

2.11

1.33

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

Devaitions / concession

Month Deviation Avg

Aug-09 02

0Sep-09 5 0Oct-09 0 0

Nov-09###

0Dec-09 0Jan-10 0

Feb-10###Mar-10

Apr-10

May-10###Jun-10

Jul-10

Aug-10###Sep-10

Oct-10

Customer complaints against deviations

NILHard copy pasted in files

Feed back forms

Month Feedback forms AvgAug-09

5Sep-09 5Oct-09

Nov-09#DIV/0!Dec-09

Jan-10

Feb-10#DIV/0!Mar-10

Apr-10

May-10#DIV/0!Jun-10

Jul-10

Aug-10#DIV/0!Sep-10

Oct-10

Documents

1st MRM Minutes Dated 20th Nov 09