Abnormality Handling Module
MARUTI SUZUKI INDIA LIMITED
Quality Assurance Business Vertical
(C) 2019 Maruti Suzuki India Limited
1 Handling of Fallen Part
Fallen part may get
damage
Don`t keep Fallen part in Identify & Keep Fallen
OK/WIP bin part in Red Bin
(C) 2019 Maruti Suzuki India Limited
2 Handling of NG Part in inspection
Identify NG part with
Red mark & rejection
Tag
Part found
NG during
Inspection
NG
Keep NG Part in
Red Bin
Don’t keep NG part without Identify & keep NG part in
identification Red Bin
(C) 2019 Maruti Suzuki India Limited
3 Handling Set-Up NG Part
Part found NG during Set up
Identify NG part with Red
mark & rejection Tag
NG Set up Part
neither identified
nor kept in Red Put NG Set-Up
Bin Part in Red Bin
Don’t keep NG Set-up part Identify & Keep NG Set-up
unidentified part in Red Bin
(C) 2019 Maruti Suzuki India Limited
4 Handling of Unidentified Part
Unidentified part
Unidentified part kept in Red bin
Part kept in WIP Bin Part kept in OK Bin
Don’t put Unidentified part in Keep Unidentified part in
OK/WIP bin Red Bin
(C) 2019 Maruti Suzuki India Limited
5 Part Handling at Inspection table
Checked
parts
Unchecked
parts
Checked
Parts
Unchecked Part Checking --Single Piece
parts flow at inspection Table
Don’t keep checked and Keep checked and unchecked parts
unchecked parts together in separate bin &
on inspection table Follow single piece flow
(C) 2019 Maruti Suzuki India Limited
6 Handling of Power failure Part
Identify Part
Power with Red
marker and Tag
Failure
Part produced
during Power Failure
– Riveting NG
Part left
unidentified Keep Identified part in Red Bin
(produced during Power Failure)
Don’t leave Power failure part Identify & Keep Power
without identification failure Part in Red Bin
(C) 2019 Maruti Suzuki India Limited
7 Incomplete Process
INPUT OUTPUT
TEA LUNCH SHIFT Complete Cycle
- 4 Nut Welding
BREAK BREAK END
(Example)
Part left
without
Complete the cycle & keep part in
completing
WIP bin/Trolley
the Process : 2
Nut weld
Don’t leave the station without Complete the cycle before
completing the cycle leaving the station
(C) 2019 Maruti Suzuki India Limited
8 Incomplete Inspection
Part
Inspection at
PDI Station
TEA LUNCH SHIFT Put OK Part in Finished
BREAK BREAK END Good ( FG ) Bin
Put NG Part in Red Bin
Don’t
leave any
Incomplete part on
inspection the
Part left on inspection
the table table
Don’t leave the station without Complete the Inspection
completing the Inspection before leaving the station
(C) 2019 Maruti Suzuki India Limited
9 Packing Standard- Final part
Non standard Bin without Separator Standard Bin with Separator
Part storage Part storage
in wrong in OK
orientation orientation
Don’t store parts in Non Store parts in Standard
Standard Bin/Trolley Bin/Trolley
Don`t Keep Parts in wrong orientation Keep parts in bin as per standard
If Standard trolley/bin not available : Follow STOP-CALL-WAIT Rule
(C) 2019 Maruti Suzuki India Limited
10 Packing Standard - Child part
Child Parts supply on assembly line in non standard bin Parts should supply on assembly line in standard bin
Parts
storage
as per
standard
Parts quantity
Overflow /No Parts
Overflow
Don’t store parts in Non Standard
Store parts in Standard Bin
Packing
Store defined quantity in bin
Don`t keep excess parts in bin
If Parts received from store in Non standard packing :- Follow STOP-CALL-WAIT Rule
(C) 2019 Maruti Suzuki India Limited
11 Material Mix-Up
RH LH RH LH
RH & LH
Parts in Separate
one bin Bin for RH
from & LH
Store Parts
Separate
Child Bin for
Parts mix each type
up from of child
Store Part
Don’t keep different type of Keep different type of parts
parts in one Bin in Separate Bin
If Parts found mix : Follow STOP-CALL-WAIT Rule
(C) 2019 Maruti Suzuki India Limited
12 Traceability Abnormality Handling
Part Taking out
Part Under End after Testing
Of Line ( EOL )
Testing
Part Under End Of
Line ( EOL ) Testing
No Advance
printing of
Barcode Sticker
Barcode Stickers
printed in advance
Printing Barcode and paste one by
one when the part is OK in testing
Don`t Print Barcode Print single Barcode if Part is OK
in advance in EOL Testing (Ensure through Poka Yoke )
If Rule Violation : Follow STOP-CALL-WAIT Rule
(C) 2019 Maruti Suzuki India Limited
Abnormal Situation Handling
Help Me
असामान्य पररस्थिती मे
असामान्य पररस्थिकतयााँ
Rule
1. कबजली जािा
2. टू ल / मशीि ब्रेकडाउि प्रोसेस को
3. लगातार NG पाटट बििा(>2 nos) STOP रोककये
4. पोका योके फेल/NG
5. पाटट कफटमेंट हाडट सुपरवाईजर को
6. कजग क्लैस्पंग / डीए क्लैस्पंग िही ं CALL बुलाइये
7. रोबोट िे कफक्सचर मे Hit मारा
किर्दे श का
8. हवा/कूलेंट का ररसाव होिा
9. स्टोर से चाइल्ड पाटट खराब कमले
WAIT इं तजार कररये
10. स्टोर से चाइल्ड पाटट Mix कमले
11. कोई अन्य पररस्थिती, जो सामान्य िही ं
है
(C) 2019 Maruti Suzuki India Limited
Prepared by
MARUTI SUZUKI INDIA LIMITED
(C) 2019 Maruti Suzuki India Limited
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(C) 2019 Maruti Suzuki India Limited