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Training Topic Vs Name
S.no Name of Perso Designation Level 5s TS Positive att 7QC Tools
1 Ram oper oper Y N Y Y2 Shyam mgr top N Y Y Y
3 Ghanshyam supp. middle Y Y Y Y
4 Sonu oper oper Y Y N N
5 monu mgr top Y Y N N
6 Bhavesh mgr top N Y N N
7 Pintu engg middle N Y N N
8 Tinku engg middle Y Y N N
9 ratiram mgr top Y N N N
10 rajaram am top Y N Y Y11 ratanlal am top Y N Y Y
12 joshi dm top N Y Y Y
13 pk dm top N Y N Y
14 rajeev oper oper N Y N N
15 mandal oper oper N Y Y Y
16 miglani supp. middle N Y Y Y
17 parveen supp. middle N N Y Y
18 jangra ae middle N N N Y
19 vikasbh oper oper Y N Y Y
20 vabhav engg middle Y Y N N
21 anil engg middle Y Y Y N
22 ajit am top Y Y N Y
23 kky dm top Y Y Y Y
24 ashok am top Y Y N Y
25 teeka oper oper Y N Y N
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Kaizan
Y
N
Y
Y
Y
N
N
Y
YY
N
N
N
N
N
N
Y
Y
N
N
N
Y
Y
Y
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AA A B CMkt
gEngg Dev
2 Pre-Feasibility O O O O O
5 Cost Estimation O O O O O
10 BOM O O O O
17 Process FMEA O O O O O O O
18 Productivity Goals O O O O O
Work Instruction for Resposibility(APQP)
Purpose : To define the rank of new product for development & activities & responsibiliti
process change of existing items.
Scope : This WI is applicable for development of new product,Engg change and any Pr
Method : Description,Rank of Development and responsibility is defined as below
S.No Description
Development Respo
1 Reciept of drawing along with spec drg/ref.sample O O O O
3 Clarification from customer for incomplete info O O O O O O
4 Technical feasibility. O O O O O
6 Reciept of LOI from customer O O O O O
7 Preparation of PDF O O O O
8 Preparation of Timing Chart O O O O O
9 Process Flow Chart O O O O
11 Passed History Study O O O
12 Component Drawing O O O O
13 Drawing Review O O O O
14 Review of Process Flow chart O O O
15 Listing of special Characteristics O O O O O
16Evaluation of Regulatory/Statutory requirements,
environmental Health & Safety IssuesO O O O
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22 Tool Manufacturing O O O O
23 Gauge Testing Equipment O O O O
24 Sourcing Raw Material/BOPs O O O O O25 Sample Trial Run O O O O O O
26 Follow-Up Results during Product Development O O O O O
27 Review with Customer O O O O
28 Layout Plan O O
29 Component Procurement O O O O O
30 Ppk Study Plan O O O O
31 Operator Process Instruction O O O O
32 Logistic Study O O O O
33 Packaging Specifications O34 Pre-Launch control Plan O O
35 MSA Plan O O O O
36 Production Trail Run,Pilot Lot O O O O O
37 Process Product Validation O O O O O
38 Process Capability Evaluation O O O O O
39 MSA study O O O O
40 PPAP O O O
41 Customer Approval O O O O O
43 Production control Plan O O O O O
44 Production Source Approval O O O
Rank
AA
Legend
42 Feedback Analysis & Corrective Action O O O O O O
That whenever the Environment (Containing comtaminants like Metallic Chips,Dust) or
and the safety contents
Development Rank:
Details
BThat Whenever there happens to be a Minor Deviation in the Component produced so f
CThat whenever there happens to be extremely minor change in details related to the co
becomes non mandatory(It becomes more of checks in regard to monitoring of the poin
Absolutely new component : no Experience of Production so farA That the part happens to be similar to what had been produced so far but there happen
material,Machining Methodology,In the structure or in the function.
A component similar to the component produced so far but there happens to be
That whenever there happens to be changed in production site
That whenever the place/country of development happens to be different from the place
Review Required/Important from discussion
(Blank)
LEGENDS:
For Development Rank
Definition
Point to be Implemented
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Legend Definition
For Responsibility
Prime Responsibility
Co-Responsibility
00' New Issue
Rev.No. Description
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QA Prod Matls
O
O
Document No.
es for product development , Engg change and any
cess change of existing items.
nsibility
RemarksDocument
Reference
O O
O
O
O
O
O
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O O O
O O
OO O
O
O
O
O O
O O
O O O
O
O O
O
O
O
O
lse the degree of Moisture,Temperature,Pressure
O O O
ar(To implement only for inspection of initial product)
ponent ,so much so that even the inspection
s of variation in regard to 4M
to be large scale difference in raw
/country of production
oint of view
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19/8/2004
Date
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Advanced Product Quality Planning DateStatus Report Review No.:
Diamond Point:
Supplier Program
Location Model Year
Supplier Code Lead Part No.Risk Assessment Part Name
New: Site X Technology Process Eng. Level
Other Risks User Plant(s)
Team Members Company/Title E-Mail Phone/Fax
Build Level IPD Into Plant Status GYR Quantity Concurred P.I.S.T. P.I.P.C.
Date (MRD) Present History No. SC's No. CC's % %
G G
1Risks: 1 = No Risk 3 = medium Risk (PSW part submission date can still be achieved - Special effort necessary) 5 = high (PSW part submission date endangered)
APQP Elements GYR Risk Program Supplier Closed Resp. Remarks or
Status Evaluation Need Timing Date Engineer Assistance Required
Present History per Element Date Date Initials
1 Customer Input Requirements G G 4/15/2005 4/13/2005 4/14/2005 OW2 Agreed GQA G Y 4/15/2005 4/13/2005 TF
3 Product Feasibility G G 4/15/2005 4/13/2005 4/14/2005 AZ
4 Sourcing Decision G G 4/15/2005 4/13/2005 4/14/2005 OW
5 Change Management G G 5/20/2005 5/18/2005 AZ
6 Environmental-Management/ IMDS/ ELV G G 6/3/2005 6/1/2005 5/22/2005 TF
7 Prototype Build Control Plan G G 5/20/2005 5/18/2005 5/18/2005 TF
8 Design Verification Plan G G 4/29/2005 4/27/2005 4/27/2005 AZ
9* Facilities, Tools, Gauges G G 6/10/2005 6/8/2005 AZ
10* Design FMEA R R 5/13/2005 5/11/2005 AZ11* DFMA @ Customer level G G 5/20/2005 5/18/2005 5/18/2005 AZ
12* Drawings and Specifications (Design Freeze) G G 5/20/2005 5/18/2005 5/18/2005 AZ
13 Information about Subcontractors G G 4/22/2005 4/20/2005 4/20/2005 OW
14* Logistic Concept G G 4/29/2005 4/27/2005 4/28/2005 UE
15* Packaging Specification (Serial & Spare Parts) G G 5/20/2005 5/18/2005 5/2/2005 UE
16* Design Validation @ Supplier Level G G 5/13/2005 5/11/2005 5/11/2005 AZ
17* Design Validation @ Customer Level G G 5/20/2005 5/18/2005 5/18/2005 AZ
18* Measurement Syst. Analysis/ Measuring Agreem. G G 5/20/2005 5/18/2005 5/18/2005 TF
19 Definition of Team for Serial Support G G 6/3/2005 6/1/2005 6/1/2005 OW
20 Definition of Quality Reporting G G 6/3/2005 6/1/2005 6/1/2005 TF
21 Prelaunch Control Plan G G 4/29/2005 4/27/2005 4/27/2005 TF
1
1
1
3 In negociation
2 Points to be cleared
1
1 1 Gauge may be unnecessary
1
1
1
1
5 see below1
1
1
1
1
1
1
1
1
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Part Name:
Part Number
Clause No.1.3
Implementati
on date
TGR / TGW (PDCA Format)
Defect / Problem Incharge Action Taken Target Date
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Status
1st 2nd 3rd OK/NG
Effectiveness of Checking
Remarks
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Part Name __________________________________ Model _______________ Station _________________
Part Number________________________________ Customer _____________________________________________
Start date of Initial Supply Control ________________________________________________________________________
End Date of Initial Supply Control ________________________________________________________________________
Remarks.
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
Incharge ( Product Development)
Extended upto (If required) ______________________________________________________________________________
Reason for Extention _________________________________________________________________________________
Incharge ( Product Development)
INTIAL SUPPLY CONTROL
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Clause No.2.7
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________
________
_________
_________
__________
__________
__________
_________
___________
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Implemented Not Implemented
1 Is the assembly line, stage under "ICP" is identified
clearly --- "Under Initial Control Period" ?
YES
2 Are additional check points given in Supervisor
check sheet for " ICP" ?
YES
3 Are additional check points given in Operator check
sheet for " ICP" ?
YES
4 Are additional points in check sheet / WI for ICPclearly highlighted or is special identification of these
additional points done ( Star mark etc) ?
YES
5 Are the Operators and respective Initial Flow Incharge
aware of their / his responsibilities?
YES
6 Is the timing plan made detailing all the activities ? YES
7 Is follow up of respective activities being done as per
Timing Plan and is review status being updated in
Timing Plan and are remarks for any delay or
rescheduling recorded ?
YES
8 Is PDCA Approach followed for problem solving
during ICP ? ( Rejection Analysis , rejection trend , To
fillup the CM Sheet , to decide the actions and
YES
9 Is Process FMEA carried out ? YES
10 Is cut off limit of RPN decided for taking actions on
the basis of FMEA ?
YES
11 Is evaluation of Process capability done ?( Once in 3 months)
YES
12 Is supplier audit planned and is carried out at decided
frequency?
YES
13 Are operators being trained for the work they are
performing ? ( training record / training plan / Skill
matrix)
YES
14 Are Managers and Supervisors clear about their
added responsibilities ?
YES
15 Is problem solving technique used for the faced
problems ( inhouse , customer line rejection)
( See Counter Measure sheet History of possible
YES
Status
CHECK SHEET FOR " INITIAL CONTROL PHASE"
1) NAME OF THE PRODUCT UNDER " Production Preparation Phase" --- WASHER ASSY. WINDSHIELD (YC-5)
2) NAME OF THE CUSTOMER :--- MARUTI SUZUKI INDIA LIMITED
3) PART NUMBER :- 38400M68K00/K10
4) DATE OF STARTING OF " ICP" :-
5) TERMINATION DATE OF " ICP" ( Period for Initial Control ) :-
6) PROJECT LEADER / CFT LEADER :-
S No Points to be Implemented / Reviewed
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17 Are identification tags used to identify initial products
from the changed process and is the identification
controlled through out the subsequent supplier
process till despatch ?
18 Is Initial product supplied to customer with necessary
inspection reports and with FPP tag ?
19 Are all the instruments calibrated ?
20 Are all the fixtures validated ? ( Is Drawing available?
)
21 Is MSA study carried out ?
22 Are Breakdown trend maintained and is action plan
made to reduce breakdown ?
YES
Signature of Initial Flow Incharge :-
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Responsibility /Remarks
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Implemented
1 Are all the problems occuring before SOP are
resolved ans a recheck done to confirm that they
remain solved ?
2 Is any new problem arising in Initial Control Period
resolved ? ( Verify the concerned records)
3 Is cross verification of all the additional check
points given in Supervisor check / Operator check
sheet and Work Instructions sheet for " ICP" done ?Is
there still a need for these additional points ?
Are these documents revised before terminating the
ICP?
4 Is Cpk > 1.67 ( If not , is action decided to increase
the Cpk value? ) ( Verify from the SPC records)
5 Is ICP at supplier's end over. Are all the incomingparts related to ICP product OK ?
6 Are Acceptance Standard revised ( Remove the extra
check points -- if there is no quality issue during ICP )
7 Is History of all the problem faced during ICP
maintained ( CM , rejection trends , History of
possible reasons etc)
8 Are Control Plan , FMEA rocess Flow Diagram ,Work Instructions. Operator and Supervisor Check
sheets have been updated ( Highlight the marks
related to Customer Complaint , Customer Line
rejection or related to Critical Process)
9 Is the skill matrix of Operators and their Competency
records updated ?
10 Are the necessary Limit samples , Sketches available
on all the required stages as per Control Plan
11 Are all the jigs and fixtures suitable for their respective
CHECK SHEET FOR " TERMINATION OF INITIAL
1) NAME OF THE PRODUCT UNDER " Production Preparation Phase" ---
2) NAME OF THE CUSTOMER :---
3) PART NUMBER :-
4) DATE OF STARTING OF " ICP" :-
5) TERMINATION DATE OF " ICP" :-
6) PROJECT LEADER / CFT LEADER :-
S No Points to be Implemented / Reviewed St
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12 Are all the jigs and fixtures validated at regular
interval ?
13 Is History sheet of all the machines maintained ?14 Is time study carried out ? Are action taken for line
balancing ?
15 Is OEE carried out for this line ? Is the line capable of
meeting Customers requirements ?
16 Is MSA records updated as per Control Plan?
17 Is there any repeated Breakdown ?
18 Are all the machines suitable for their respective
usage ?
19 Are Production trial and Mass Production trial records
available ? ( Verify the records)
Signature of CFT Members :-
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Not Implemented
CONTROL PHASE"
atus Responsibility /Remarks
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Part Number _____________________ Part Name _
Control duration : From ___________________ To ________
Extension (if any) _________________________________
Reason of extension _________________________________
Details of initial supply control :
New component (Model) ___________________________
Design change (ECN number) ______________________
Process change :
Process parameter change Su
Tool/Die/Machine/Equipment change O
Layout change Re
S.No. Control Item UOM
Specificat
ion
R
c
1 Customer complaints numbers 0
2 Inprocess rejection ppm 30
3 Incoming rejection ppm 30
4 Cpk value 1.67
5
Result of c'measure taken
aginst problems during
production preparation
current vs
previous Effective
6
Result of c'measure taken
aginst problems during initial
supply control
current vs
previous Effective
7 Any other
Result of Initial Supply Control NG
Initial control checks can be terminated NO
Initial supply control period extended by da
Ap
C
INITIAL SUPPLY CONTROL SIGN O
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__________________
__________________
_________________
pplier change
erator change
located plant
esult at end of
ontrol duration Remarks
OK
YES
ys
proved by (Devp Incharge)
FF
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Part Name
Part Number
Reason of IPP
Date of Production
Inspected by
Signature
Clause No.
IPP Tags
Initial Part Product Tag
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3.2
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Sect ion / Department
List of Activities performed by Operator 1
Are the operator verification sheets completed daily by all shifts ?
Are the tagging procedures being followed?
Are the Non conforming rejection are located in the specified area.
Procedure for carrying activities done as per the Operation standard
Clause No.11
If Rating < 03, Operator counselling required, Training to be give
OBSERVANCE OF OPERATOR
Operator Name
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2 3 4 5
Rating Criteria
to Operator.
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SI NO.DATE OF
OCCURRENCEPART NAME
MODEL/
CUSTOMERDEFECT REPEAT NO
PLAN
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ROOT CAUSE ANALYSIS ACTION TO BE TAKENTAR
DATE
ACTUAL
CLOSURE
DATE
RESP.
CUSTOMER COMPLAINTS VERIFICATION CHECKSHEET
DO
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1 2 3 4 5 6 FMEACONTRO
L PLAN
INSPECTI
ON STD
WORK
INSTRUCTIO
NS
QUALITY
ALERT
FOLLOW UP / DATESHorizontal
Deployme
nt
INSTITUTIONALISE THE PROBLEM WITH UPDA
CHECK ACT
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LESSON
LEARNTREMARKS
ION OF FOLLOWINGS
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1 6
2 7
3 8
4 9
5 10
1 2 3 4 5 6 7 8 9 10
End Point
Unloading of Raw MaterialLoading of Finish
Goods
PART NAME:-
PART NO:-
MODEL:-
Team Menber
DEFECT POSSIBILITIES
Orientation
Proper Seating
Damage
Missing
Starting Point
Safety
Identification
Operation Missing
Reverse
Double
Wrong parts (different parts)
Date:-
Process Precision Check
OBSERVATIONSSl.No PROCESS STEPSDefect Possibilities
STATUSACTION RESPONSIBILITYTARGET
DATE
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Clause No 13
MAKE A PLAN FOR PRECISION PRECISION
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S.NOPARAMETER TO
CHECK1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 REMARKS
X
CHECKED BY
OK AFTER CORRECTION APPROVED BY
VERIFIED BY
OKLEGAND NG
DAILY INSPECTION OF INSTRUMENT / EQUIPMENT / MACHINE
MONTH:-
INSTRUMENT / EQUIPMENT / MACHINE NAME:-
CONTROL NO:-
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QA Production
Date Date
Time Time
Note: Retension period :
In Charge Prod. In Charge QA
Part Name
Part No
Model
QUALITY ALERT / FLASH NOTE
(Customer / In-house / Warranty / Supplier)
DEFECTS:-
PHOTO/SKETCH:-
ACTION REQUIRED:-
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Apr. May Jun Jul Aug Sep Oct Nov Dec Jan Feb
P
A
P
A
P
A
P
AP
A
P
A
P
A
P
A
P
A
S.No Topic Date
Month
YEAR Prepared By Verified By Approve
HigherMgt.
MiddleMg
t
Operatorlevel
ANNUAL TRAINING PLAN Vs ACHIEVEMENTNo. of
Persons
Faculit
yDurationTopicCat.
Next Date Sign.
Sign.
Total
Date
Reasion for Delay
Plan/
Actu
al
DepartmentFacilities
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Mar
By
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Parameter
No
Pr.
No
1 6
2 7
3 8
4 9
5 10
Parameter
No1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1
2
3
4
5
7
9
10
Opr. Sign.
Sup. Sign.
LEGAND X
Date Sketch (if any)Abnormality Action Taken Impl. Date Resp.
Prepared By Approved By
DAILY STARTUP CHECK SHEET(for Equipment/ Machine/ Instrument etc)
Name:- No:- Deptt./Section:- Last Call/ Maint. Date:- Call/ Maint. Due Date:- Resp.:-
Month
Parameter Specification Check Method Freq.Parameter Specification Check Method Freq.
OK AFTER CORRECTION APPROVED BYOK NG
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S.No Parameter to Check 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1
2
3
4
5
7
9
10
Opr. Sign.
Sup. Sign.
LEGAND X
Date
OK NG
Abnormality Action Taken Impl. Date Resp.
OK AFTER CORRECTION APPROVED BY
Sketch (if any)
DAILY STARTUP CHECK SHEET(for Equipment/ Machine/ Instrument etc)
Deptt./Section:- Resp.:-Control No:-Inst/Equi.Name:-
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1 2 3 4 5 6 7 8 9 10
Remarks
4 7
TOPIC
S.No EMP.NO PHOTO EMP.NAMECan work under supervision
Plan
Can handle independently
Actual
Can train other
SKILL MATRIX
Minium no.of person req. for skill level
Minium no.of person req. for skill level
Minium no.of person req. for skill level
Revised on:
De
cember
Ja
nuary
Fe
bruary
M
arch
Basic Knowledge only
Minium no.of person req. for skill level
Year
April
May
June
July
A
ugust
September
O
ctober
No
vember
1 A
2 B
3 C
DATE REASION FOR DELAY
4 D
NEW DATENAME
SIGN.
DATE