1. DATE OF AUDIT : 19 SEP 2008
2. AUDITOR :
HMI: SARAVANAKUMAR
3. IMPROVEMENT PLAN SUBMISSION DATE :
4. SIGNATURE
BENCH MARK GAP ANALYSIS - HM AUTO INDUSTRIES (SL Lumax)
BENCH MARK GAP ANALYSIS - HM AUTO INDUSTRIES (SL Lumax)
HM AUTO SL LUMAX HMI
SL
NOCategory
Plan
Completed Remaining
Monthly Completion
Trend
Initial Added Total 09/08 10/08 11/08 12/08
1 Material
2 Machine
3 Method
4 Man
5 3C / 5S
Total
IMPROVEMENT STATUS
BENCHMARK COMPANY H. M Auto Industries
Functional Layout, no back and forth movement
Subsequent operations not linked
0101 FUNCTIONAL LAYOUTArea SHOP FLOOR
Resp Vijayakumar / Magesh
Target Date 15/11/08
BENCHMARK COMPANY H. M Auto Industries
Painted shop floor with effective 3C/5S activities
3C/5S (Press shop standards
not available)
0202 SHOP FLOOR PAINTINGArea SHOP FLOOR
Resp Vijayakumar/ Magesh/ Saleem
Target Date 15/11/08
BENCHMARK COMPANY H. M Auto Industries
Incoming Inspection area with trends display
Area not identified for Incoming Inspection
0303 SUPPLIER CONTROLArea INCOMING INSP.
Resp Magesh/ Saleem
Target Date 10/11/08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Incoming inspection flow chart displayedIncoming inspection flow chart
not available
0404 RECEIVING INSPECTIONArea INCOMING INSP.
Resp MAGESH
Target Date 20.10.08
BENCHMARK COMPANY H. M Auto Industries
Incoming Inspection as per Inspection Std
AOI not available with the sub supplier, Regular inspection not carried out
0505INCOMING INSPECTION
– CHILD PARTS
Area INCOMING INSP.
Resp MAGESH
Target Date 15.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Raw material, child part master sample with validity
Master samples not available for
sub supplier parts
0606 MASTER SAMPLEArea INCOMING INSP.
Resp SALEEM / MAGESH
Target Date 1.11.08
MASTER SAMPLES
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Packing standardized for incoming partsPacking not standardized for raw
material / sub supplier parts
0707 RECEIVING INSPECTIONArea INCOMING INSP.
Resp MAGESH
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
Supplier rejections analyzed and
counter measures verifiedSupplier rejection reporting system and
proper procedure not available
0808 SUPPLIER REJ. ANALYSISArea INCOMING INSP.
Resp Magesh / Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Storage area with FIFO racks for child parts
Storage area identified, FIFO not in practice
0909 CHILD PART STORAGEArea R/M STORES
Resp Vijayakumar / Magesh/ Saleem
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
R/m stock status with FIFO system FIFO Board displayed with alerts
1010INCOMING MATERIAL
STOCK WITH FIFO
Area R/M STORES
Resp Vijayakumar
Target Date 10.07.08
BENCHMARK COMPANY H. M Auto Industries
Coils stored properly with identification Keeping coils on to the floor
1111 R/M STORAGEArea R/M STORES
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Chowel photo
Storage racks available for steel strips, location identified, stock monitored
Raw Material storage and FIFO system not in proper
1212 R/M STORAGEArea R/M STORES
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Material identification well definedIdentification tag available for some raw materials, basic information not covered in tags
1313 R/M STORAGEArea R/M STORES
Resp Magesh / Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Wooden support to eliminate damage Chances of scratch is more
1515 COIL STORAGEArea R/M STORES
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Fork lift operator can move around easily
1717 MIRROR FOR SAFETYArea R/M GANG WAY
Resp Saleem
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
Welding line organized with functional layout & visual controls
Welding line not organized properly
1818 WELDING LINE SET UPArea WELDING LINE
Resp Vijayakumar / Magesh/ Saleem
Target Date 25.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Enough lighting, proper ventilation to avoid operator fatigue
Additional lighting & ventilation, proper ventilation to avoid operator
fatigue
1919 SAFETY MEASURESArea WELDING LINE
Resp Vijayakumar / Saleem
Target Date 25.11.08
BENCHMARK COMPANY H. M Auto Industries
My Machine Concept will be introduced
2020 MY MACHINE CONCEPTArea Incoming Storage
Resp Vijayakumar
Target Date 20.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Detailed machine preventive maintenance check sheet
Preventive maintenance check sheet not available
2121 MACHINE MAINTENANCEArea M/C TABLE
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Machine check points highlighted on the machine
2222 CHECK POINTS ON M/CArea MACHINE
Resp Vijayakumar/ MAGESH
Target Date 5.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Critical spares list prepared and maintained
2323 M/C CRITICAL SPARESArea MACHINE
Resp Vijayakumar
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
2424PROCESS PARAMETER MONITORING
Area Machine
Resp Magesh
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
2525PROCESS PARAMETER MONITORING
Area Machine
Resp Magesh
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
Work instruction and process parameters not displayed
2626PROCESS PARAMETER MONITORING
Area Machine
Resp Magesh
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Recommend to replace a single tank to parallel connection
2727PROCESS PARAMETER MONITORING
Area Incoming Storage
Resp Saleem
Target Date 30.11.08
BENCHMARK COMPANY H. M Auto Industries
Electrode coil not protected from atmosphere
2828PROCESS PARAMETER MONITORING
Area Machine
Resp Vijayakumar
Target Date 20.10.08
BENCHMARK COMPANY H. M Auto Industries
Unit description different
litre / min flow rate
2929PROCESS PARAMETER MONITORING
Area Incoming Storage
Resp Magesh
Target Date 7.10.08
BENCHMARK COMPANY H. M Auto Industries
3030MACHINE STATUS – VISUAL DISPLAY
Area Machine
Resp Vijayakumar
Target Date 10.11.08
MACHINE STATUS DISPLAY
BENCHMARK COMPANY H. M Auto Industries
Welder certificate not available
3131 WELDER CERTIFICATIONArea Welding
Resp Vijayakumar / Saleem
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Welding parameter specification not available, refer to STD
3232 WELDER CERTIFICATIONArea Welding
Resp Magesh
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
3333 GRAVITY CHUTEArea Welding
Resp Vijayakumar / Saleem
Target Date 25.11.08
BENCHMARK COMPANY H. M Auto Industries
Recommended to install a gravity chute
3434 PRODUCTION LINE UPArea Welding
Resp Vijayakumar / Saleem
Target Date 25.11.08
CHUTE
BENCHMARK COMPANY H. M Auto Industries
All types of safety wearing provided Poor man safety
3535 PERSONAL SAFETYArea Welding
Resp Saleem / Vijayakumar
Target Date 20.11.08
BENCHMARK COMPANY H. M Auto Industries
3636 HANDLING OF WIP PARTArea Welding
Resp Vijayakumar
Target Date 25.11.08
BENCHMARK COMPANY H. M Auto Industries
Rubber sleeve provided at goose neck area
3737 WELDING – JOB REPORTArea Welding
Resp Vijayakumar
Target Date 30.10.08
RUBBER SLEEVE
BENCHMARK COMPANY H. M Auto Industries
3838 NOZZLE CLEANINGArea Welding
Resp Vijayakumar
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Periodic jig maintenance, Inspection
(Plan Vs Actual)
3939 JIG MAINTENANCEArea MACHINE
Resp Vijayakumar/ MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
4040 WIRE FEEDER GUIDEArea Welding
Resp Vijayakumar
Target Date 15.10.08
BENCHMARK COMPANY H. M Auto Industries
Poorly routed cable
4141 EARTH CABLE ROUTINGArea Welding
Resp Vijayakumar
Target Date 30.10.08
POOR EARTHING
BENCHMARK COMPANY H. M Auto Industries
4242PROCESS MONITORING –
GAS FLOW METER
Area Welding
Resp Magesh
Target Date 30.10.08
GAS FLOW METER
BENCHMARK COMPANY H. M Auto Industries
4343 WELDING – JOB REPORTArea Welding
Resp Magesh
Target Date 30.10.08
PARTITION
BENCHMARK COMPANY H.M AUTO INDUSTRIES
4444CHIP REMOVAL
PROCEDURE
Area Welding
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
Master samples and defective samples not displayed
4545MASTER, DEFECTIVE, F/M/L SAMPLES DISPLAY
Area Incoming Storage
Resp Magesh/ Saleem
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
4646 WELDING – JOB REPORTArea Welding
Resp Magesh
Target Date 30.10.08
JOB REPORT
BENCHMARK COMPANY H. M Auto Industries
4747REJECTION TREND DISPLAY – CELL WISE
Area Quality
Resp Magesh
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
1818 NC PART CONTROLArea Quality
Resp Magesh
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Poor 3C & 5S of rejected part bin
4949 REJECTION STORAGEArea Rejection
Resp Maesh
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
5050 NC PART HANDLINGArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
5151 Q ALERT DISPLAY ON M/C Area Incoming Storage
Resp Magesh
Target Date 30.10.08
Q ALERTDISPLAY
BENCHMARK COMPANY H. M Auto Industries
5252INSPECTION TABLE FOR ALL MACHINES
Area Incoming Storage
Resp Magesh / Saleem
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Clamping screw length oversize
5353INSPECTION TABLE FOR ALL MACHINES
Area Incoming Storage
Resp Vijauakumar
Target Date 30.9.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Break down status monitored
5454 BREAK DOWN STATUSArea PRODUCTION
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Idle time monitored for all machines
5555MACHINE IDLE TIME
MONITORING
Area PRODUCTION
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Direction of flow marking with colour coding
5656FLOW MEDIUM / DIRECTION MARKING
Area WATER LINE
Resp Vijayakumar / SALEEM
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
Material over stacking (WIP)
5757 IN-PROCESS STORAGEArea WIP
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Material over stacking (WIP)
5858 IN-PROCESS STORAGEArea WIP
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Big sized wooden bins used for
in-process
5959 WIP STORAGE & HANDLINGArea WIP
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Over stacking, more chances of component damage
6060 WIP STORAGE & HANDLINGArea WIP
Resp Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Rust on the component (awaiting for inspection)
6161DUST COVER FOR PLATED PARTS
Area WIP
Resp Vijayakumar
Target Date 15.11.08
Transparent LDPE Lid to avoid Dust
BENCHMARK COMPANY H.M AUTO INDUSTRIES
TROLLIES WITH CASTERS FOR EASY HANDLING - WIP
6262TROLLIES FOR EASY
HANDLING
Area SHOP FLOOR
Resp SALEEM / MAGESH
Target Date 10.07.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Fork lift for material handling to avoid fatigue
6363FORK LIFT FOR LOADING /
UNLOADING
Area SHOP FLOOR
Resp SALEEM / MAGESH
Target Date 10.07.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
RED LINE PROVIDED IN TROLLIES FOR MAX. STACK HEIGHT
6464STACKING LEVEL IN
TROLLIES
Area SHOP FLOOR
Resp Vijayakumar
Target Date 25.10.08
BENCHMARK COMPANY H. M Auto Industries
Traceability not available from raw material incoming stage to F/G dispatch
6565 LOT TRACEABILITYArea Incoming Storage
Resp Magesh
Target Date 25.11.08
BENCHMARK COMPANY H. M Auto Industries
6666 ASSY SHOP SET UPArea Incoming Storage
Resp Saleem / Vijayakumar / Magesh
Target Date 25.22.08
BENCHMARK COMPANY H. M Auto Industries
6767 FINAL INSP. STANDARDArea Incoming Storage
Resp Magesh
Target Date 20.10.08
FINAL INSP STD
BENCHMARK COMPANY H. M Auto Industries
Inspection area needs more light
7070 FINAL INSP. AREA LIGHTINGArea Incoming Storage
Resp Saleem / Vijayakumar
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
Master samples to be prepared with master list / due date /
location
6868 MASTER SAMPLESArea Incoming Storage
Resp Magesh / Saleem
Target Date 1.11.08
MASTER SAMPLES
BENCHMARK COMPANY H.M AUTO INDUSTRIES
FINISHED GOODS STOCK STATUS WITH VISUAL CONTROLS
6969 F/G STOCK STATUSArea F/G STORAGE
Resp SALEEM / MAGESH
Target Date 10.07.08
BENCHMARK COMPANY H. M Auto Industries
Inspection area needs more light
7171 FINAL INSP. AREA LIGHTINGArea Incoming Storage
Resp Vijayakumar / Saleem
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
Rack of Weld bead width
7272 FINAL INSP. AREA LIGHTINGArea Welding
Resp Vijayakumar
Target Date 20.10.08
BENCHMARK COMPANY H. M Auto Industries
NG parts out going without any proper check
7373 FINAL INSP. AREA LIGHTINGArea Incoming Storage
Resp Magesh
Target Date 20.10.08
BENCHMARK COMPANY H. M Auto Industries
7474 REJECTION TREND DISPLAYArea Incoming Storage
Resp Magesh
Target Date 25.10.08
BENCHMARK COMPANY H. M Auto Industries
7575INSPECTION TABLE FOR DESTRUCTIVE TEST
Area Welding
Resp Vijayakumar / Saleem
Target Date 20.11.08
BENCHMARK COMPANY H. M Auto Industries
7676 SAMPLES RETAININGArea Incoming Storage
Resp Magesh
Target Date 20.11.08
BENCHMARK COMPANY H. M Auto Industries
7777 TRANING ROOMArea Incoming Storage
Resp Magesh / Saleem
Target Date 25.11.08
BENCHMARK COMPANY H. M Auto Industries
7878 CALIBRATION STICKERArea Incoming Storage
Resp Magesh
Target Date 30.10.08
BENCHMARK COMPANY H. M Auto Industries
7979 CHECKER, JIG STORAGEArea Incoming Storage
Resp Magesh / Vijayakumar
Target Date 15.11.08
BENCHMARK COMPANY H. M Auto Industries
Testing facilities not sufficient (Hardness testing, welding penetration
testing & roughness testing not available)
8080 INSPECTION & TESTINGArea Incoming Storage
Resp Magesh / Saleem
Target Date 30.11.08
BENCHMARK COMPANY H. M Auto Industries
8181 TOOL STORAGEArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
Tooling rack to be modified to minimize the area of contact bet. the tool and the rack
8282 TOOL STORAGEArea Incoming Storage
Resp
Target Date 7.10.08
BENCHMARK COMPANY H. M Auto Industries
There is no place / identification for tools
8383 TOOL STORAGEArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
Finished goods storage area not organized
8484 FINISHED GOODS STORAGEArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 10.11.08
BENCHMARK COMPANY H. M Auto Industries
No QC identification tag on the pallet
8585 FINISHED GOODS STORAGEArea Incoming Storage
Resp Magesh
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Improper bin leads more people to handle, Needs to improve size and type of bins
8686 RECEIVING INSPECTIONArea INCOMING INSP.
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Sensors provided between ram & bed
to avoid accidentSensors Provided
8787 SAFETY MEASURESArea WATER LINE
Resp SALEEM / MAGESH
Target Date 25.06.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
First, middle, last samples - top
Master, defective samples –second
Checker – bottom
8888 SAMPLES DISPLAYArea INSP. TABLE
Resp SALEEM / MAGESH
Target Date 15.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool daily preventive maintenance
check sheet
8989 TOOL CHECK SHEETArea M/C TABLE
Resp Vijayakumar/ MAGESH
Target Date 25.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
OPERATORS PROPERLY TRAINED AND CERTIFIED
9090 WELDER CERTIFICATIONArea MACHINE
Resp SALEEM / MAGESH
Target Date 15.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Cover provided for welding coil to isolate it from surrounding
9191COVER FOR WELDING COIL
(MIG WELDING)
Area MACHINE
Resp Vijayakumar/ MAGESH
Target Date 30.09.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool maintenance schedule displayed & followed
9292TOOL MAINTENANCE
SCHEDULE
Area MOULD STORAGE
Resp Vijayakumar/ MAGESH
Target Date 25.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool layout display for traceability
9393 TOOL LAYOUTArea MOULD STORAGE
Resp Vijayakumar/ MAGESH
Target Date 25.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool name plate provided on all tools
9494 TOOL IDENTIFICATIONArea MOULD STORAGE
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
9595TOOLING TABLE WITH
RUBBER MAT
Area MOULD STORAGE
Resp SALEEM / Vijayakumar
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
9696TOOL PAINTING – MODEL
WISE COLOUR
Area MOULD STORAGE
Resp SALEEM / Vijayakumar
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Critical spares list prepared and maintained
9797 TOOLING CRITICAL SPARESArea MACHINE
Resp Vijayakumar
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Detailed mould history card
9898 TOOL HISTORY CARDArea MOULD STORAGE
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
All components revalidated periodically to monitor the process / tooling consistency
9999COMPONENT
REVALIDATION
Area SHOP FLOOR
Resp MAGESH
Target Date 25.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
CHOWEL PHOTO
Weld penetration tested samples displayed
100100 FMEA SAMPLES DISPLAYArea SHOP FLOOR
Resp MAGESH
Target Date 20.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Inspection plan based on quality issues
101101SAMPLING INSPECTION PLAN
Area FINAL INSP.
Resp MAGESH
Target Date 25.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Inspection standard prepared with all quality check points
102102FINAL INSPECTION
STANDARD
Area FINAL INSP.
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Control plan & work instruction in line with AOI
103103 INSPECTION AGREEMENTArea SHOP FLOOR
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Quality check points for all parts
104104 PDI STANDARDArea PDI
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Customer approved packing standard displayed in PDI area
Packing standards not available
105105 PACKING STANDARD AT PDIArea PDI
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Trend charts displayed in shop floor
106106 PERFORMANCE DISPLAYSArea SHOP FLOOR
Resp MAGESH
Target Date 10.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Customer complaint free days monitored
107107CUSTOMER COMPLAINT
MONITORING
Area SHOP FLOOR
Resp MAGESH
Target Date 30.10.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Finished parts stored & identified properly
Proper location (layout) not yet identified for F/G storage
108108FINISHED PART FIFO/
IDENTIFICATION
Area F/G STORAGE
Resp Vijayakumar/ MAGESH
Target Date 15.11.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
NC parts located on the customer complaint review area
Customer complaints not reviewed properly through daily meeting
109109CUSTOMER COMPLAINT
REVIEW
Area SHOP FLOOR
Resp SALEEM / MAGESH
Target Date 30.9.08
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Plant safety status displayed Safety visual control not displayed
Area SHOP FLOOR
Resp Vijayakumar/ Saleem
Target Date 20.11.08110110
PLANT SAFETY STATUS DISPLAY