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Abnormal Handling Module (English Version)

The document provides guidelines for handling abnormalities during automobile production. It outlines 11 situations where abnormalities may occur, such as fallen parts, non-conforming parts, incomplete processes, material mix-ups, and issues with traceability. For each situation, it describes the abnormality, identifies the correct way to handle it, and warns against improper handling which could compromise quality. The overall document instructs readers to properly identify, contain and manage any abnormal parts or situations according to standard procedures.
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© © All Rights Reserved
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88% found this document useful (8 votes)
8K views15 pages

Abnormal Handling Module (English Version)

The document provides guidelines for handling abnormalities during automobile production. It outlines 11 situations where abnormalities may occur, such as fallen parts, non-conforming parts, incomplete processes, material mix-ups, and issues with traceability. For each situation, it describes the abnormality, identifies the correct way to handle it, and warns against improper handling which could compromise quality. The overall document instructs readers to properly identify, contain and manage any abnormal parts or situations according to standard procedures.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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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


“The content of this document is exclusive property of MSIL. Unauthorized copying,
reproduction and circulation is strictly prohibited.”

(C) 2019 Maruti Suzuki India Limited

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