sharda p2 kap obs 06 07 10

AUDIT FINDING/OBSERVATIONS AUDIT FINDING/OBSERVATIONS

VENDOR :Sharda Motor India Ltd

1. DATE : 15.04.101. DATE : 15.04.10

2. AUDITOR : 2. AUDITOR :

- HMC : -Mr.LEE SANG SYUNG- HMC : -Mr.LEE SANG SYUNG

- HMI : Jayabalaji( SQA)- HMI : Jayabalaji( SQA)

- HMI : - HMI :

3. CORRECTIVE ACTION SUBMISSION DATE: 12.07.2010 3. CORRECTIVE ACTION SUBMISSION DATE: 12.07.2010

KAP/HMI

Sharda P2

Summary of the Observations

Sl No.

Problem Improvement Details Targt Date

Plan

Remarks05/10 06/10 07/10

1Raw Material – to be stored part name wise, material grade wise, customer wise, lay out and stock status to be provided

Raw Material – Stored part name wise, material grade wise, customer wise, lay out and stock status provided

13.05.10

11 6

2Stock to be provided in stock status board

Safety stock, preparation stock, emergency stock

Stock provided in stock status board

Safety stock, preparation stock, emergency stock

15.05.10

3Tube mill coil storage – pallet height to be reduced to prevent damage during loading unloading time

Stock status to be provided part number wise Feasibility will be studied 28.07.10

4Scrap sheets to be stored out side shop floor

Identification for storageScrap sheets removed from shopfloor 12.05.10

5 In lay out – stock status to be added (storage qty) In lay out – stock status added (storage qty) 13.05.10

6Cut pipes to be arranged properly

Sliding trolley to be provided to ensure FIFOCut pipes arranged properly 15.05.10

7

Sliding oil insufficient at RH side

Visual arrow mark to be provided for daily

maintenance

Sliding oil sufficiently used at RH side

Visual arrow mark provided for daily

maintenance

30.05.10

8Die cushion oil pressure range marking to be provided for all gauges

Inspection numbers to be provided

Die cushion oil pressure range marking provided for all gauges

Inspection numbers provided25.05.10

9 Shut height unbalance to be checked periodicallyShut height unbalance checked periodically and check point added in check sheet

30.06.10

10Press cushion pins damaged

Daily cushion pins seating area and mould wear and tear monitoring required

Damaged Press cushion pins replaced

Daily cushion pins seating area and mould wear and tear monitoring

15.06.10

Summary of the Observations

Sl No.

Problem Improvement Details Targt Date

Plan

Remarks05/10 06/10 07/10

11 Die to be clamped with standard single block Die clamped with standard single block 30.06.10

11 6

12 Standard block to be used to maintain tool height Standard blocks used to maintain tool height 10.06.10

13 Same bolt size to be use for upper & lower die plate .Same bolt size used for upper & lower die plate

25.06.10

14 Blank sheets to be stored in table for operator access Blank sheetsstored in table for operator access 25.05.10

15 Visual colour marking for tool controlVisual colour marking provided for tool control

25.05.10

16Master defect sample to be marked with different

colourMaster defect sample marked with red colour 20.05.10

17 Route card operation wise Route card operation wise provided 25.05.10

BEFORE AFTER

Raw Material – to be stored part name wise, material grade wise, customer wise, lay out and stock status to be provided

Raw Material – stored part name wise, material grade wise, customer wise, lay out and stock status provided

PROBLEM IMPROVED

QUALITY IMPROVEMENT 1Target Date

13.05.10

BEFORE AFTER

Stock to be provided in stock status boardSafety stock, preparation stock, emergency stock

Stock provided in stock status boardSafety stock, preparation stock, emergency stock

PROBLEM IMPROVED

QUALITY IMPROVEMENT 2Target Date

15.05.10

BEFORE AFTER

•Tube mill coil storage – pallet height to be reduced to prevent damage during loading unloading time•Stock status to be provided part number wise

PROBLEMIMPROVED

QUALITY IMPROVEMENT 3Target Date

28.07.10

•Tube mill coil storage – pallet height reduced to prevent damage during loading unloading time•Stock status provided size wise

BEFORE AFTER

•Scrap sheets to be stored out side shop floor•Identification for storage

•Scrap sheets removed from shop floorPROBLEM IMPROVED

QUALITY IMPROVEMENT 4Target Date

12.05.10

BEFORE AFTER

In lay out – stock status to be added (storage qty)

In lay out – stock status added (storage qty)PROBLEM IMPROVED

QUALITY IMPROVEMENT 5Target Date

13.05.10

BEFORE AFTER

•Cut pipes to be arranged properly•Sliding trolley to be provided to ensure FIFO

•Cut pipes arranged properlyPROBLEM IMPROVED

QUALITY IMPROVEMENT 6Target Date

15.05.10

BEFORE AFTER

•Sliding oil insufficient at RH side•Visual arrow mark to be provided for daily maintenance

•Sliding oil sufficiently used at RH side•Visual arrow mark provided for daily maintenance

PROBLEM IMPROVED

QUALITY IMPROVEMENT 7Target Date

30.05.10

BEFORE AFTER

•Die cushion oil pressure range marking to be provided for all gauges•Inspection numbers to be provided

•Die cushion oil pressure range marking provided for all gauges•Inspection numbers provided

PROBLEM IMPROVED

QUALITY IMPROVEMENT 8Target Date

25.05.10

BEFORE AFTER

•Shut height unbalance to be checked periodically

•Shut height unbalance checked periodically and check point added in check sheet

PROBLEM IMPROVED

QUALITY IMPROVEMENT 9Target Date

30.06.10

BEFORE AFTER

•Press cushion pins damaged•Daily cushion pins seating area and mould wear and tear monitoring required

•Damaged Press cushion pins replaced•Daily cushion pins seating area and mould wear and tear monitoring checked

PROBLEM IMPROVED

QUALITY IMPROVEMENT 10Target Date

15.06.10

BEFORE AFTER

•Die to be clamped with standard single block

•Die clamped with standard single blockPROBLEM IMPROVED

QUALITY IMPROVEMENT 11Target Date

30.06.10

BEFORE AFTER

•Standard block to be used to maintain tool height

•Standard blocks used to maintain tool heightPROBLEM IMPROVED

QUALITY IMPROVEMENT 12Target Date

10.06.10

BEFORE AFTER

Same bolt size to be use for upper & lower die plate .

Same bolt size used for upper & lower die plate

PROBLEM IMPROVED

QUALITY IMPROVEMENT 13Target Date

25.06.10

BEFORE AFTER

• Blank sheets to be stored in table for operator access

• Blank sheets stored in table for operator access

PROBLEM IMPROVED

QUALITY IMPROVEMENT 14Target Date

25.05.10

BEFORE AFTER

•Visual colour marking for tool control

•Visual colour marking provided for tool control

PROBLEM IMPROVED

QUALITY IMPROVEMENT 15Target Date

25.05.10

BEFORE AFTER

•Master defect sample to be marked with different colour

•Master defect sample marked with red colour

PROBLEM IMPROVED

QUALITY IMPROVEMENT 16Target Date

20.05.10

BEFORE AFTER

•Route card operation wise •Route card operation wise provided

PROBLEM IMPROVED

QUALITY IMPROVEMENT 17Target Date

25.05.10