plant perform.1

Supplier Inhouse Customer end Total

Cost ofPoor

quality( %)

Totalprod.Qty.

TotalRej.Qty.

Rejectionppm

(inhouse)

TotalRej.Qty.

Rejectionppm

(Supplier)

Rejection Cost - (sell value)

TotalDisp. Qty.

Rej. PPM, SELL & COPQMonth - Jan.2015

Sr.No

Part No

Inhouse Supplier Customer End

value/ piece Total SellProd qty.

(sell value) Totaldisp.

Rej.Qty.

Rejectionppm

(cust. End)

Total

Prepared by : Reviewed By:

Sr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status

DAILY REJECTION - INWORD,INHOUSE , FINAL STAGE

Jan.2015

Reviewed By:Prepared By:





DAILY REJECTION - Major NC ( Top Five defects)Jan.2015

Total

Total

Total

TotalSr. No. Date Component Heat No. Process Machine Defect Qty Arrested stage U/D,R/W,Scrap Responsibility Status

Prepared By: Reviewed By:

Total

Total

SrNo NC Total

rej.REJ % CF %

1

2

3

4

5

REJECTION PARATO Jan2015 - Major NC

0.00

0.20

0.40

0.60

0.80

1.00

1.20

REJ

% &

CF%

REJ.PARATO

REJ %

#REF!

Series3

5

TOTAL


Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15

Target ( PPM)

Company Level PPM

Trend Chart-Company Level PPM (Rejection)

4000

5000

Company Level PPM Target ( PPM) Linear (Company Level PPM)


0

1000

2000

3000

Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15

( PPM

)

Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Total Rej Qty

1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

SCRAP NOTE

Jan.2015

Sr.No

DefectPart No & Qty.

15 0

16 0

17 0

18 0

19 0

20 0

21 0

22 0

23 0

24 0

25 0

26 0

27 0

28 0

29 0

30 0

31 0

32 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Production Incharge QA Incharge Store Incharge Plant Incharge MD

Total

Production Incharge QA Incharge Store Incharge Plant Incharge MD

Complaintrec. Via.

Complaint Summary

Month : Jan.2015

Sr.No.

Date Part No. Part Name Customer Part No.Customer

NameProblem Description

ComplaintRaised By



Target (Total max. Complaints) (Nous.) 2 2 2 2 2 2 2 2 2 2 2 2

No. of Complaints Received (Nous.)

Target (Repeat Complaints) (Nous.) 0 0 0 0 0 0 0 0 0 0 0 0

No. of Repeat Complaints Received(Nous.)

Target (Field Failure) (Nous.) 0 0 0 0 0 0 0 0 0 0 0 0

No. of Incidences of Field Failure (Nous.)

Trend Chart-Customer Complaint Details

No. of Complaints Received (Nous.) No. of Repeat Complaints Received (Nous.) No. of Incidences of Field Failure (Nous.)

Target (Total max. Complaints) (Nous.) Target (Repeat Complaints) (Nous.) Target (Field Failure) (Nous.)

Updated By: Reviewed By (Head-QA):

0

1

2

3

4

5


Target (Total max. Complaints) (Nous.) Target (Repeat Complaints) (Nous.) Target (Field Failure) (Nous.)

Nou

s.

Updated By: Reviewed By (Head-QA):


Target ( PPM )

Customer PPM

Trend Chart-Customer PPM (Rejection)

1600

1800

2000

Customer PPM Target ( PPM ) Linear (Customer PPM)


0

200

400

600

800

1000

1200

1400


PPM


Cost of Poor QualityJan.2015 to jul.2015

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00%

% Cost of poor quality

Month Jan.2015 Feb.2015 Mar.2015 Apr.2015 May.2015 Jun.2015 Jul.2015

Cost of scrap

Cost of customerDissatisfaction

0 0 0 0 0 0 0

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Reviewed By:

Sr. No.

1

2

Total

Sales(Rs.)

Cost of poor quality %

Prepared By:

0.00 0.00 0.00 0.000.00

0.00 0.000.00

0.50

Jan.

201

5

Feb.

201

5

Mar

.201

5

Apr

.201

5

May

.201

5

Jun.

201

5

Jul.2

015


Target ( %)

Delivery Performance [%]

Trend Chart-Delivery Performance (%)

Delivery Performance [%] Target ( %) Linear (Delivery Performance [%])


0



Sr.No.

Name of Customer Unit Jan'15 Feb'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 sept'15 Oct'15 Nov'15 Dec'15

PPM

Grade

Rating

PPM

Grade

Rating

Customer Feedback

Mar'15

1

2 Grade

Rating

2

Colour Code for Unit:

Customer PPM Customer Grade Customer Rating

Prepared By (Manager-QA): Reviewed By (Plant Head):


Machines Planned (Nos.)

Machines Completed ( Nos.)

Target [%]

Plan Adherence [ % ]

Trend Chart-Preventive Maintenance Plan Adherence

90.00

100.00

Plan Adherence [ % ] Target [%] Linear (Plan Adherence [ % ])

Prepared By (Manager-Maintenance): Reviewed By (Plant Head):

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00




Target ( %)

Actual MDT Factor ( % )

CNC

Hobbing

Press

Shaping

Shaving

Milling

Broaching

Grinding

VMC

HMC

Trend Chart-Machine Downtime Factor

HMC

General

Total ( Hours.) 0 0 0 0 0 0 0 0 0 0 0 0

0.00

0.50

1.00

1.50

2.00


Actual MDT Factor ( % ) Target ( %) Linear (Actual MDT Factor ( % ))

0 0 0 0 0 0 0 0 0 0 0 00

50

100

150

200

250

300


%H

ours

.


Month Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sept'15 Oct'15 Nov'15 Dec'15

Incidences of Downtime( Nos.)

Trend Chart-Downtime Due to Non-Availability of Toolings

1Incidences of Downtime ( Nos.)

Prepared By (Engineer-Toolings): Reviewed By (Head-Production):

0

Jan'15 Feb'15 Mar'15 Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sept'15 Oct'15 Nov'15 Dec'15

Nos

.


PA Planned ( Nos.)

PA Completed ( Nos.)

Not in Production ( Nos.)

Target ( % )

PA Plan Adherence ( % ) #DIV/0! #DIV/0! #DIV/0! #DIV/0!

No. of NCs

Trend Chart-Product Audit Data

60.00

70.00

80.00

90.00

100.00

110.00 PA Plan Adherence ( % ) Target ( % ) Linear (PA Plan Adherence ( % ))

%

Prepared By (Incharge-QA): Reviewed By (Head-QA):

0.0

0

0.0

0

0.0

0

0.0

0

0.00

10.00

20.00

30.00

40.00

50.00

60.00


0

1

2

3

4

5


No. of NCs

Nos

.%

Prepared By (Incharge-QA): Reviewed By (Head-QA):


Audits Planned

Audits Completed

Target (%)

Adherence (%)

Major NC's (NC1)

Minor NC's (NC2)

OFIs

Total 0 0 0

Trend Chart-Manufacturing Process Audit Data

Adherence (%) Target (%) Linear (Adherence (%))

0.00

20.00

40.00

60.00

80.00

100.00


0

10

20

30


Major NC's (NC1) Minor NC's (NC2) OFIs

Prepared By (Executive-QMS): Reviewed By (Head-Production):



Minor Injuries (Nos.)

Target (Nos.)

Major Injuries ( Nos.)

Trend Chart-Incidences of Injury

4

5

6

Major Injuries ( Nos.) Minor Injuries (Nos.)

Prepared By (Executive - HR): Reviewed By (Plant Head):

0

1

2

3

4


Nos

.

Prepared By (Executive - HR): Reviewed By (Plant Head):


Target %

Plan Adherence %

Trend Chart-Training Plan Adherence

80

90

100

110

Plan Adherence % Target % Linear (Plan Adherence %)

Prepared By (Executive-HR): Reviewed By (Plant Head):

0

10

20

30

40

50

60

70

80


%

Prepared By (Executive-HR): Reviewed By (Plant Head):


Inquiries Received

Inquiries Quoted

Received PO

Trend Chart-Inquiry Status

1

1


0

0

0

1

1

Inquiries Received Inquiries Quoted Received PO




New Received

Under Development

Development Completed

Trend Chart-Development Status

20

25

New Received Under Development Development Completed

Prepared By (Engineer-PED): Reviewed By (Head-PED):

0

5

10

15

20



Month Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'15 Feb'15 Mar'15

Sample Submission Plan

Samples Submitted(as per Timeline)

Samples Delayed

Target (%)

Plan Adherence (%)

Trend Chart-Sample Submission Plan Adherence

110.00

Plan Adherence (%) Target (%) Linear (Plan Adherence (%))


0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

Apr'15 May'15 Jun'15 Jul'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'15 Feb'15 Mar'15


Documents

plant perform.1