MARUTI SUZUKI INDIA LIMITED Provisional audit report

Issue Deptt. QA-VSA Prepared Verified Approved

Vendor Quality System Audit Report
Date of Issue Mr.Paramjit Mr. Prag
Zafar / Ankush
Copy to Supplier name 31st Jan'22 Singh Basil

QAPQ 1 Supplier Attendant Name Audit Date

Deusch Kyosei Engineering Pvt. Ltd., Chennai Mr.Ramesh Chandra Panda - Plant Head
Vendor 1 Mr.Ashutosh Gupta - DGM Corp 6th - 7th Jan'22
Mr.Rahul Sharma - Maintenance/Production
SC 1 Supplier code New Plant (YFG) Mr.Manoj Yadav - Quality Audit Person
Mr.Sokesh Kumar - NPD
(Audit Score) Zafar Javed
Ankush Bhasker
Achieved Score： #REF!

×１００ = #REF!
Total Score： ### Description Current Previous
22 Audit Score #REF! NA
.. Total 3
RR Category Green NA
ee
gg Part Number： 82160-76T00, 76430-76T00
uu Subject: Vendor System Audit
ll Part Name: Cable Comp.Hood Latch Release, Cable Comp.Fuel Lid Opene
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1
t1 t This is a provisional audit report. Final score and Category may revise subject to Gemba audit observations.
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o 1. APQP time plan review system need to be improved.
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F003-3 QA/MT Ver. 5
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t Improvement Submission
Pre decided negative marking (if any) 0 7th Feb'22 Last Audit Rating NA
Date

F003-3 QA/MT Ver. 5

 LEAN MANUFACTURING GLASS WALL
Yesterday Plan Yesterday Actual Remarks Today Plan Today Actual
PRODUCTION
PLAN - INPUT
4600 4600 4600 4800

Yesterday Plan Yesterday Actual Remarks Today Plan Today Actual

PRODUCTION
PLAN- ASSY.
4050 4200 4050 4200
Yesterday
Why-Why Corrective Action Preventive action Preodic Action
MACHINE Breakdown
BREAKDOWN

IQC In- Process Final Customer Market

Quality
No No rejection 3 NOS No N/A

Material/ Child Part Mould / Tooling Maintenance Packing

Consumable
Shortage
ZYTEL, INNER(1.2)
YES NO NO NO
WHITE BOOT
Poka -Yoke kaizen
Improvement
OK NO
Yesterday Plan Yesterday Actual Today Plan Weekly Plan Next Weekly Plan
Dispatch
 Dispatch
As per magna
NO NO NO NO
portal

Condition PM Problem Countermeasure Improvement

Mould
OK OK NO - -

Working Condition Air Pressure Air Buzzers Light/ Signal Air Leakage
Poka -Yoke
Validation
Ok Ok Ok OK YES

Today Weekly Monthly Power Factor Monthly Chart

Electric
consumption
1080 kwh 98

Yesterday Plan Yesterday Actual Remarks Today Plan Today Actual

DCM Plan
120min inner
4000 3090 4000 4000
shortage
DCM Monthly DCM Monthly
PM Plan PM Actual Other
PM Plan PM Actual
PM Plan
NO NO NO NO NO

Staff walfare Accident Admin & Shortage

Other
NO NO NO
 RESPONSIBLE
PERSON

Remarks
GOPAL

Remarks
GOPAL

Remarks
MAHENDER

Remarks
MANOJ
Silver
strike(3059766)

Remarks
VARUN SHARMA
-

Remarks

Remarks
SARVANA
 SARVANA

Remarks
MAHENDER

Remarks
MANOJ

Remarks
MAHENDER

Remarks
GOPAL

Remarks
MAHENDER

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS WALL
Yesterday Plan Yesterday Actual Remarks Today Plan Today Actual
PRODUCTION
PLAN - INPUT
4600 4800 4600 4600

Yesterday Plan Yesterday Actual Remarks Today Plan Today Actual

PRODUCTION
PLAN- ASSY.
4050 4200 4050 4200
Yesterday
Why-Why Corrective Action Preventive action Preodic Action
MACHINE Breakdown
BREAKDOWN
NO - - - -

IQC In- Process Final Customer Market

Quality
NO 0 8 NO NO

Material/ Child Part Mould / Tooling Maintenance Packing

Consumable
Shortage
ZYTEL, INNER(1.2)
YES NO NO NO
WHITE BOOT
Poka -Yoke kaizen
Improvement
OK NO
Yesterday Plan Yesterday Actual Today Plan Weekly Plan Next Weekly Plan
Dispatch
 Dispatch
As per magna
NO NO NO NO
portal

Condition PM Problem Countermeasure Improvement

Mould
OK OK NO - -

Working Condition Air Pressure Air Buzzers Light/ Signal Air Leakage
Poka -Yoke
Validation
YES OK OK OK NO

Today Weekly Monthly Power Factor Monthly Chart

Electric
consumption
1086 KWH - - 97 -

Yesterday Plan Yesterday Actual Remarks Today Plan Today Actual

DCM Plan
4000 4000 4000 4225
DCM Monthly DCM Monthly
PM Plan PM Actual Other
PM Plan PM Actual
PM Plan
NO NO NO NO NO

Staff walfare Accident Admin & Shortage

Other
NO NO NO
 RESPONSIBLE
PERSON

Remarks
GOPAL

Remarks
GOPAL

Remarks
MAHENDER

Remarks
MANOJ
Silver
strike(3059766)

Remarks
VARUN SHARMA
-

Remarks

Remarks
SARVANA
 SARVANA

Remarks
MAHENDER

Remarks
MANOJ

Remarks
MAHENDER

Remarks
GOPAL

Remarks
MAHENDER

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks Today Plan
PRODUCTION
PLAN - INPUT
4600 4600 4600

Yesterday Plan Yesterday Actual Remarks Today Plan

PRODUCTION
PLAN- ASSY.
4050 4200 4050
Yesterday Why-Why Corrective Action Preventive action
MACHINE Breakdown
BREAKDOWN
NO - - -

IQC In- Process Final Customer

Quality
1 LOT RECEIVED 0 0 NO

Material/
Consumable Child Part Mould / Tooling Maintenance
Shortage
YES ZYTEL, INNER(1.2) NO NO
WHITE BOOT
Poka -Yoke kaizen
Improvement
 Yesterday Plan Yesterday Actual Today Plan Weekly Plan
Dispatch
NO NO 8640 -

Condition PM Problem Countermeasure

Mould
OK OK NO -

Working Condition Air Pressure Air Buzzers Light/ Signal

Poka -Yoke
Validation
YES OK OK OK

Today Weekly Monthly Power Factor

Electric
consumption
1097 - - 99

Yesterday Plan Yesterday Actual Remarks Today Plan

DCM Plan
4000 4225 4000
DCM Monthly DCM Monthly
PM Plan PM Actual PM Plan PM Actual
PM Plan
NO NO NO NO

Staff walfare Accident Admin & Shortage

Other
NO NO NO
LASS WALL RESPONSIBLE
PERSON

Today Actual Remarks

GOPAL
4600

Today Actual Remarks

GOPAL
4200

Preodic Action Remarks

MAHENDER
-

Market Remarks
MANOJ
NO NO

Packing Remarks
VARUN SHARMA
NO -

Remarks
Next Weekly Plan Remarks
SARVANA
- -

Improvement Remarks
MAHENDER
-

Air Leakage Remarks

MANOJ
NO -

Monthly Chart Remarks

MAHENDER
-

Today Actual Remarks

GOPAL
4065

Other Remarks
MAHENDER
NO

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 4200

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
OCM Tool not cleaned Tool clean

IQC In- Process Final

Quality
NO 0 0

Material/
Consumable Child Part Mould / Tooling
Shortage
YES ZYTEL, INNER(1.2) NO
WHITE BOOT,DELRIN
Poka -Yoke kaizen
Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch
8640 8640 NO

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1106 - -

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 4065
DCM Monthly
PM Plan PM Actual PM Plan
PM Plan
NO NO NO

Staff walfare Accident Admin & Shortage

Other
RING GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4600

Today Plan Today Actual Remarks

GOPAL
4050 4200

Preventive action Preodic Action Remarks

MAHENDER
check tool status -

Customer Market Remarks

MANOJ
NO -

Maintenance Packing Remarks

VARUN SHARMA
NO NO -

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- -

Countermeasure Improvement Remarks

MAHENDER
- -

Light/ Signal Air Leakage Remarks

MANOJ
OK NO

Power Factor Monthly Chart Remarks

MAHENDER
98 -

Today Plan Today Actual Remarks

GOPAL
4000 4150
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO NO

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 4200

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
OCM Temp.drop increase temp

IQC In- Process Final

Quality
NO 0 1

Material/
Consumable Child Part Mould / Tooling
Shortage INNER(1.2)
YES WHITE BOOT NO

Poka -Yoke kaizen

Improvement
Improvement

Yesterday Plan Yesterday Actual Today Plan

Dispatch
NO NO NO

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1119 - -

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 4150
DCM Monthly
PM Plan PM Actual PM Plan
PM Plan
NO NO NO

Staff walfare Accident Admin & Shortage

Other
RING GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4600

Today Plan Today Actual Remarks

GOPAL
4050 4200

Preventive action Preodic Action Remarks

MAHENDER
check tool status -

Customer Market Remarks

MANOJ
NO - 3053558-1
(outer damage)

Maintenance Packing Remarks

VARUN SHARMA
NO NO -

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- -

Countermeasure Improvement Remarks

MAHENDER
- -

Light/ Signal Air Leakage Remarks

MANOJ
OK NO

Power Factor Monthly Chart Remarks

MAHENDER
98 -

Today Plan Today Actual Remarks

GOPAL
4000 4200
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO NO

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 4200

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN

IQC In- Process Final

Quality
0 0 1

Material/
Consumable Child Part Mould / Tooling
Shortage INNER(1.2) ,
YES WHITE BOOT, ZINC NO
OUTER
Poka -Yoke kaizen
Improvement
Improvement

Yesterday Plan Yesterday Actual Today Plan

Dispatch
NO NO NO

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1132 KWH 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 4200
DCM Monthly
PM Plan PM Actual PM Plan
PM Plan
NO NO NO

Staff walfare Accident Admin & Shortage

Other
RING GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4600

Today Plan Today Actual Remarks

GOPAL
4050 4050

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks

Latch SideRing MANOJ
0 Mark
(3053559)
Maintenance Packing Remarks
VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA

Countermeasure Improvement Remarks

MAHENDER
- -

Light/ Signal Air Leakage Remarks

MANOJ
OK NO

Power Factor Monthly Chart Remarks

MAHENDER
99

Today Plan Today Actual Remarks

GOPAL
4000 1810 INNER SHORTAGE
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 4050

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
NO

IQC In- Process Final

Quality
0 0 1

Material/
Consumable Child Part Mould / Tooling
Shortage INNER(1.2) ,
YES WHITE BOOT, ZINC NO
OUTER,FOAM(100mm)
Poka -Yoke kaizen
Improvement
Improvement

Yesterday Plan Yesterday Actual Today Plan

Dispatch
NO NO NO

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1141 KWH 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 1810 inner shortage
DCM Monthly
PM Plan PM Actual PM Plan
PM Plan
NO NO NO

Staff walfare Accident Admin & Shortage

Other
RING GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4700

Today Plan Today Actual Remarks

GOPAL
4050 4050

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks

MANOJ
0 - -

Maintenance Packing Remarks

VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- - -

Countermeasure Improvement Remarks

MAHENDER
- -

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER
98 - -

Today Plan Today Actual Remarks

GOPAL
4000 MAGANA340
LINE INNER SHORTAGE SO YFG LINE RUNNING
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

Remarks
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4700

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 4050

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN

IQC In- Process Final

Quality
0 0 0

Material/
Consumable Child Part Mould / Tooling
Shortage
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
Improvement

Yesterday Plan Yesterday Actual Today Plan

Dispatch
NO NO NO

Condition PM Problem
Mould

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1151kwh 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 340 Inner shortage 1.2
DCM Monthly
PM Plan PM Actual PM Plan
PM Plan

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
ING GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4600

Today Plan Today Actual Remarks

GOPAL
4050 3200White boot and 1.2 inner shortage

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks

MANOJ
0 - -

Maintenance Packing Remarks

VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- - -

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER
98

Today Plan Today Actual Remarks

GOPAL
4000 535 Inner shortage yfg line runing
DCM Monthly
PM Actual Other Remarks
MAHENDER

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLASS W
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 3200 White boot and 1.2 inner shortage

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
NO

IQC In- Process Final

Quality
O O O

Material/
Consumable Child Part Mould / Tooling
Shortage day wise
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
Improvement

Yesterday Plan Yesterday Actual Today Plan

Dispatch
NO NO NO

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES

Today Weekly Monthly

Electric
consumption
1160 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 535 Inner shortage yfg line runing
DCM Monthly
PM Plan PM Actual PM Plan
PM Plan
NO NO NO

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
ING GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4600

Today Plan Today Actual Remarks

GOPAL
4050 magna
450 line material shortage so yfg line running

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks

MANOJ
0 - -

Maintenance Packing Remarks

VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- - -

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ

Power Factor Monthly Chart Remarks

MAHENDER
0.97

Today Plan Today Actual Remarks

GOPAL
4000 385 Inner shortage yfg line runing
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLAS
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 450 magna line material shortage so yfg line running

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
NO

IQC In- Process Final

Quality
NO 8 NOS 3 NOS
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch
375 375 225

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1170 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 385 Inner shortage yfg line runing

PM Plan PM Actual DCM Monthly PM Plan

PM Plan
NO NO NO

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
2000 1900 material shortage

Today Plan Today Actual Remarks

GOPAL
1000 300
magna line material shortage so yfg line running

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

FINAL 76430-76T00-
NO - 1NO
INNER DAMAGE-1
Maintenance Packing Remarks
VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- -

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO

Power Factor Monthly Chart Remarks

MAHENDER
0.98

Today Plan Today Actual Remarks

GOPAL
2000 1450 YFG line running
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLAS
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
2000 1900 material shortage

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
1000 300 magna line material shortage so yfg line running

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
NO

IQC In- Process Final

Quality
NO NO 7 NOS
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch
225 225 -

Condition PM Problem
Mould

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption

Yesterday Plan Yesterday Actual Remarks

DCM Plan
2000 1450 YFG line running

PM Plan PM Actual DCM Monthly PM Plan

PM Plan

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4600

Today Plan Today Actual Remarks

GOPAL
4050 3350 die casting machine break down

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

- HARD MOVEMENT-3
OUTER DAMAGE-3
Maintenance Packing Remarks
VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA
- - -

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER

Today Plan Today Actual Remarks

GOPAL
4000 0 DIE Casting machine break down
DCM Monthly
PM Actual Other Remarks
MAHENDER

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLAS
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 3350 die casting machine break down

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
dcm nozzale new requard

IQC In- Process Final

Quality
NO 13 NOS -
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould
ok no no

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1186 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 0 DIE Casting machine break down

PM Plan PM Actual DCM Monthly PM Plan

PM Plan
no no no

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
1200 1294 MANPOWER MOVE TO YFG LINE

Today Plan Today Actual Remarks

GOPAL
4050 die0casting machine break down so yfg line running

Preventive action Preodic Action Remarks

MAHENDER
no no

Customer Market Remarks MANOJ

CASING CAP COMES
- OUT-5
OUTER DAMAGE-3
Maintenance Packing Remarks
VARUN SHARMA

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA

Countermeasure Improvement Remarks

MAHENDER
no no

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER
0.98

Today Plan Today Actual Remarks

GOPAL
4000 0 DIE Casting machine break down
DCM Monthly
PM Actual Other Remarks
MAHENDER
no

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLAS
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
1200 1294 MANPOWER MOVE TO YFG LINE

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 0 die casting machine break down so yfg line running

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
DCM 1 NOZZOLE

IQC In- Process Final

Quality
NO 6 NOS -
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould
OK NO NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1190 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 0 DIE Casting machine break down

PM Plan PM Actual DCM Monthly PM Plan

PM Plan
no no no

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 0 4.2 outer shortage

Today Plan Today Actual Remarks

GOPAL
4050 die0casting machine break down so yfg line running

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

FLO-76430-76T00
- CASING CAP COMES
OUT-4
Maintenance Packing Remarks
VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA

Countermeasure Improvement Remarks

MAHENDER
NO NO

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER
0.98

Today Plan Today Actual Remarks

GOPAL
4000 0 DIE Casting machine break down
DCM Monthly
PM Actual Other Remarks
MAHENDER
no

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLA
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 0

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
4050 0

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
END FORMOING BASE PLATE BOLD BROKEN

IQC In- Process Final

Quality
NO NO -
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption

Yesterday Plan Yesterday Actual Remarks

DCM Plan
4000 0 DIE Casting machine break down

PM Plan PM Actual DCM Monthly PM Plan

PM Plan

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 4500 NOZZEL BLOCK ISSUE

Today Plan Today Actual Remarks

GOPAL
4200 4230

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

- -
Maintenance Packing Remarks
VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER

Today Plan Today Actual Remarks

GOPAL
4000 0 DIE Casting machine break down
DCM Monthly
PM Actual Other Remarks
MAHENDER

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLA
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN

IQC In- Process Final

Quality
NO NO NO
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
YES 0 ( DAYS) NO

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption

Yesterday Plan Yesterday Actual Remarks

DCM Plan

PM Plan PM Actual DCM Monthly PM Plan

PM Plan

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL

Today Plan Today Actual Remarks

GOPAL

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

- -
Maintenance Packing Remarks
VARUN SHARMA
NO NO

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARVANA

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER

Today Plan Today Actual Remarks

GOPAL

DCM Monthly
PM Actual Other Remarks
MAHENDER

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLA
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT
4600 4600

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.
6000 6800

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
NO

IQC In- Process Final

Quality
NO NO NO
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
NO 4 -

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould
OK OK OK

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1223 52 52

Yesterday Plan Yesterday Actual Remarks

DCM Plan
5400 6000

PM Plan PM Actual DCM Monthly PM Plan

PM Plan
NO NO NO

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL
4600 1900 MANPOWER MOVED TO YFG LINE

Today Plan Today Actual Remarks

GOPAL
4050 4050

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

- -
Maintenance Packing Remarks
VARUN SHARMA
- - OK

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARAVANAN

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER
0.98

Today Plan Today Actual Remarks

GOPAL
4000 4000
DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLA
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
NO

IQC In- Process Final

Quality

Material/ Child Part Mould / Tooling

Consumable
Shortage day wise
NO 4 -

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould
OK NO NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation

Today Weekly Monthly

Electric
consumption
1230 52 109

Yesterday Plan Yesterday Actual Remarks

DCM Plan

PM Plan PM Actual DCM Monthly PM Plan

PM Plan
NO NO NO

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL

Today Plan Today Actual Remarks

GOPAL

Preventive action Preodic Action Remarks

MAHENDER

Customer Market Remarks MANOJ

Maintenance Packing Remarks

VARUN SHARMA
- - OK

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARAVANAN

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ

Power Factor Monthly Chart Remarks

MAHENDER
0.97

Today Plan Today Actual Remarks

GOPAL

DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA
 LEAN MANUFACTURING GLA
Yesterday Plan Yesterday Actual Remarks
PRODUCTION
PLAN - INPUT

Yesterday Plan Yesterday Actual Remarks

PRODUCTION
PLAN- ASSY.

Today break down Why-Why Corrective Action

MACHINE
BREAKDOWN
END FORMING BOLT THREAD LOSSE PROPER TITE

IQC In- Process Final

Quality
NO NO 1
Material/ Child Part Mould / Tooling
Consumable
Shortage day wise
NO 3 -

Poka -Yoke kaizen

Improvement
 Yesterday Plan Yesterday Actual Today Plan
Dispatch

Condition PM Problem
Mould
OK OK NO

Working Condition Air Pressure Air Buzzers

Poka -Yoke
Validation
YES OK OK

Today Weekly Monthly

Electric
consumption
1237 52 109

Yesterday Plan Yesterday Actual Remarks

DCM Plan

PM Plan PM Actual DCM Monthly PM Plan

PM Plan
TL CHECKING M/C OK NO

3059766 3059765 3053558

FG INVENTORY
10 DAYS 5 DAYS 32 DAYS

Staff walfare Accident Admin & Shortage

Other
Other
NG GLASS WALL RESPONSIBLE
PERSON

Today Plan Today Actual Remarks

GOPAL

Today Plan Today Actual Remarks

GOPAL

Preventive action Preodic Action Remarks

MAHENDER
THREAD CHACK

Customer Market Remarks MANOJ

INPROCESS
FLO-76430-76T00
OUTER DAMAGE-1
Maintenance Packing Remarks
VARUN SHARMA
- - OK

Remarks
 Weekly Plan Next Weekly Plan Remarks
SARAVANAN

Countermeasure Improvement Remarks

MAHENDER

Light/ Signal Air Leakage Remarks

MANOJ
OK NO -

Power Factor Monthly Chart Remarks

MAHENDER
0.99

Today Plan Today Actual Remarks

GOPAL

DCM Monthly
PM Actual Other Remarks
MAHENDER
NO

3053559 3053622 3053623

VARUN
SHARMA
37 DAYS 14 (DAYS) 9 DAYS

Remarks
RAMESH PANDA
RAMESH PANDA