Quality System Procdures

INTERNAL

QUALITY SYSTEM PROCEDURE

TITLEPURCHASING

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

1 PURPOSE:

TO ENSURE THAT THE PURCHASED PRODUCTS CONFORM TO SPECIFIED REQUIREMENTS.

2 SCOPE : APPLICABLE TO RAW MATERIAL, PRODUCTION CONSUMABLES , PACKING MATERIALS,CATALOGUE ITEMS , BOUGHT OUT PARTS , TOOLS AND GAUGES , SERVICES FOR CALIBRATION , JOB - WORK AND CONTRACTS.

3 ABBREVIATION AND DEFINITION :

3.1 BOP BOUGHT OUT PARTS

3.2 VD VENDOR DEVELOPMENT

3.3 SUB-CONTRACTOR A SUPPLIER / VENDOR / JOB - CONTRACTOR.

3.4 SUPPLIER INDIVIDUAL / ORGANISATION , WHO SUPPLIES RAWMATERIALS, CATALOGUE ITEMS , PACKING MATERIAL,PRODUCTION CONSUMABLES TOOLING & GAUGES.

3.5 VENDOR INDIVIDUAL / ORGANISATION , WHO SUPPLIES COMPONENTS TO RICO AUTO INDUSTRIES LIMITEDAGAINST RICO AUTO INDUSTRIES LIMITED DRAWING'SSPECIFICATIONS.

3.6 JOB-CONTRACTOR ANY OUT SIDE AGENCY WHICH PERFORMS / PROVIDESJOB / SERVICES AS PER RICO AUTO INDUSTRIES REQUIREMENT EITHER AT HIS PLACE OF WORK OR INSIDE RICO AUTO INDUSTRIES PREMISES INCLUDINGJOB - WORK ON COMPONENTS.

3.7 PURCHASE ORDER ANY ORDER RAISED FOR SUPPLY OF RAWMATERIALS / BOUGHT OUT PARTS / PRODUCTIONCONSUMABLES.

3.8 JOB ORDER / ANY ORDER RAISED FOR PROCESSING , REPAIR ANDWORK ORDER MAINTENANCE AT SUB-CONTRACTOR'S PLACE OR

RICO AUTO INDUSTRIES LIMITED PREMISES.

3.9 PRODUCTION MATERIALS WHICH ARE USED DIRECTLY IN THE CONSUMABLE PROCESS OF PRODUCT MANUFACTURING SUCH AS

WELDING ROD / BRAZING WIRE , FLUX AND GASES ETC

PREPARED BY APPROVED BY ISSUED BY

INTERNAL


TITLEPURCHASING


3.10 CATALOGUE ITEMS MATERIALS FOR WHICH MANUFACTURER PUBLISHTHEIR CATALOGUE / LITRATURE INDICATING THE SPECIFICATION AND ARE AVAILABLE IN THE MARKETTHROUGH THEIR DISTRIBUTION NETWORK.

4 ORGANISATION CHART AND RESPONSIBILITY

PLANT MANAGERALUMINIUM FACILITIES

SECTION HEAD(MATERIALS)DHARUHERA

MATERIALS ENGR. MATERIALS SR. ENGR. MATERIALS ENGR.

MISC ITEM BOP BOP

PURCHASE

ASSISTANT

4.1 OVER ALL RESPONSIBILITY FOR IMPLEMENTATION OF THIS PROCEDURE LIES WITH HOD (MATERIALS).

4.2 OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.


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TITLEPURCHASING


5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS

6 DESCRIPTION

SL.NO ACTIVITY

6.1 PURCHASE ORDER

6.1.1 PREPARE THE ORDER INDICATING ALL THEREQUIREMENTS LIKE , DESCRIPTION OF MATERIAL SPECIFICATION / DRAWING, QUANTITY, INSPECTION INSTRUCTIONS,OTHER DELIVERY TERMS AND CONDITIONS

6.1.2 INDICATE APPLICABLE GOVERNMENT REGULA-TION IN THE COUNTRY OF PURCHASE AND SALES ON SAFETY , TOXIC AND HAZARDOUS SUBSTANCES , AS REQUIRED IN THE PURCHASING DOCUMENT.

6.1.3 REVIEW THE PURCHASING DOCUMENT FORADEQUACY AND COMPLETENESS ANDFORWARD TO PLANT MANAGER / HODMATERIALS (CORP.) FOR APPROVAL.

6.1.4 REVIEW AND APPROVE THE PURCHASING DOCUMENT

6.1.5 RECEIVE AND ENTER THE DETAILS IN P.O.CONTROL REGISTER.

(REFER TURTLE DIAGRAM - MATERIALS)

http://ricoauto/rico/ISO%20TS%2016949/Doc/RICO%2014/TURTLE%20%20DIAGRAM%20-%20MATERIALS.htm

6.2 RAW MATERIAL & BOUGHT OUT PARTS

6.2.1 IDENTIFY THE NEED ON THE BASIS OFPRODUCTION PLAN , INTERNAL REVIEW AND DEVELOPMENT PLAN IN CONSULTATIONWITH HOD (MATERIALS)

6.2.2 IDENTIFY THE CAPABLE SUB-CONTRACTOR FOR- INTRODUCTION FOR NEW COMPONENT.- ENGG. CHANGES IN DRAWING.- SECOND SOURCE / ALTERNATIVE SOURCE

FOR EXISTING COMPONENTS.


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SL.NO ACTIVITY

6.2.3 ALLOCATE THE VENDOR FOR DEVELOPINGTHE COMPONENTS FROM THE LIST OF APPROVED SUB-CONTRACTOR.

6.2.4 CO-ORDINATE FOR INSPECTION / TRIAL OFTOOLS , JIG AND FIXTURE WITH SUPPLIER.

6.2.5 RECEIVE THE SAMPLES ALONG WITH THE DOCUMENTS AND CARRY OUT INSPECTION AND PREPARE INSPECTION REPORT ANDFORWARD TO HOD (QA) FOR REVIEW ANDCOMMENTS.

6.2.6 REVIEW THE INSPECTION REPORT AND IF FOUND "O.K." RECOMMEND FOR SUPPLYING PILOT SUPPLY & SEND THE INSPECTION REPORT TO HOD (MATERIALS) / SECTION HEAD(MATERIALS) .

6.2.7 RECEIVE THE PILOT LOT SUPPLY AND INSPECTFOR CONFORMANCE . IF MATERIAL AREACCEPTABLE ALLOW FOR REGULAR SUPPLY

6.2.8 AFTER APPROVAL OF PILOT LOT SUPPLY RELEASE REGULAR DELIVERY SCHEDULE.

6.2.9 AFTER THE STARTING OF REGUAR SUPPLY CARRY OUT THE VENDOR PERFORMANCE EVALUATION QUARTERLY.

6.2.10 EXAMINE VENDOR PERFORMANCE RATING ON QUARTERLY BASIS AND TAKE NECESSARYACTIONS.

6.2.11 FOR HIGH IMPACT PARTS IDENTIFIED IN APPROVED VENDOR LIST, ARRANGE MIS DATA FROM VENDOR ON MONTHLY BASIS FOR KEY INDICATORS OF PROCESS / PRODUCTS OFSUPPLIER AS APPROPRIATE e.g. - Cpk DATA,INTERNAL REJECTION DATA, DELIVERYPERFORMANCE, R.M. STOCK ETC….


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SL.NO ACTIVITY

6.3 CATALOGUE ITEMS, CONSUMABLES & MISC. ITEMS

6.3.1 RECEIVE THE PURCHASE REQUISITION ORMONTHLY REQUIREMENT DULY APPROVED.

6.3.2 PREPARE PURCHASE ORDER MENTIONING THE ITEM DESCRIPTION, REFERENCE / SPECIFICATION GIVEN IN THE CATALOGUE, ANY OTHER REQUIREMENT LIKE TRANSPORTATION METHOD AND OTHER DELIVERY TERMS AND CONDITIONS.

6.4 JOB WORK ITEMS

6.3.3 REVIEW THE PURCHASING DOCUMENT FORADEQUACY AND COMPLETENESS AND FORWARD TO PLANT MANAGER / HODMATERIALS (CORP.).

6.4.1 INCASE OF MATERIAL / COMPONENT TO BE SENT FOR JOB WORK FROM RICIO AUTO INDUSTRIES LIMITED, ADVISE STORE TO ISSUE THE MATERIAL / COMPONENTS TO THE SUB-CONTRACTORS

6.4.2 FOLLOW STEP 5.3.3 TO 5.3.4

6.5 SCHEDULING OF SUB-CONTRACTOR

6.5.1 BASED ON PPC REQUIREMENT, RELEASE THEPART WISE / VENDOR WISE SCHEDULE TOCONCERN VENDOR.

6.5.2 IF SCHEDULING IS REQUIRED ON DAILY /WEEKLY / FORTNIGHTLY BASIS AND MENTIONIT IN DELIVERY SCHEDULE (SPECIFICALLY INSCHEDULE).

6.5.3 MONITOR THE SCHEDULE ON DAILY BASISAND TAKE ACTION ACCORDINGLY IN ORDERTO MAKE SUPPLIES 100% ON TIME.

6.5.4 IF SUPPLIES ARE RECEIVED EXCEEDING ±10%LIMIT NORMS OF SCHEDULE QTY

6.5.5 TAKE CORRECTIVE ACTION ACCORDINGLY


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SL.NO ACTIVITY

6.6 SUPPLIER VERIFICATION AT SUBCONTRACTOR END

6.6.1 ARRANGE AND SPECIFY THE VERIFICATION OFPURCHASED PRODUCT AT SUBCONTRACTOREND AND INDICATE THE REQUIREMENT ALONGWITH PURCHASE ORDER

6.7 CUSTOMER VERIFICATION OF SUBCONTRACTED PART

6.7.1 FIND OUT FROM APQP LEADER WHEATHER

CUSTOMER VERIFICATION ATSUBCONTRACTOR END IS REQUIRED OR NOT.

6.7.2 IF REQUIRED BY CUSTOMER INDICATE THEREQUIREMENT IN THE SUBCONTRACTORPURCHASE ORDER AND ARRANGEACCORDINGLY TO CUSTOMER REQUIREMENT

6.8 PART APPROVAL PROCESS (APPLICABLE IF CUSTOMER SPECIFIC PROCEDURE DOES NOTEXIST FOR TIER 2)

6.8.1 RECEIVE SAMPLES ALONG WITH RELEVENT DOCUMENTS FROM SUBCONTRACTOR AS PER DEVELOPMENT REQUIREMENTS

6.8.2 FILL THE SAMPLE EVALUATION REQUESTAND SUBMIT TO Q.A. DEPARTMENT FORINSPECTION

6.8.3 ENSURE THAT ALL APPROPRIATE DOCUMENTSARE SUBMITTED ALONG WITH SAMPLES ASAGREED WITH Q.A.

6.8.4 ARRANGE THE INSPECTION AND DO VENDORVISIT FOR PROCESS IF REQUIRED

6.8.5 SUBMIT THE REPORT TO HOD (Q.A.) FORAPPROVAL AND FURTHER ACTION.

6.8.6 IF SAMPLE O.K. , ARRANGE PILOT LOT AS PERINSTRUCTION OF Q.A. DEPARTMENT

6.8.7 RECORD THE SAMPLE DETAILS i.e. O.K. /REJECT & DATES ETC IN PART APPROVALLOG SHEET


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SL.NO ACTIVITY

6.8.8 IF PILOT LOT O.K. , RECORD THE DATE OFINTRODUCTION OF PART IN PRODUCTION LINEIN PART APPROVAL LOG SHEET

6.8.9 FOLLOW THE CUSTOMER SPECIFIC

REQUIREMENT FOR PART APPROVAL (IF ANY)

6.10 PART APPROVAL PROCESS (FOR REGULAR BOP ITEMS)

6.9.1 RECEICVE THE CHANGE APPROVAL REQUESTFORM DULY FILLED ALONG WITH SAMPLESAND RELATED DOCUMENTS

6.9.2 SEND THESE SAMPLES TO HOD (Q.A.) FORANALYSIS

6.9.3 DO THE INSPECTION OF SAMPLES AND DOFOLLOW UP WITH CHANGE APPROVAL REQUEST FORM.

6.9.4 INFORM TO PURCHASE DEPTT REGARDINGSTATUS OF THE SAMPLES

6.9.5 COMMUNICATE THE FINAL APPROVAL TOVENDOR.

6.9.6 DO FINAL CUSTOMER NOTIFICATION ASAPPROPRIATE (AS PER CUSTOMER SPECIFICREQUIREMENTS)

6.10 PREMIUM FREIGHT

6.10.1 RECORD THE PREMIUM FREIGHT PAID BYEITHER US OR BY VENDOR IF ANY. ANDINTIMATE TO MANAGEMENT ON MONTHLYBASIS FOR REVIEW & ACTION.

6.11 CUSTOMER APPROVED SOURCES

6.11.1 WHERE SPECIFIED BY THE CONTRACT,ENSURE THAT PRODUCT / MATERIAL /SERVICES ARE SOURCED FROM APPROVEDSOURCES.


INTERNAL


TITLEPURCHASING

TITLERef ISO-TS 16949 , MMOG , QM Sec. 7.4

SL.NO ACTIVITY

6.12 SUPPLIER MONITORING

6.12.1 DO SUPPLY MONITORING THROUGH FOLLOWINGINDICATORS(A) DELIVERY PERFORMANCE(B) QUALITY PERFORMANCE(C) QUALITY RATING CONSIDERING FIELD FAILURES(D) ANY OTHER CUSTOMER SPECIFIC INDICATORS

6.13 CUSTOMER SPECIFIC REQUIREMENTS -

FORD (NOV 2003)

4.27 Subcontractor Development (ISO/TS 16949:2002 7.4.1.2)

4.28 Customer approved sources (ISO/TS 16949:2002 cl. 7.4.1.3)

4.30 Scheduling subcontractors (ISO/TS 16949:2002 cl. 7.4.3.2)


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TITLEPURCHASING


7 DOCUMENTS :

7.1 PROCEDURE FOR ASSESSMENT AND SELECTION OF SUB-CONTRACTORS

7.2 PROCEDURE FOR INVENTORY CONTROL

7.3 PROCEDURE FOR INCOMING MATERIAL INSPECTION AND TESTING.

7.4 PROCEDURE FOR ISSUE OF MATERIAL FOR JOB-WORK.

7.5 WORK INSTRUCTION FOR ASSESSMENT OF VENDOR RATING SYSTEM.

8 RECORDS :

RECORD DESCRIPTION LOCATIONFORM NO TITLE

PURCHASE ORDER HOD

(MATERIALS)

DELIVERY SCHEDULE HOD(MATERIALS)

LIST OF APPROVED SUB-CONTRACTOR HOD

(MATERIALS)

CHANGE APPROVAL REQUEST FORM HOD(Q.A.)

PURCHASE REQUISITION HOD(MATERIALS)

P.O.CONTROL REGISTER HOD(MATERIALS)

RECEIPT MONITORING HOD(PURCHASE)

SAMPLE EVALUATION REQUEST HOD(MATERIALS)

RICO 08 QSP 02

RICO 14 QSP 04

RICO 06 QSP 01

RICO 16 QSP 02

RICO 06 QWI 03

RICO 08 QFO 01

RICO 08 QFO 02

RICO 08 QFO 03

RICO 08 QFO 06

RICO 08 QFO 07

RICO 08 QFO 08

RICO 08 QFO 09

RICO 08 QFO 10

NOTE :- FORMATS ARE COMMON FOR BOTH PLANTS HENCE EITHER OF THE CONFIGURATION NUMBER PRINTED ON FORMAT CAN BE USED.


INTERNAL


TITLEPURCHASING


9 BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO. DATE NATURE OF CHANGE / DESCRIPTION

06 25-06-2003

07 25-12-2003

08 15-04-2004 Procedure reviewed for Ford specific requirements NOV 2003

09 05-05-2004

10 25-01-2006 MS-9000 System upgraded to MMOG

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

MIS Data requirement added for high impact parts identified in approved list

MS-9000 System requirements added as per Ford Q1 Programme


QUALITY SYSTEM DOCUMENT

QUALITY SYSTEM PROCEDURE DOC. NO. RICO 08 QSP 01

PURCHASING ISSUE NO 10

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4 ISSUE DATE 25-01-2006

TO ENSURE THAT THE PURCHASED PRODUCTS CONFORM TO SPECIFIED REQUIREMENTS.

APPLICABLE TO RAW MATERIAL, PRODUCTION CONSUMABLES , PACKING MATERIALS,CATALOGUE ITEMS , BOUGHT OUT PARTS , TOOLS AND GAUGES , SERVICES FOR

A SUPPLIER / VENDOR / JOB - CONTRACTOR.

INDIVIDUAL / ORGANISATION , WHO SUPPLIES RAWMATERIALS, CATALOGUE ITEMS , PACKING MATERIAL,PRODUCTION CONSUMABLES TOOLING & GAUGES.

INDIVIDUAL / ORGANISATION , WHO SUPPLIES COMPONENTS TO RICO AUTO INDUSTRIES LIMITEDAGAINST RICO AUTO INDUSTRIES LIMITED DRAWING'S

ANY OUT SIDE AGENCY WHICH PERFORMS / PROVIDESJOB / SERVICES AS PER RICO AUTO INDUSTRIES REQUIREMENT EITHER AT HIS PLACE OF WORK OR INSIDE RICO AUTO INDUSTRIES PREMISES INCLUDINGJOB - WORK ON COMPONENTS.

ANY ORDER RAISED FOR SUPPLY OF RAWMATERIALS / BOUGHT OUT PARTS / PRODUCTION

ANY ORDER RAISED FOR PROCESSING , REPAIR ANDMAINTENANCE AT SUB-CONTRACTOR'S PLACE ORRICO AUTO INDUSTRIES LIMITED PREMISES.

MATERIALS WHICH ARE USED DIRECTLY IN THE PROCESS OF PRODUCT MANUFACTURING SUCH AS WELDING ROD / BRAZING WIRE , FLUX AND GASES ETC

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MATERIALS FOR WHICH MANUFACTURER PUBLISHTHEIR CATALOGUE / LITRATURE INDICATING THE SPECIFICATION AND ARE AVAILABLE IN THE MARKETTHROUGH THEIR DISTRIBUTION NETWORK.

E.D.(FINANCE)

D.G.M. MATERIALS(CORPORATE)

HOD (MATERIALS)

SECTION HEAD(MATERIALS)

HPDC GURGAON

MATERIALS ENGR. MATERIALS ENGR.

MISC ITEM BOP

PURCHASE

ASSISTANT

OVER ALL RESPONSIBILITY FOR IMPLEMENTATION OF THIS PROCEDURE LIES WITH

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RESPONSIBILITY REF.DOC

SECTION HEAD RICO 08 QFO 01(MATERIALS)

ENGINEERMATERIALS

SECTION HEAD(MATERIALS) /ENGINEERMATERIALS

PLANT MANAGER /HOD (MATERIALS)

SECTION HEAD RICO 08 QFO 08(MATERIALS) /ENGINEERMATERIALS



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HOD (MATERILS) /SECTION HEAD (MATERIALS)

HOD (MATERIALS) /SECTION HEAD(MATERIALS)

SECTION HEAD(QA)

HOD (QA)

SECTION HEADRECEIPT (QA)





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HOD (MATERIALS) / RICO 08 QFO 07SECTION HEAD(MATERIALS)

PURCHASE ENGR. RICO 08 QFO 01

HOD (MATERIALS) /MATERIALS ENGR.

HOD (MATERIALS)

CONCERN PERSON

HOD (MATERIALS) / SECTION HEAD(MATERIALS)





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HOD (MATERIALS) /



PART APPROVAL PROCESS (APPLICABLE IF CUSTOMER SPECIFIC PROCEDURE DOES NOT




HOD (Q.A.) /SECTION HEAD (Q.A

SECTION HEAD (Q.A

SECTION HEAD(PURCHASE)

SECTION HEAD (Q.A.)

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SECTION HEAD (Q.A.)

SECTION HEAD (Q.A.)

HOD (MATERIALS) /SECTION HEAD

HOD (MATERIALS) /SECTION HEAD

SECTION HEAD (Q.A.) /ENGINEER (Q.A.)

HOD (Q.A.) /SECTION HEAD (Q.A.)

SECTION HEAD(MATERIALS) /ENGINEER(MATERIALS)

HOD (Q.A.) /SECTION HEAD (Q.A.)


HOD (MATERIALS)

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HOD (MATERIALS)

RESP. - HOD (MATERIALS)

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PROCEDURE FOR ASSESSMENT AND SELECTION OF

PROCEDURE FOR INVENTORY CONTROL

PROCEDURE FOR INCOMING MATERIAL INSPECTION AND TESTING.

PROCEDURE FOR ISSUE OF MATERIAL FOR JOB-WORK.

WORK INSTRUCTION FOR ASSESSMENT OF VENDOR RATING

LOCATION RETENTION DISPOSAL PERIOD AUTHORITY

HOD 5 YEAR HOD (MATERIALS)

(MATERIALS)

HOD 1 YEAR HOD (MATERIALS)(MATERIALS)

HOD ON GOING HOD (MATERIALS)

(MATERIALS)

HOD 2 YEARS HOD (Q.A.)(Q.A.)



HOD 1 YEAR HOD (PURCHASE)(PURCHASE)


FORMATS ARE COMMON FOR BOTH PLANTS HENCE EITHER OF THE CONFIGURATION NUMBER PRINTED ON FORMAT CAN BE USED.

COPY STATUS SHEET

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NATURE OF CHANGE / DESCRIPTION W.e.f. APPROVED BY

25-06-2003

25-12-2003

Procedure reviewed for Ford specific requirements NOV 2003 15-04-2004

05-05-2004

MS-9000 System upgraded to MMOG 25-01-2006

Procedures are upgraded in line with ISO TS 16949 : 2002 & Management

Representative - QEHS Corp.

MIS Data requirement added for high impact parts identified in Management


Management Representative -

QEHS Corp.

MS-9000 System requirements added as per Ford Q1 Management



QEHS Corp.

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6

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE


INTERNAL


TITLESUPPLIER QUALITY MANAGEMENT DEVELOPMENT


1 PURPOSE:

To establish and implement control measures for development and review of systems atsub-controctor's end.

2 SCOPE : This procedure is applicable to identified sub-contractors of bought out parts (H, Q, C, R Class) and carrying out job work (JW Class) on components.

3 ABBREVIATION AND DEFINITION :

3.1 BOP Brought Out Parts

3.2 H-Class Supplier come in the High Impact supplier category, If it falls in(High Impact Supplier) any of flollowing criteria -

(a) New Supplier(b) New part with existing supplier(c) New technology to supplier(d) Monthly Quality PPM is higher than standard target for consecutive3 months(e) Environmental, Health, Safety Risk Involved in the process(f) Others as specified by CFT

3.3 Q-Class Supplier Quality Class i.e. Item important w.r.t. Form, Fit, Function, Safety,Government & Apperanace

3.4 C-Class Supplier C-Class i.e. Item not much important w.r.t. end use

3.5 P-Class Supplier Properiery Class

3.6 R-Class Supplier Raw Material Class

3.7 RP-Class Supplier Raw Material Properiery Class

3.8 JW-Class Supplier Job Work Class

3.9 CSP Customer Supplied Product

3.10 CFT Cross functional team

severe class of Part no, supplying to RICO i.e. any supplier having parts within C-Class and Q-Class. Supplier will come in Q-Class category.


INTERNAL





For organisation please refer organisation chart

Note : Any supplier which is supplying multiple part no. The supplier will be designated accordingly to the most

Plant Manger (s)

HOD-Corp. Quality

Section Head(Materials-Plants)

Section Head(Quality)

Engineers(Materials-Plants)

Engineers (Quality)

Typical Audit Team (CFT Team)

HOD-Material Plants

4.1 Hod (materials) is over all responsible for implementation of this procedure.

4.2 Hod (Corp.- Quality) is over all responsible for reviewing of implementation of corrective andpreventive actions

4.3 Identified audit teams are responsible for carrying out systems audits.

4.4 Other responsibilities are as mentioned against each activity


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SL.NO ACTIVITY

5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS(REFER TURTLE DIAGRAM - MATERIALS)

5.1 Process Input

Sl.No Process Input Source / Supplier

1 Supplier selection criteria HOD QA

2 EHS specific requirements MR

3 Specification of the material to be procured Process Owner

4 Customer specific requirement. HOD QA

5.2 Process Output

Sl.No Process Output

1

2 Quality System Complying Vendors

5.3 Process Effectiveness And Efficiency Measurable

Sl.No Measurables

Timely procurement of the material conforming to customer specified requirement, user specification, all other applicable specifications.

1 Supplier delivery schedule V/s Actual2 Vendor Rating trend

6 DESCRIPTION

SL.NO ACTIVITY

6.1 Classify the Bought Out Parts and Job WorkComponents according to end use , status of supplier performance. viz - H, Q, C, P, R, RP and CSP Class

6.2 Prepare list of approved sub-contractor for boughtout parts as well as sub contractors doing job work on components for development of system.


INTERNAL




SL.NO ACTIVITY

6.3 Review and update sub-contractor list for H, Q, C,P, R, RP and CSP Class after every three months

6.4 Identify resource requirements for sub-contractordevelopment e.g. visit expenses, training tosuppliers etc and get it sanctioned through yearlybudget review committee.

6.5 Bifurcate the vendor on the basis of present qualitysystem status and nature of supplier in thefollowing category

1- H - Class Category Supplier(a) New Supplier(b) New part with existing supplier(c) New technology to supplier(d) Monthly Quality PPM is less than standard target for consecutive 3 months(e) Environmental, Health, Safety Risk Involved in the process(f) Others as specified by CFT (Annual Auidit as per RICO 06 QFO 88)

2- Q - Class Category SupplierMinimum ISO 9001:2000 Certified suppliers supplying Quality Product (Annual Auidit as per RICO 06 QFO 23)

3- C - Class Category Supplier

Minimum ISO 9001:2000 Certified suppliers supplying Parts having relatively less important on Quality (Annual Auidit as per RICO 06 QFO 23, but these C-Class items are not Audited during Audit)

4- P - Class Category SupplierSuppliers supplying Proprietary items (Not in Audit Scope)

5- R - Class Category SupplierMinimum ISO 9001:2000 Certified suppliers supplying Quality Product (Annual Auidit as per RICO 06 QFO 23)

6- JW - Class Category SupplierMinimum ISO 9001:2000 Certified suppliers carrying Job Works. (Annual Auidit as per RICO 06 QFO 23)

7- RP - Class Category SupplierRaw Material Properiery Supplied Product (Not in Audit Scope)

8- CSP - Class Category SupplierCustomer Supplied Product (Not in Audit Scope)


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SL.NO ACTIVITY

FOLLOWING IS THE CRITERIA FOR DECIDING THE AUDIT CHECK LIST

S.NO CATEGORY

1 H - Class Category Supplier

2 Q - Class Category Supplier

3 R - Class Category Supplier

4 Q - Class Category Supplier Become H - Class Category Supplier

5 H - Class Category Supplier Become Q - Class Category Supplier

6 R - Class Category Supplier Become H - Class Category Supplier

7 H - Class Category Supplier Become R - Class Category Supplier

8 JW - Class Category Supplier Become H - Class Category Supplier

9 H - Class Category Supplier Become JW - Class Category Supplier

6.6 Get Quality System Certificate i.e. ISO 9001:2000,ISO TS 16949:2002 & other applicable systemcertificate as per requirement

6.7 Prepare Annual Audit Schedule in consultation withHOD (Corp.-Quality). The Audit Plan consists ofH-Class Suppliers & Q-Class Suppliers

6.8 Intimate the Supplier for audit in advance as per Annual Audit Schedule.

6.9 Decide Date & Time in consultation with supplierto be audited

6.10 Perform Audit as per Rico Defined Check List.(1) H-Class Category Supplier(2) Q-Class Category Supplier


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SL.NO ACTIVITY

6.11 Appraise the supplier with systemconformances & non-conformances and Handover the audit report to supplier for taking action attheir end and submission of short term & long termaction plan for issues raised by RICO

6.12 Submit the audit report to HOD (Corp.-Quality) /Hod (Plant Quality) and HOD (Plant Purchase) forReview

6.13 Do follow up with supplier for getting feed backregarding corrective and preventive actionsubmission.

6.14 Perform Audit at least once in a year for eachsupplier unless other wise waived by HOD (QualityCorporate)

6.15 Do the audit of supplier based on the supplierstatus (Class / Category) of that month

6.16 receive the corrective and preventive action reportfrom supplier

6.17 Review the effectiveness of counter measure takenby supplier .

6.18 Visit the supplier for checking the effectiveness andimplementation if required

6.19 Q-Class Category Supplier becomes H-Classcategory Supplier, if its Monthly PPM for consecutive 3 Months is more than 100 PPM & H-Class Category Supplier becomes Q-Class Category supplier, if its Monthly PPM forconsecutive 3 Months is less than 100 PPM

6.20 Review the Sub-supplier list at three monthfrequency and reallocate the supplier in H-ClassCategory & Q-Class Category based PPMPerformance.

6.21 Re-schedule the supplier audit plan based on thischanged category


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SL.NO ACTIVITY

6.22 Inform to Vendor Development Department / Plantmaterial Department so as to taken action in caseof supplier quality rating is going lower incontinuous months plan for alternative sourcedevelopment & re-scheduling of supply

6.23 Minimum 60% Rating as per Risk & Qualityassessmenet check list is to be achieved tobecome RICO Poitential Supplier or to Continuebusiness to RICO.

NOTE : 1 Customer designated sub-supplier / Quality system developed by customer. So it will notcome under perview of Rico sub-supplier system development

2 Depending upon the subcontractor size certain sub element can be waived by Audit Team.

3 Properietary part & c-class items are not included in the subcontractor systemdevelopment and audit.

4 In case of customer specific requirement, follow the customer advise forsub-contractor development.

5 Minimum 60% quality rating must be achieved in the assessment to becomepotential supplier to Rico or To be continued as supplier to RICO.

7 DOCUMENTS :

7.1 RICO 08 QSP 01 Procedure for Purchasing.7.2 RICO 08 QSP 02 Procedure for Assessment and selection of Sub-Supplier7.3 RICO 06 QWI 02 Work Instruction For Assessment of Vendor Rating System7.4 RICO 06 DOC 02 Classification of Boughtout Parts


INTERNAL




8 RECORDS :

RECORD DESCRIPTIONLOCATION

FORM NO TITLE

RICO 06 QFO 07Vendor Audit Schedule Section Head (QA)

RICO 06 QFO 23Vendor Quality Audit Report Section Head (QA)

RICO 06 QFO 88Quality & Risk Assessment check list Section Head (QA)

RICO 06 QFO 88Quality & Risk Assessment check list Section Head (QA)



05 25-06-2003

06 05-05-2004 MS-9000 System requirements added as per Ford Q1 Programme


08 05-09-2006




Procedure re-designed for selection & initial development of sub-supplier


QUALITY SYSTEM PROCEDURE DOC. NO. RICO 08 QSP 03SUPPLIER QUALITY MANAGEMENT DEVELOPMENT ISSUE NO 08


This procedure is applicable to identified sub-contractors of bought out parts (H, Q, C, R Class)

Supplier come in the High Impact supplier category, If it falls in

(d) Monthly Quality PPM is higher than standard target for consecutive

(e) Environmental, Health, Safety Risk Involved in the process

Quality Class i.e. Item important w.r.t. Form, Fit, Function, Safety,

C-Class i.e. Item not much important w.r.t. end use

severe class of Part no, supplying to RICO i.e. any supplier having parts within C-Class and Q-Class. Supplier

COPY STATUS SHEET01 OF 08



Any supplier which is supplying multiple part no. The supplier will be designated accordingly to the most

Hod (Corp.- Quality) is over all responsible for reviewing of implementation of corrective and





Source / Supplier

HOD QA

MR

Process Owner

HOD QA

Process Output User / Customer

HOD (Materials Plant)

Quality System Complying Vendors HOD (Materials Plant)

Measurables Unit

When To Collect The Input (Frequency Of Collection)

Before vendor development and procurement of the engineering

goods

Timely procurement of the material conforming to customer specified requirement, user specification, all other applicable specifications.

Supplier delivery schedule V/s Actual % AgeVendor Rating trend Rating


Section Head ___(Plant Material)

Section Head ___(Plant Material)





Section Head RICO 06 DOC 02(Quality Assurance)

HOD (Plant Materials)

HOD (Plant Materials) ___

Minimum ISO 9001:2000 Certified suppliers supplying Parts having relatively less important on Quality (Annual Auidit as per RICO 06 QFO 23, but these C-Class items are not Audited during Audit)





CATEGORY CHECK LIST REQUIRED

H - Class Category Supplier RICO 06 QFO 88

Q - Class Category Supplier RICO 06 QFO 23

R - Class Category Supplier RICO 06 QFO 23

Q - Class Category Supplier Become H - Class Category Supplier RICO 06 QFO 88

H - Class Category Supplier Become Q - Class Category Supplier RICO 06 QFO 23

R - Class Category Supplier Become H - Class Category Supplier RICO 06 QFO 88

H - Class Category Supplier Become R - Class Category Supplier RICO 06 QFO 23

JW - Class Category Supplier Become H - Class Category Supplier RICO 06 QFO 88

H - Class Category Supplier Become JW - Class Category Supplier RICO 06 QFO 23

Section Head (VDD) /Section (Plant Quality)

Section Head (PlantQuality) / Section Head(Plant Materials)

HOD (Plant Materials)









Section Head (Plant Manterials)


Section Head(Plant Quality)











HOD (Corp.- Quality)

HOD (Corp.- Quality)

Customer designated sub-supplier / Quality system developed by customer. So it will not

Depending upon the subcontractor size certain sub element can be waived by Audit Team.

Properietary part & c-class items are not included in the subcontractor system

In case of customer specific requirement, follow the customer advise for

Minimum 60% quality rating must be achieved in the assessment to become

Procedure for Assessment and selection of Sub-SupplierWork Instruction For Assessment of Vendor Rating System




LOCATION

Section Head (QA) 1 Year HOD(QA)



RETENTION PERIOD

DISPOSAL AUTHORITY

Section Head (QA)Section Head (QA) 1 Year HOD(QA)


25-06-2003

MS-9000 System requirements added as per Ford Q1 Programme 05-05-2004


05-09-2006






QEHS Corp.


QEHS Corp.

Procedure re-designed for selection & initial development of sub-Management


6

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE


INTERNAL


TITLEPRODUCTION PLANNING & CONTROLRef ISO-TS 16949 , MMOG , QM Sec. 7.5

1 PURPOSE :

TO MAKE A PRODUCTION PLAN SO AS TO MEET THE CUSTOMER DEMANDS AND PROPER UTILISATION OF MAN , MATERIAL AND MACHINES AND ALSO GIVE GUIDE LINES FOR THEACTIVITIES OF THE SUPPORTING DEPARTMENTS.

2 SCOPE :

IT COVERS ALL THE PRODUCTION ACTIVITIES AS WELL AS THE ACTIVITIES OF THE SUPPORTINGDEPARTMENTS TO MEET THE CUSTOMER REQUIREMENT FOR COMPONENTS AND JOB WORK.

3 ABBREVIATION & DEFINITIONS :

PPC PRODUCTION PLANNING AND CONTROL.MP&L MATERIAL PLANNING & LOGISTICSDI SYSTEM DELIVERY INSTRUCTION SYSTEM - MULCMMS3 COMMON MATERIAL MANAGEMENT SYSTEMCFT CROSS FUNCTIONAL TEAM( MP&L,MKT.,Q.A,PURCHASE,DEVELOPMENT)


PLANT MANAGER

HOD (MKT - EXPORT)

HOD(HPDC) HOD (MP&L)

HOD(M/C SHOP-I) HOD(M/C SHOP-II)

SECTION HEAD SECTION HEAD

(HPDC) (MP&L)

4.1 PLANT MANAGER IS RESPONSIBLE TO RECEIVE THE CUSTOMER PRODUCTION SCHEDULE.

4.2 HOD (MP&L ) / SECTION HEAD (MP&L) IS RESPONSIBLE TO CONVERT THE CUSTOMER PRODUC-TION / DELIVRY SCHEDULE IN TO RICO AUTO INDUSTRIES LIMITED PRODUCTION PLAN.



INTERNAL



5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS(REFER TURTLE DIAGRAM - PPC)

6 DESCRIPTION

SL.NO ACTIVITY

6.1 RECEIVE THE ANNUAL / MONTHLY DESPATCHSCHEDULE FROM CUSTOMER / MARKETING / HEAD OFFICE.

6.2 INFORM AND DISCUSS WITH PLANT MANAGERFOR PRODUCTION PLANNING AS PER SCHEDULE (S) RECEIVED AND PREPAREAGREED DISPATCH PLAN TO FEED INCOMPUTER

6.3 BASED ON CUSTOMER SCHEDULE PREPAREMONTHLY DESPATCH SCHEDULE (IF REQUIRED),INCORPORATE IN FLASH REPORT AND INTIMATETO ALL CONCERNED INCLUDING PURCHASEDEPARTMENT FOR RAW MATERIAL PLANNING& PROCUREMENT

6.4 BASED ON DESPATCH SCHEDULE PREPAREMONTHLY BOP REQUIREMENTS AND GIVECOPY TO PURCHASE AND STORE DEPTT.

6.5 ON TIME DELIVERY

6.5.1 FOR HHML DHARUHERA & GURGAON / AUTOFIT

6.5.1.1 TAKE DAY'S PRODUCTION PLAN FROM HHML

BY MEANS OF PHONE / E-MAIL ETC ON DAILYBASIS.

6.5.1.2 TAKE PHYSICAL STOCK DATA OF OUR PARTSBY MEANS OF PHONE / E-MAIL OR VIAPHYSICAL UNDERTAKING AT CUSTOMER ENDBY OUR REPRESENTATIVE.

6.5.1.3 DECIDE DESPATCH PLAN (IN CONCSULTATIONWITH PLANT MANAGER) FOR DAY ANDINTIMATE TO ALL CONCERNED.


INTERNAL



SL.NO ACTIVITY

6.5.1.4 DO MINIMUM 4HRLY DESPATCH MONITORING INORDER TO MAINTAIN JUST IN TIME AND ONTIME DELIVERY AND APPRAISE THE STATUSTO PLANT MANAGER.

6.5.1.5 KEEP TRACK WITH CUSTOMERREPRESENTATIVE FOR NECESSARY FEEDBACK AND ALTERATIONIN DESPATCH (IF ANY.)

6.5.1.6 ENSURE 100% ON TIME DELIVERY.

6.5.2 FOR MARUTI UDYOG LIMITED

6.5.2.1 RECEIVED THE "DI" FROM THE CUSTOMER /MARKETING BY FAX / E-MAIL

6.5.2.2 INTIMATE TO ALL CONCERNED WELL INADVANCE FOR "DI" REQUIREMENT OF MUL.

6.5.2.3 ARRANGE THE "DI" REQUIREMENT OFPARTICULAR DAY IN ADVANCE ASAPPROPRIATE

6.5.2.4 ARRANGE THE DESPATCH AS PER "DI"

REQUIREMENT IN ORDER TO REACH SUPPLYON REQUIREMENT DATE AND TIME AS WELLAS AT REQUIRED LOCATION OF MARUTISTORES.

6.5.2.5 KEEP TRACK WITH CUSTOMER FOR CHANGE IN"DI" SCHEDULE / NON "DI" SCHEDULE FORNECESSARY ACTION AT OUR END.

6.5.2.6 ENSURE 100% ON TIME DELIVERY AS PER DIGIVEN BY MUL.


INTERNAL



SL.NO ACTIVITY

6.5.3 FOR EXPORT CUSTOMERS

6.5.3.1 RECEIVED CUSTOMER REQUIREMENTPLANNING, INFORMATION & SHIP SCHEDULETHROUGH CMMS3/EDI

6.5.3.2 DISCUSS THE CUSTOMER SCHEDULE WITHPRODUCTION TEAM AND PLANT MANAGERTAKING INTO CONSIDERATION THE PLANTSCAPACITY & TIME REQUIRED FORPRODUCTION.

6.5.3.3 PREPARE PRODUCTION PLAN / DESPATCHPLAN FOR INHOUSE PRODUCTION , RAWMATERIAL PLANNING & PROCUREMENT &SCHEDULING OF SUB-CONTRACTORS &VENDORS

6.5.3.4 FEED THE DESPATCH PLAN IN THE ERPSYSTEM, WHICH WILL TAKE CARE OFUNAUTHORISED SHIPMENTS TO CUSTOMER

MP&L PROCESS TO AVOID POTENTIAL PROBLEM6.5.3.5 REVIEW THE CMMS3 ON DEFINE INTERVAL

6.5.3.6 DISCUSS THE PRODUCTION REQUIREMENT INPRODUCTION MEETING

6.5.3.7 MAKE SURE THE PRODUCTION AS PER PLAN ,IF ANY ABNORMALITY INFORM TO HOD FORNECESSARY ACTION.

6.5.3.8 INCASE OF POTENTIAL FAILURE IN MP&LSERVICES , INFORM TO CUSTOMER WELL INADVANCE SO THAT POSSIBLE ACTION CAN BETAKEN BY CUSTOMER

6.5.3.9 KEEP TRACK WITH CUSTOMER FOR CHANGE IN"CMMS3 / EDI" SCHEDULE / NON "CMMS3 /EDI" SCHEDULE FOR NECESSARY ACTION ATOUR END.

6.5.3.10 ENSURE 100% ON TIME DELIVERY AS PER CMMS3 / EDI GIVEN BY EXPORT CUSTOMER.


INTERNAL



SL.NO ACTIVITY

6.5.4 QUANTITY VERIFICATION PROCESS FOR CUMULATIVE SHIP(BETWEEN RICO INDIA & WAREHOUSES)

6.5.4.1 UPDATE THE DESPATCHES IN THE PIPE LINEFORMAT ON WEEKLY BASIS

6.5.4.2 SEND THE PIPE LINE DETAIL TO WAREHOUSEAT LEAST ONCE IN A MONTH

6.5.4.3 ARRANGE RECONCILING WITH THEWAREHOUSE PERSONNEL

6.5.4.4 INCASE OF DISAGREEMENT, DETECT THECAUSE AND TAKE CORRECTIVE ACTION ASPER ADVICE OF HOD (MP&L)

(BETWEEN WAREHOUSES & CUSTOMER)6.5.4.5 REVIEW THE CMMS3 IN THE FIRST WEEK OF

MONTH FOR LAST QTY. RECEIVED FORPREVIOUS MONTH AND TOTAL SHIP QTY. TOCUSTOMER

6.5.4.6 RECONCILE IT IF THERE IS DISCREPANCY,DISCUSS WITH CUSTOMER AND FIND OUT THEROOT CAUSE

6.5.4.7 IMPLEMENT THE CORRECTIVE ACTION INADVICE WITH DIRECTOR WARE HOUSE.

6.5.5 FOR OTHER CUSTOMER

6.5.5.1 RECEIVED THE SCHEDULE FROM MARKETINGFOR DISPATCH

6.5.5.2 INTIMATE TO ALL CONCERNED ACCORDINGLYVIA FLASH REPORT

6.5.5.3 ARRANGE DESPATCH AS PER SCHEDULE

6.5.5.4 KEEP TRACK WITH MARKETING FOR ANYALTERATION IN DESPATCH PLAN AND INTIMATETO ALL CONCERNED (IF APPLICABLE)

6.5.5.5 ENSURE 100% ON TIME DELIVERY.


INTERNAL



SL.NO ACTIVITY

PLANNING AMENDMENT6.6 RECEIVE THE AMENDMENT DETAIL FROM

CUSTOMER / HEAD OFFICE BY WRITTEN MEDIAOR VERBALLY

6.7 PREPARE THE AMENDMENT NOTE AS PER INFORMATION RECEIVED INDICATING SOURCEDETAIL OF AMENDMENT

6.8 REVIEW THE AMENDMENT FOR VALIDITY

6.9 ENSURE THAT AMENDMENT ARE IN-CORPORA-TED IN FLASH REPORT

6.10 CARRY OUT MONTHLY PHYSICAL INVENTORYAND INTIMATE TO ALL CONCERN REGARDINGPLAN AND MACHINE LOADING INLINE WITHINVENTORY STOCK.

6.11 DISCUSS AND REVIEW THE FLASH REPORTIN DAILY PRODUCTION MEETING ALONG WITHALL CONCERN HODS AND DECIDE ACTIONON IMPROVING DELIVERY PERFORMANCE.

6.12 PREPARE MONTHLY FLASH SUMMARY REPORTINDICATING THE REASON OF DELIVERY FAILURE AND IDENTIFY THE AREA / CUSTOMER WHERE DELIVERY PERFORMANCE NEED IMPROVEMENT.

6.13 MAKE CORRECTIVE ACTION PLAN IN CASE OFDELIVERY FAILURE.

6.14 INTIMATE TO CUSTOMER WELL IN ADVANCEWITH REGRET, IN CASE OF SUPPLIES CAN NOTBE MADE ON DUE DATE AND TIME.

6.15 PREMIUM FREIGHT

6.15.1 RECORD THE PREMIUM FREIGHT PAID BYEITHER US OR BY VENDOR IF ANY. ANDINTIMATE TO MANAGEMENT ON MONTHLYBASIS FOR REVIEW & ACTION.


INTERNAL



SL.NO ACTIVITY

ONGOING CAPACITY MONITORING & CAPACITY ENHANCEMENT SYSTEM6.16 EVALUATE EFFECTIVENESS OF EXISTING

OPERATIONS BY TRACKING "OEE" , CYCLE

TIMES, NON-VALUE ADDED ACTIVITIES ETC.

6.17 RECEIVE THE FORE CAST PRODUCTION PLANOR CAPACITY ENHANCEMENT REQUIREMENTDETAIL FROM CUSTOMER.

6.18 CALL CFT MEETING FOR REVIEW & ANALYSEOF THE CAPACITY ENHANCEMENT / FORECASTSCHEDULE WITHIN A WEEK AFTER RECEIPT OFCUSTOMER REQUIREMENT. ANALYZE THECAPACITY REQUIREMENT BASED ONCUSTOMER OPERATING PATTERN.

6.19 DECIDE THE WEEKLY AND MONTHLYREQUIREMENT AND FIX THE GAPS FOR MAN,MACHINES, METHODS, MATERIALS, MP&L ANDPLANT FACILITIES AS APPLICABLE.

6.20 DECIDE ACTION PLAN TO FILL THE GAP TOACHIEVE THE REQUIRED CAPACITY.

6.21 COMMUNICATE TO CUSTOMER FORCONFORMANCE & TIMINGS & ESTABLISH THEAGREEMENT ON SUPPLIES

6.22 IN CASE OF INABILITY TO MEET THE SCHEDULE(INCLUDING SUB-SUPPLIER REQUIREMENT)INFORM TO CUSTOMER WITH IN ONE WEEKTIME.


INTERNAL



7 DOCUMENTS

7.1 RICO 08 QSP 01 PROCEDURE FOR PURCHASING

7.2 ----------- CUSTOMER PLAN

CAPACITY UTILIZATION PLAN

8 RECORDS :


RICO 09 QFO 01 PRODUCTION PLAN AMENDMENT MP&L

RICO 09 QFO 02 DELIVERY CORRECTIVE ACTION PLAN MP&L

RICO 09 QFO 03 FLASH REPORT MP&L

RICO 09 QFO 04 PHYSICAL INVENTORY STATUS -HPDC MP&L

RICO 09 QFO 05 PHYSICAL INVENTORY STATUS - CNC MP&L

RICO 09 QFO 06 DESPATCH PLAN FOR THE MP&LMONTH OF ……………….

------ CONTAINER LOADING PLANS MP&L

------- CAPACITY UTILIZATION PLAN MP&L(SOFT COPY)

------- WEEKLY SHIP SCHEDULE CMMS3 MP&L(SOFT COPY)

------- DAILY SHIP SCHEDULE CMMS3 WARE (SOFT COPY) HOUSE


INTERNAL





06 25-06-2003


08 11-11-2004


10 16-03-2006


Ongoing capacity monitoring & Capacity enhancement system added

Capacity Enhancement Process of Suppliers & Subsupplier on the basis of Customer Requirement added.



HOME

http://ricoauto.com/rico/qs.htm

http://ricoauto.com/rico/index.htm


ALUMINIUM PLANTS


PRODUCTION PLANNING & CONTROL ISSUE NO 10


TO MAKE A PRODUCTION PLAN SO AS TO MEET THE CUSTOMER DEMANDS AND PROPER UTILISATION OF MAN , MATERIAL AND MACHINES AND ALSO GIVE GUIDE LINES FOR THE

IT COVERS ALL THE PRODUCTION ACTIVITIES AS WELL AS THE ACTIVITIES OF THE SUPPORTINGDEPARTMENTS TO MEET THE CUSTOMER REQUIREMENT FOR COMPONENTS AND JOB WORK.

CROSS FUNCTIONAL TEAM( MP&L,MKT.,Q.A,PURCHASE,DEVELOPMENT)

HOD (MATERIALS)

HOD(M/C SHOP-II)

SECTION HEAD SECTION HEAD

PAINT SHOP MATERIALS

PLANT MANAGER IS RESPONSIBLE TO RECEIVE THE CUSTOMER PRODUCTION SCHEDULE.

HOD (MP&L ) / SECTION HEAD (MP&L) IS RESPONSIBLE TO CONVERT THE CUSTOMER PRODUC-TION / DELIVRY SCHEDULE IN TO RICO AUTO INDUSTRIES LIMITED PRODUCTION PLAN.

COPY STATUS SHEET

01 OF 09

ALUMINIUM PLANTS





HOD (MP&L) /SECTION HEAD

(MP&L)

HOD (MP&L) / RICO 09 QFO 06SECTION HEAD

(MP&L)


(MP&L)


(MP&L)

S.H. (MKT.) /

HOD (MP&L) /SECTION HEAD (MP&L)

S.H. (MKT.) /HOD (MP&L) /

SECTION HEAD (MP&L)


(MP&L)

COPY STATUS SHEET

02 OF 09

ALUMINIUM PLANTS





HOD (MP&L) /SECTION HEAD (MP&L) /

HOD (PRODN.) /S.H. (MARKETING)


HOD (PRODN.)


HOD (PRODN.)

HOD (MP&L)

HOD (MP&L)

HOD (PRODN.)

HOD (PRODN.)

HOD (MP&L) /HOD (PRODN.)


COPY STATUS SHEET

03 OF 09

ALUMINIUM PLANTS





HOD (MP&L) /SECTION HEAD(MP&L)

HOD (MP&L)SECTION HEAD(MP&L)

HOD (PRODN.) /SECTION HEAD(MP&L)

SECTION HEAD(MP&L)

SECTION HEAD(MP&L)

HOD (MP&L) /SECTION HEAD(MP&L)

SECTION HEAD(PRODN.)

HOD (MP&L)



COPY STATUS SHEET

04 OF 09

ALUMINIUM PLANTS





SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

WARE HOUSEINCHARGE

WARE HOUSEINCHARGE

WARE HOUSEINCHARGE

PLANT MANAGER /HOD(MP&L)

HOD (MP&L) RICO 09 QFO 03



HOD (PRODN.)


HOD (PRODN.)

COPY STATUS SHEET

05 OF 09

ALUMINIUM PLANTS





SECTION HEAD(MP&L)

SECTION HEAD RICO 09 QFO 01(MP&L)

HOD (MP&L)

HOD (MP&L) / RICO 09 QFO 01SECTION HEAD RICO 09 QFO 03

(MP&L)

HOD (STORES) RICO 09 QFO 04HOD (MP&L) / RICO 09 QFO 05

SECTION HEAD(MP&L)


(MP&L)


(MP&L)

HOD (HODC) /HOD (M/C SHOP) /

HOD (MP&L)


(MP&L)


(MP&L)

COPY STATUS SHEET

06 OF 09

ALUMINIUM PLANTS





PLANT TEAM RICO 14 QSP 03

MKT. / MP&L

CFT

CFT

MKT. / MP&L

MKT. / MP&L

MKT. / MP&L

COPY STATUS SHEET

07 OF 09

ALUMINIUM PLANTS




LOCATION RETENTION DISPOSAL

PERIOD AUTHORITY

MP&L 1 YEAR HOD (MP&L)






MP&L 3 MONTHS HOD (MP&L)


MP&L 3 YEARS HOD (MP&L)

WARE 3 YEARS WARE HOUSEHOUSE INCHARGE

COPY STATUS SHEET

08 OF 09

ALUMINIUM PLANTS





25-06-2003


11-11-2004


16-03-2006




QEHS Corp.

Ongoing capacity monitoring & Capacity enhancement system Management



QEHS Corp.

Capacity Enhancement Process of Suppliers & Subsupplier on the Management


COPY STATUS SHEET

09 OF 09


http://ricoauto.com/rico/qs.htm

6

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE


INTERNAL


TITLEMATERIAL HANDLING AND PRESERVATION


1 PURPOSE :

TO PROVIDE EFFECTIVE METHODS OF HANDLING OF PRESERVATION SO AS TO PREVENTDAMAGE OR DETERIORATION OF MATERIALS AND PRODUCTS.

2 SCOPE :

IT COVERS UNLOADING OF MATERIAL AT RECEIPT , TRANSFER TO DIFFERENT SHOPS AND THEIR STORAGE DURING THE PROCESS.


R.M. RAW MATERIALFIFO FIRST IN FIRST OUT


FOR ORGANISATION, PLEASE REFER ORGANISATION CHART.

4.1 OVER ALL RESPONSIBILITY LIES WITH PLANT MANAGER.

4.2 HOD'S ARE RESPONSIBLE FOR MATERIAL HANDLING, PRESERVATION AND MOVEMENT IN THEIR RESPECTIVE AREA.

4.3 HOD (STORES) IS RESPONSIBLE FOR HANDLING, PRESERVATION AND MOVEMENT OF MATERIAL IN MAIN STORES, RECEIPT STORE AND FEEDING TO PRODUCTION LINES.

4.4 OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY.

5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS(REFER TURTLE DIAGRAM - STORES, MATERIL HANDLING & INVENTORY)

6 DESCRIPTION

SL.NO ACTIVITY

6.1 RECEIPT OF RAW MATERIAL

6.1.1 ARRANGE TO PUT CARRIER LOADED WITH

RAW MATERIAL IN THE ALLOCATED AREA.

6.1.2 UNLOAD THE MATERIAL AT APPROPRIATELOCATION BY ANY OF FOLLOWING METHOD ASAPPLICABLE.FOR RICO DHARUHERA(I) RAW MATERIAL > 10 TONS

- USE HEAVY DUTY CRANE.(II) RAW MATERIAL > 3 TONS

- USE CHAIN PULLY BLOCK.(III) RAW MATERIAL > 20 KG BUT < 3 TONS

- USE FORK LIFT.(IV) RAW MATERIAL < 20 KG

- MANUAL / FORK LIFT / PALLET ETC.


INTERNAL




SL.NO ACTIVITY

FOR HPDC DIV. GURGAON(I) RAW MATERIAL > 3 TONS

- USE FORK LIFT OR MANNUALY.(II) RAW MATERIAL > 20 KG BUT < 3 TONS

- USE FORK LIFT OR MANUAL TROLLY.(III) RAW MATERIAL < 20 KG

- MANUAL / FORK LIFT / PALLET ETC.

6.1.3 PROVIDE RAW MATERIAL IDENTIFICATION ANDTRACEABILITY DETAIL AS PER REQUIREMENT.

6.1.4 TRANSFER THE RAW MATERIAL TO ALLOY MAKING SECTION BY MEANS OF FORK LIFT /HAND PALLET / MANUAL ETC.

6.1.5 HANDLE THE PRODUCT (RAW MATERIAL) WITHPROPER SAFETY.

6.2 RECEIPT OF BROUGHT OUT PARTS, CONSUM-ABLES , SPARES , TOOLING , GAUGE, INSTRU-MENTS AND SAFETY ITEMS.

6.2.1 UNLOAD THE MATERIAL MANUALLY AND KEEP THEM ON HAND PALLET / TROLLEY AND TRANSFER THEM TO RECEIPT AREA.

6.2.2 PROVIDE IDENTIFICATION TAG ON INCOMING

AREA.

6.2.3 PROTECT THE MATERIAL KEPT IN STORES FROM RUST AND DAMAGES FOLLOW FIRST INFIRST OUT (FIFO) FOR ITEM HAVING LIMITED SELF LIFE.

6.3 TRANSFER THE MATERIAL FROM STORE TOTHE RESPECTIVE SHOPS.

6.3.1 TRANSFER THE REQUIRED RAW MATERIAL TORESPECTIVE SHOP (HPDC, MACHINE SHOP,PAINT SHOP & ASSY. LINES) BY MEANS OF HAND PALLETS OR MANUALLY.

6.3.2 SUPPLY BOUGHT OUT PARTS TO MACHINE SHOP BY MEANS OF HAND PALLETS OR MANUALLY.


INTERNAL




SL.NO ACTIVITY

6.3.3 SUPPLY THE PRODUCTION CONSUMABLES,MACHINERY , SPARES, TOOLINGS , GAUGES,INSTRUMENTS AND SAFETY ITEMS ETC.MANUALLY OR ON TROLLEY DEPENDING UPONSIZE , WEIGHT AND QUANTITY TO RESPECTIVEDEPARTMENT.

6.4 MOLTEN METAL HANDLING IN HPDC

6.4.1 POURING METAL FROM MELTING FURNACE TOTRANSFER LADDLE MANUALLY.

6.4.2 MOVE THE TRANSFER LADDLE ON RAIL UP TOEOT CRANE LEVEL.

6.4.3 LIFT THE LADDLE BY CRANE.

6.4.4 MOVE THE LADDLE UP TO HOLDING FURNACEFOR POURING.

6.4.5 DO CROSS MOVEMENT UP TO HOLDING FURNACE FOR POURING.

6.4.6 POUR THE METAL IN TO HOLDING FURNACE BYCROSS WHEEL.

6.4.7 PICK UP THE METAL WITH SPOON.

6.4.8 POUR THE METAL IN SLEEVE.

6.5 HANDLING OF MATERIAL DURING PROCESS

6.5.1 HANDLE THE MATERIAL DURING PROCESS INBINS / TROLLEYS WITH HAND PALLET.

6.5.2 KEEP THE PARTS IN SUCH A WAY THAT THEIRMACHINED SURFACE SHOLD NOT TOUCH EACHOTHER DURING PROCESS / MATERIALHANDLING.

6.5.3 APPLY RUST PREVENTIVE OIL ON THE MATERIAL IN RAINY SEASON ON UNPAINTEDMATERIAL / SURFACES (IF REQUIRED).


INTERNAL




SL.NO ACTIVITY

6.6 TRANSFER OF MATERIAL FROM MACHINE SHOPTO PAINT SHOP AND DESPATCH SECTION

6.6.1 TRANSFER THE MATERIAL FROM MACHINE SHOP TO PAINT SHOP BY MEANS OF BINS / TROLLEY NEAR PAINT SHOP LOADING AREAOR NEAR CONVEYOR.

6.6.2 ENSURE UTMOST PRODUCT SAFETY DURINGHANDLING

6.6.3 LOAD THE PART ON THE CONVEYOR HANGERCAREFULLY

6.6.4 AFTER THE PAINT TRANSFER THE MATERIAL

TO NEXT OPERATION / FINAL INSPECTION &PACKAGING.

6.6.5 PACK THE PARTS AS PER PACKAGING WORK INSTRUCTION

6.6.6 DESPATCH THE MATERIAL TO CUSTOMER INSPECIAL TROLLEYS , BINS & CONTAINERS PACKED IN CORRUGATED BOX & WOODEN BOXAS APPLICABLE.

6.6.7 FOLLOW THE WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF FINISHED GOODS.

6.6.8 DO PRESERVATION OF MATERIAL BY MEANSAS PER APPLICABILITY.

6.7 CONTROL OF CONTAINER & DUNNAGE

6.7.1 STORE CONTAINER & DUNNAGE IN ALLOCATEDAREA TO AVOID DAMAGE

6.7.2 ASSUME THAT RETURNABLE CONTAINER ANDDUNNAGE ARE RETURNED IN TIMELY MANNERAND IN ACCEPTABLE CONDITION.


INTERNAL




7 DOCUMENTS :

7.1 RICO 14 QSP 02 PROCEDURE FOR PACKAGING AND DELIVERY OF PRODUCT

7.2 RICO 14 QWI 01 WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF FINISHED GOODS.

8 RECORDS :

RECORD DESCRIPTIONLOCATION

FORM NO TITLE

___ ____ ___

___ ____ ___

___ ____ ___


INTERNAL






07 25-06-2003


09 05-08-2004

10 25-12-2004 Control of Containers & Dunnage in Column 6.7


TURTLE DIAGRAM - STORES, MATERIAL HANDLING & INVENTORYDOCUMENT NO. :

INTERFACE

- ALL EMPLOYEE OF ORGANISATION- PURCHASE DEPT.- QUALITY ASSURANCE DEPT.- PRODUCTION, PLANNING & CONTROL DEPT.- HPDC SHOP- M/C SHOP- PAINT SHOP- HR & TRAINING DEPT.

- INTERNAL & EXTERNAL CUSTOMERS

REQUIREMENTS ON HANDLING AND STORAGE

- BOP'S

- RAW MATERIAL


Material handling guidelines for operator provided for machining parts in process and in handling in column 6.5.2

STORES , HANDLING & INVENTORY

- RECEIPT OF MATERIAL FROM SUPPLIER

- CUSTOMER SPECIFIC REQUIREMENTS

PROCEDURES

RICO 16 QSP 01 / QSP/RICO GGN/ 15.1 PROCEDURE FOR STORES

RICO 16 QSP 02 PROCEDURE FOR ISSUE OF MATERIAL FOR JOB WORK

RICO 14 QSP 04 / QSP/RICO GGN/ 15.3 PROCEDURE FOR INVENTORY MANAGEMENT

RICO 15 QSP 01 / QSP/RICO GGN/ 18.1 PROCEDURE FOR TRAINING

PROCESS OWNER : HOD (STORES) / SECTION HEAD (STORES)



ALUMINIUM PLANTS


MATERIAL HANDLING AND PRESERVATION ISSUE NO 11


TO PROVIDE EFFECTIVE METHODS OF HANDLING OF PRESERVATION SO AS TO PREVENT

IT COVERS UNLOADING OF MATERIAL AT RECEIPT , TRANSFER TO DIFFERENT SHOPS AND

HOD'S ARE RESPONSIBLE FOR MATERIAL HANDLING, PRESERVATION AND MOVEMENT IN

HOD (STORES) IS RESPONSIBLE FOR HANDLING, PRESERVATION AND MOVEMENT OF MATERIAL IN MAIN STORES, RECEIPT STORE AND FEEDING TO PRODUCTION LINES.


SECTION HEAD

RECEIPT STORE

SECTION HEADRECEIPT STORE

COPY STATUS SHEET

01 OF 06

ALUMINIUM PLANTS






OPERATOR

OPERATOR


SECTION HEAD

RECEIPT STORE

HOD (STORES)

SECTION HEAD(STORES)


COPY STATUS SHEET

02 OF 06

ALUMINIUM PLANTS






MELTING FURNACEOPERATOR





M/C OPERATOR

M/C OPERATOR

M/C OPERATOR

SECTION HEAD(PRODN.) / SECTIONHEAD (STORES)

OPERATOR

SECTION HEAD(PRODN.) / SECTIONHEAD (STORES)

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03 OF 06

ALUMINIUM PLANTS





SECTION HEAD(M/C SHOP)

HOD'S

OPERATOR

OPERATOR

OPERATOR RICO 14 QSP 02

SECTION HEADDESPATCH

OPERATORS/ RICO 14 QWI 01HELPERS IN RESPECTIVE DEPARTMENTS

OPERATORS/HELPERS IN RESPECTIVE DEPARTMENTS

HOD (MP&L)

HOD (MP&L)

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04 OF 06

ALUMINIUM PLANTS




PROCEDURE FOR PACKAGING AND DELIVERY OF PRODUCT

WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF

LOCATIONRETENTION DISPOSAL

PERIOD AUTHORITY

___ ___ ___

___ ___ ___

___ ___ ___

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05 OF 06

ALUMINIUM PLANTS





25-06-2003


05-08-2004

Control of Containers & Dunnage in Column 6.7 25-12-2004


TURTLE DIAGRAM - STORES, MATERIAL HANDLING & INVENTORYISSUE NO. / REV NO. : 01

INTERFACE COMPETENCE AND SKILL




QEHS Corp.

Material handling guidelines for operator provided for machining parts in process and in handling in column 6.5.2


QEHS Corp.


QEHS Corp.


QEHS Corp.


PROCEDURES

PROCEDURE FOR ISSUE OF MATERIAL FOR JOB WORK

PROCEDURE FOR INVENTORY MANAGEMENT


6

TURTLE DIAGRAM - STORES, MATERIAL HANDLING & INVENTORYEFFECTIVE DATE :

COMPETENCE AND SKILL

- MANAGERIAL SKILLS- AWARENESS ABOUT STORE LAYOUT PLAN- STORE FUNCTION SKILL- INVENTORY MANAGEMENT FUNCTION SKILL- MATERIAL HANDLING SKILL & KNOWLEDGE- KNOWLEDGE OF QUALITY SYSTEM

1. STORE MANAGEMENT AS PER SYSTEM REQUIREMENT2. IMPROVEMENT IN STORAGE CONDITION TO AVOID DAMAGE AND DETERIOTATION

PERFORMANCE

EFFECTIVENESS EFFICIENCY(1) INVENTORY TURN OVER RATIO (1) REDUCING TREND IN (2) MONTHLY INVENTORY TREND VS SALES INVENTORY IN RUPEES(3) TREND IN OBSOLETE / NON MOVING

STOCK IN INR(4) NO OF TIMES FIFO FAILURE(5) TREND IN REJECTION FOLLOWING

PERIODIC STOCK VARIATION(6) TRENDS IN ACCIDENTS RELATING

TO HAZARDOUS MATERIAL HANDLING

1. STORE MANAGEMENT AS PER SYSTEM REQUIREMENT2. IMPROVEMENT IN STORAGE CONDITION TO AVOID DAMAGE AND DETERIOTATION

DOCUMENTS :

TURTLE DIAGRAM - STORES, MATERIAL HANDLING & INVENTORY

COMPETENCE AND SKILL

PERFORMANCE

EFFICIENCY(1) REDUCING TREND IN

INVENTORY IN RUPEES

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE


INTERNAL


TITLEPACKAGING AND DELIVERY OF PRODUCT


1 PURPOSE :

TO ESTABLISH A SYSTEM FOR PACKAGING & DELIVERY OF FINISHED PRODUCTS.

2 SCOPE :

ALL FINISHED PRODUCTS.


HOD HEAD OF DEPARTMENT


FOR ORGANISATION, PLEASE REFER ORGANISATION CHART.

4.1 HOD (MP&L) IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE.

4.2 HOD (HPDC) / HOD (M/C SHOP) / SECTION HEAD (PAINT SHOP) / HOD (MP&L) IS RESPONSIBLE FOR DAY TO DAY MONITORING OF THE ACTIVITIES OF THE DEPARTMENT.


5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS(REFER TURTLE DIAGRAM - )

6 DESCRIPTION

SL.NO ACTIVITY

6.1 RECEIVE THE PARTS FOR PACKAGING.

6.2 REMOVE THE BURR CHIPS AND OTHER FORIGNPARTICLES

6.3 CLEAN THE PARTS PROPERLY.

6.4 DO PACKAGING & LABELLING AS PER WORK

INSTRUCTION AND / OR AS CONFIRMED BY CUSTOMER DURING PPAP.

6.5 INCASE OF CUSTOMER HERO HONDA MOTERSLIMITED , PUT THE PARTS IN BINS / TROLLEYS AS APPLICABLE.

6.6 TRANSFER THE SAME TO FINISHED GOODS STORES.


INTERNAL




SL.NO ACTIVITY

6.7 ENSURE THAT ONLY CONFORM PRODUCTS AREPACKED.

6.8 RECEIVE THE FINISHED GOODS FROM PRODUCTION ALONG WITH PRODUCTION SLIP.

6.9 COUNT THE MATERIAL AFTER VERIFICATIONOF PROPER DESCRIPTION.

6.10 IF THERE IS ANY DESCREPENCY BRING IT TOTHE ATTENTION OF HOD (EXCISE & DESPATCH)

6.11 REFER THE MATTER TO CONCERNEDPRODUCTION SHOP AND RESOLVE THE SAME.

6.12 ENSURE THAT ONLY CONFORMING PRODUCT ARE TAKEN.

6.13 ENSURE THAT EACH BIN / TROLLEY / RACKCONTAINING PRODUCT IS DULY IDENTIFIED BYPLATE / TAG.

6.14 DO THE STACKING OF THE PRODUCT IN THEBIN / TROLLEY / WOODEN BOXES / PLLETS TOAVOID DAMAGE DURING STORAGE ANDDESPATCH.

6.15 PREPARE NECESSARY DOCUMENTS FOR DESPATCH OF MATERIAL TO CUSTOMER

6.16 SHIP THE MATERIAL AS PER THE REQUIREMENTOF THE CUSTOMER. ALSO CONSIDER THE

TRANSPORTATION MODE, ROUTING DEFINED BY THE CUSTOMER.

6.17 RECEIVE ACKNOWLEDGEMENT FROM THECUSTOMER FOR MATERIAL SUPPLIED AS A TOKEN OF RECEIPT OF MATERIAL.

6.18 PREPARE THE DAILY STOCK STATEMENT INDICATING MATERIAL RECEIVED , MATERIAL DESPATCHED, STOCH IN HAND

6.19 MONITOR DELIVERY PERFORMANCE AGAINST SCHEDULE / PLAN ON DAILY BASIS.


INTERNAL




SL.NO ACTIVITY

6.20 INCASE OF DESCREPENCY, TAKE NECESSARY CORRECTIVE AND PREVENTIVE ACTION TO IMPROVE DELIVERY PERFORMANCE. INCLUD-ING COMMUNICATION TO CUSTOMER WHERE REQUIRED.

6.21 COMMUNICATE THE DETAILS OF SHIPMENT TO THE CUSTOMER AT THE TIME OF DESPATCH OFMATERIAL BY FAX, LETTER, OR ON TELEPHONE.

6.22 WHEN COMMUNICATION SYSTEM BY ELECTRO-NIC MEDIA , IN THE EVENT OF ITS FAILURE, INT-IMATE ADVANCE SHIPMENT DETAILS, BY LETTER / FAX / PHONE.

6.23 REVIEW DELIVERY PERFORMANCE AT LEASTONCE IN A MONTH AND INFORM CUSTOMER ONCORRECTIVE AND PREVENTIVE ACTION TAKENTO IMPROVE DELIVERY PERFORMANCEWHERE DISCREPENCY EXISTS.

6.24 EXPORT SHIPPING

6.24.1 PREPARE CONTAINER / VEHICLE LOADINGPLAN TO ENSURE DAMAGE FREE TRANSITNOTIFY TO CONCERN AGENCIES

6.24.2 PREPARE PACKING LIST FOR MATERIAL TO BEDESPATCH

6.24.3 ENSURE EACH BOX CONTAINING PRODUCTS ISIDENTIFIED BY LABEL / TAGS

6.24.4 PREPARE / ARRANGE EFFICIENTLY THENECESSARY DOCUMENTS FOR DESPATCH OFTHE MATERIAL TO THE CUSTOMER AS PERCUSTOMER STANDARD BIZ. EXPORT INVOICE,PACKAGING LIST , EXCISE INVOICE, LABELS,SHIPPING BILL , FUMIGATION CERTIFICATE &INSURANCE CERTIFICATE.

6.24.5 LOAD THE CONTAINER / VEHICLE AS PER PACKAGING LIST / CONTAINER LOADING PLAN


INTERNAL




SL.NO ACTIVITY

6.24.6 SHIP THE MATERIAL & WHEN CONTRACTULLYSPECIFIED BY CUSTOMER, COMMUNICATETRANSPORTATION ROUTING (CARRIER , MODEETC).

6.24.7 TRACK THE CONTAINER / CONSIGNMENT TILL IT REACHES THE DESTINATION

6.24.8 DO PACKAGING AUDIT AT LEAST ONCE IN AYEAR

6.24.9 INFORM TO ALL CONCERNED IF THERE IS ANYDEVIATION FROM MATERIAL PLANNING &LOGISTIC INSTRUCTION

6.24.10 INVESTIGATE THE ROOT CAUSE &COMMUNICATE TO CUSTOMER & SUPPLIER ASWELL FOR IMPLEMENTATION

6.25 CUSTOMER SPECIFIC REQUIREMENTS -

FORD (NOV 2003)

4.34 Identification and traceability, preservation, storage and inventory(ISO/TS 16949:2002 cl. 7.5.3, 7.5.4, 7.5.5, 7.5.5.1)


INTERNAL




7 DOCUMENTS :

7.1 RICO 14 QSP 01 PROCEDURE FOR MATERIAL HANDLING AND PRESERVATION.7.2 RICO 06 QSP 15 PROCEDURE FOR INSPECTION AND TEST STATUS.

(APPLICABLE TO RICO DHARUHERA)7.3 RICO 14 QWI 01 WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF

FINISHED GOODS.7.4 RICO 10 QWI 14 WORK INSTRUCTION FOR PACKAGING OF SHROUD RADIATOR7.5 RICO 10 QWI 17 WORK INSTRUCTION FOR PACKAGING FOR MISC. COMPONENT

( M/S AMTEK AUTO & RICO GGN )7.6 RICO 10 QWI 24 WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE P-407.7 RICO 10 QWI 30 WORK INSTRUCTION FOR PACKAGING OF OUTER CLUTCH (CD 100)7.8 RICO 10 QWI 31 WORK INSTRUCTION FOR PACKAGING OF CENTRE CLUTCH (CD 100)7.9 RICO 10 QWI 32 WORK INSTRUCTION FOR PACKAGING OF PRESSURE PLATE (CD 100)7.10 RICO 10 QWI 33 WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE (CD 100)7.11 RICO 11 QWI 01 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

FRONT HUB (HHML-I & HHML-II) 7.12 RICO 11 QWI 02 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

REAR HUB (HHML-I & HHML-II)7.13 RICO 11 QWI 03 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

FRONT PANEL (HHML-I & HHML-II)7.14 RICO 11 QWI 04 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

REAR PANEL (HHML-I & HHML-II)7.15 RICO 11 QWI 05 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

CFD-CD (HHML-I)7.16 RICO 11 QWI 08 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

C - PLATE (HHML-I , HHML-II & FCC-GGN)7.17 RICO 11 QWI 09 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

FFD - ASSY (HHML-I & HHML-II)7.18 RICO 11 QWI 11 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

GSD (HHML-I & HHML-II)7.19 RICO 11 QWI 12 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

CLUTCH ASSY (HHML-I & HHML-II)7.20 RICO 11 QWI 13 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

PR- PLATE (HHML-I , HHML-II & FCC-GGN)7.21 RICO 11 QWI 14 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

L - PLATE (HHML-I , HHML-II & FCC-GGN)7.22 RICO 11 QWI 25 WORK INSTRUCTION FOR MARUTI COMPONENT PACKAGING

OPERATOR7.23 RICO 11 QWI 27 WORK INSTRUCTION FOR CLEANING AND PACKAGING OPERATOR

OF OIL PUMP YE - 27.24 RICO 11 QWI 41 WORK INSTRUCTION FOR PACKAGING OPERATOR

OF H.S.P.P.L7.25 RICO 11 QWI 42 WORK INSTRUCTION FOR PACKAGING OPERATOR

OF A.V.R.7.26 RICO 11 QWI 44 WORK INSTRUCTION FOR PACKAGING UPPER &

LOWER BRACKET.


INTERNAL




7 DOCUMENTS :(APPLICABLE TO RICO HPDC DIV. GURGAON)

7.1 RICO 10 QWI 17 WORK INSTRUCTION FOR PACKAGING OF FCC RICO CASTINGCOMPONENTS

7.2 RICO 10 QWI 18 WORK INSTRUCTION FOR PACKAGING OF CRANK CASE RIGHT (HMSI)

7.3 RICO 10 QWI 34 W.I FOR PACKAGING OF FCC COMPONENTS ( CENTRE CLUTCH)

7.4 RICO 10 QWI 35 W.I FOR PACKAGING OF FCC COMPONENTS ( OUTER CLUTCH)

7.5 RICO 10 QWI 36 W.I FOR PACKAGING OF FCC COMPONENTS ( LIFTER PLATE)

7.6 RICO 10 QWI 37 W.I FOR PACKAGING OF FCC COMPONENTS ( PRESSURE PLATE )

7.7 RICO 11 QWI 06 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HUB FRONT

7.8 RICO 11 QWI 07 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HUB REAR

7.9 RICO 11 QWI 08 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF FRONT PANEL

7.10 RICO 11 QWI 09 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF REAR PANEL

7.11 RICO 11 QWI 10 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF FLANGE FINAL DRIVEN ASSY.

7.12 RICO 11 QWI 11 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF CIM 8086 FOR TCL

7.13 RICO 11 QWI 12 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HLOF 8954 FOR TCL

7.14 RICO 11 QWI 13 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF CIM 0551 FOR TCL

7.15 RICO 11 QWI 14 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HFF 969 FOR TCL

7.16 RICO 11 QWI 15 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HFF 331 FOR TCL

7.17 RICO 11 QWI 16 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER REAR 1043 FOR TCL

7.18 RICO 11 QWI 17 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER VALVE 404 FOR TCL

7.19 RICO 11 QWI 18 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER VALVE 405 FOR TCL

7.20 RICO 11 QWI 19 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER VALVE 404 / 405 FOR CUMMINS

7.21 RICO 11 QWI 20 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HFF 969 FOR CUMMINS

7.22 RICO 11 QWI 21 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF CIM 551 FOR CUMMINS

7.23 RICO 11 QWI 22 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF STRICKER LEFT FOR LGI


INTERNAL




7 DOCUMENTS :

7.24 RICO 11 QWI 23 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF STRICKER RIGHT FOR LGI

7.25 RICO 11 QWI 24 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF FMD FOR FCC RICO

7.26 RICO 11 QWI 25 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF FORKS (6 TYPES) FOR MUL

7.27 RICO 11 QWI 26 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER THERMO FOR HSCIL

7.28 RICO 11 QWI 27 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER WATER OUTLET FOR HSCIL

7.29 RICO 11 QWI 39 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF PANEL ASSY. FRONT FOR HMSI

7.30 RICO 11 QWI 42 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER CYLINDER HEAD F8D FOR MUL

7.31 RICO 11 QWI 43 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER CYLINDER HEAD F10D FOR MUL

7.32 RICO 11 QWI 44 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF CIM 1819 FOR CUMMINS

7.33 RICO 11 QWI 45 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF AIRCON BRACKET FOR JAGUAR / FORD

7.34 RICO 11 QWI 46 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF FAN IDLER BRACKET FOR JAGUAR / FORD

7.35 RICO 11 QWI 47 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF PAS BRACKET FOR JAGUAR / FORD

7.36 RICO 11 QWI 48 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF PQU 500022 BRACKET FOR LAND ROVER / FORD

7.37 RICO 11 QWI 49 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF PQU 500032 BRACKET FOR LAND ROVER / FORD

7.38 RICO 11 QWI 50 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF AUTO CLOSURE PLATE FOR LAND ROVER / FORD

7.39 RICO 11 QWI 51 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HOUSING TUNNEL ASSEMBLY FOR LAND ROVER / FORD

7.40 RICO 11 QWI 52 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF ALTERNATOR BRACKET FOR JAGUAR / FORD

7.41 RICO 11 QWI 53 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF ARC BRACKET FOR JAGUAR / FORD

7.42 RICO 11 QWI 54 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER GEAR SHIFT FOR HMSI

7.43 RICO 11 QWI 56 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HLOF FOR CUMMINS

7.44 RICO 11 QWI 57 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF CIM7069 FOR CUMMINS

7.45 RICO 11 QWI 59 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF STAY CHANGE WIRE FOR HSCIL

7.46 RICO 11 QWI 60 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER COMPOUND WATER OUTLET FOR HSCIL


INTERNAL



TITLERef ISO-TS 16949 , MMOG , QM Sec. 7.5

7 DOCUMENTS :7.47 RICO 11 QWI 61 WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERY

OF CLUTCH ASSY FOR HHML7.48 RICO 11 QWI 73 WORK INSTRUCTION FOR PACKAGING OF PROTOTYPE OR

PV TEST PARTS7.49 RICO 11 QWI 79 W.I. FOR PACKAGING OF PAS BRACKET ( AJ 42 / 44)

7.50 RICO 11 QWI 80 W.I. FOR PACKAGING OF ALTERNATOR BRACKET ( AJ 42/44)

7.51 RICO 11 QWI 82 PACKAGING OF BASE AS FUEL FILTER (136-5017) FOR CATERPILLER

7.52 RICO 11 QWI 83 PACKAGING OF BASE AS FUEL FILTER (141-5138) FOR CATERPILLER

7.53 RICO 11 QWI 84 PACKAGING OF ADOPTER (ATM PRESS) (166-6693) FOR CATERPILLER

7.54 RICO 11 QWI 85 PACKAGING OF MANIFOLD (168-0300) FOR CATERPILLER

7.55 RICO 11 QWI 87 WORK INSTRUCTION FOR PACKAGING OF COVER REAR3967200 FOR CUMMINS USA

7.56 RICO 11 QWI 88 WORK INSTRUCTION FOR PACKAGING OF COVER INTAKEMANIFOLD (3965566 & 3957907) FOR CUMMINS USA

7.57 RICO 11 QWI 93 WORK INSTRUCTION FOR PACKAGING OF TRANSFER BOX

7.58 RICO 11 QWI 95 WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING BKT (LH)

7.59 RICO 11 QWI 97 WORK INSTRUCTION FOR PACKAGING OF BKT SUPPORT AC (3711584)

7.60 RICO 11 QWI 98 WORK INSTRUCTION FOR PACKAGING OF BKT ACALTERNATOR (30731398)

7.61 RICO 11 QWI 101 W.I. FOR CHECKING , WASHING OILING & PACKAGING OFCIM & COVER REAR

7.62 RICO 11 QWI 105 WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING BKT (RH)

7.63 RICO 11 QWI 111 WORK INSTRUCTION FOR PACKAGING OF COVER COMP.THRUST (HSCIL)

7.64 RICO 11 QWI 112 WORK INSTRUCTION FOR PACKAGING OF EGR PLATE (HSCIL)

7.65 RICO 11 QWI 114 WORK INSTRUCTION FOR CHECKING, WASHING,PACKAGINGFOR PAS BKT - 6R83-3K738-BA

7.66 RICO 11 QWI 117 WORK INSTRUCTION FOR PACKAGING OF 2.2 LTR PAS BKT

7.67 RICO 11 QWI 119 PACKAGING OF BASE AS FUEL FILTER (1N3789) FOR CATERPILLER

7.68 RICO 11 QWI 120 WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT 30757329


INTERNAL




7 DOCUMENTS :7.69 RICO 11 QWI 121 WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT STAY FRONT

7.70 RICO 11 QWI 122 WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT FLYWHEEL SENSOR

7.71 RICO 11 QWI 125 WORK INSTRUCTION FOR PACKAGING OF PAS BKT - 6R83-3K738-BA

7.72 RICO 11 QWI 134 WORK INSTRUCTION FOR PACKAGING OF CRANK CASE COVER - HMSI

7.73 RICO 11 QWI 136 WORK INSTRUCTION FOR PACKAGING OF BKT 683

7.74 RICO 11 QWI 142 WORK INSTRUCTION FOR PACKAGING OF OIL FILTE HEADVERTICAL - PERKINS

7.75 RICO 11 QWI 144 WORK INSTRUCTION OF PACKAGING - BACK PLATE


INTERNAL




8 RECORDS :


---- ---- ---

---- ---- ---

---- ---- ---

---- ---- ---


INTERNAL






08 25-06-2003

09 15-04-2004 Procedure reviewed for Ford specific requirements NOV 2003



12 20-05-2006


New developed parts Packaging work instruction added to procedure



ALUMINIUM PLANTS


PACKAGING AND DELIVERY OF PRODUCT ISSUE NO 12


TO ESTABLISH A SYSTEM FOR PACKAGING & DELIVERY OF FINISHED PRODUCTS.

HOD (HPDC) / HOD (M/C SHOP) / SECTION HEAD (PAINT SHOP) / HOD (MP&L) IS RESPONSIBLE


OPERATOR(PACKAGING)

HELPER

HELPER

OPERATOR / RELEVANT

HELPER PACKAGING WORKINSTRUCTION

HELPER

HELPER

COPY STATUS SHEET

01 OF 11

ALUMINIUM PLANTS





SECTION HEAD(PRODN)

SECTION HEADEXCISE

SECTION HEADPPC / EXCISE

SECTION HEADEXCISE

SECTION HEADEXCISE

SECTION HEADEXCISE

SECTION HEADPPC

HELPER

SECTION HEADEXCISE

SECTION HEADEXCISE / HOD(PRODN)

SECTION HEADEXCISE

SECTION HEADEXCISE / SECTIONHEAD (PPC)

PLANT MANAGER /HEAD (PP/LOGISTICS)

COPY STATUS SHEET

02 OF 11

ALUMINIUM PLANTS





PLANT MANAGER /HOD (MP&L)




SECTION HEAD (MP&L)

SECTION HEAD (PRODN.)

SECTION HEAD (PRODN.)

SECTION HEAD (EXCISE) /SHOD (MP&L) / SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

COPY STATUS SHEET

03 OF 11

ALUMINIUM PLANTS





SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

SECTION HEAD(PRODN.)

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

RESP. - MP&L HOD

4.34 Identification and traceability, preservation, storage and inventory

COPY STATUS SHEET

04 OF 11

ALUMINIUM PLANTS




PROCEDURE FOR MATERIAL HANDLING AND PRESERVATION.PROCEDURE FOR INSPECTION AND TEST STATUS.

WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF

WORK INSTRUCTION FOR PACKAGING OF SHROUD RADIATORWORK INSTRUCTION FOR PACKAGING FOR MISC. COMPONENT

WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE P-40WORK INSTRUCTION FOR PACKAGING OF OUTER CLUTCH (CD 100)WORK INSTRUCTION FOR PACKAGING OF CENTRE CLUTCH (CD 100)WORK INSTRUCTION FOR PACKAGING OF PRESSURE PLATE (CD 100)WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE (CD 100)WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR








WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FORPR- PLATE (HHML-I , HHML-II & FCC-GGN)WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR

WORK INSTRUCTION FOR MARUTI COMPONENT PACKAGING

WORK INSTRUCTION FOR CLEANING AND PACKAGING OPERATOR

WORK INSTRUCTION FOR PACKAGING OPERATOR

WORK INSTRUCTION FOR PACKAGING OPERATOR

WORK INSTRUCTION FOR PACKAGING UPPER &

COPY STATUS SHEET

05 OF 11

ALUMINIUM PLANTS




WORK INSTRUCTION FOR PACKAGING OF FCC RICO CASTING

WORK INSTRUCTION FOR PACKAGING OF CRANK CASE RIGHT (HMSI)

W.I FOR PACKAGING OF FCC COMPONENTS ( CENTRE CLUTCH)

W.I FOR PACKAGING OF FCC COMPONENTS ( OUTER CLUTCH)

W.I FOR PACKAGING OF FCC COMPONENTS ( LIFTER PLATE)

W.I FOR PACKAGING OF FCC COMPONENTS ( PRESSURE PLATE )

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERY













WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER VALVE 404 / 405 FOR CUMMINSWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERY



COPY STATUS SHEET

06 OF 11

ALUMINIUM PLANTS










WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER CYLINDER HEAD F8D FOR MULWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER CYLINDER HEAD F10D FOR MULWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERY

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF AIRCON BRACKET FOR JAGUAR / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF FAN IDLER BRACKET FOR JAGUAR / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERY

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF PQU 500022 BRACKET FOR LAND ROVER / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF PQU 500032 BRACKET FOR LAND ROVER / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF AUTO CLOSURE PLATE FOR LAND ROVER / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF HOUSING TUNNEL ASSEMBLY FOR LAND ROVER / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF ALTERNATOR BRACKET FOR JAGUAR / FORDWORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERY





WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVELVERYOF COVER COMPOUND WATER OUTLET FOR HSCIL

COPY STATUS SHEET

07 OF 11

ALUMINIUM PLANTS





WORK INSTRUCTION FOR PACKAGING OF PROTOTYPE OR

W.I. FOR PACKAGING OF PAS BRACKET ( AJ 42 / 44)

W.I. FOR PACKAGING OF ALTERNATOR BRACKET ( AJ 42/44)

PACKAGING OF BASE AS FUEL FILTER (136-5017) FOR CATERPILLER

PACKAGING OF BASE AS FUEL FILTER (141-5138) FOR CATERPILLER

PACKAGING OF ADOPTER (ATM PRESS) (166-6693) FOR CATERPILLER

PACKAGING OF MANIFOLD (168-0300) FOR CATERPILLER

WORK INSTRUCTION FOR PACKAGING OF COVER REAR

WORK INSTRUCTION FOR PACKAGING OF COVER INTAKEMANIFOLD (3965566 & 3957907) FOR CUMMINS USAWORK INSTRUCTION FOR PACKAGING OF TRANSFER BOX

WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING BKT (LH)

WORK INSTRUCTION FOR PACKAGING OF BKT SUPPORT AC (3711584)

WORK INSTRUCTION FOR PACKAGING OF BKT AC

W.I. FOR CHECKING , WASHING OILING & PACKAGING OF

WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING BKT (RH)

WORK INSTRUCTION FOR PACKAGING OF COVER COMP.

WORK INSTRUCTION FOR PACKAGING OF EGR PLATE (HSCIL)

WORK INSTRUCTION FOR CHECKING, WASHING,PACKAGING

WORK INSTRUCTION FOR PACKAGING OF 2.2 LTR PAS BKT

PACKAGING OF BASE AS FUEL FILTER (1N3789) FOR CATERPILLER

WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT 30757329

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WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT STAY FRONT

WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT FLY

WORK INSTRUCTION FOR PACKAGING OF PAS BKT - 6R83-3K738-BA

WORK INSTRUCTION FOR PACKAGING OF CRANK CASE COVER - HMSI

WORK INSTRUCTION FOR PACKAGING OF BKT 683

WORK INSTRUCTION FOR PACKAGING OF OIL FILTE HEAD

WORK INSTRUCTION OF PACKAGING - BACK PLATE

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Procedure reviewed for Ford specific requirements NOV 2003 15-04-2004



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New developed parts Packaging work instruction added to Management


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INTERNAL


TITLEINVENTORY CONTROL


1 PURPOSE :

TO ESTABLISH A SYSTEM TO MAINTAIN OPTIMUM INVENTORY LEVEL AND STOCKROTATION.

2 SCOPE :

THIS PROCEDURE COVERS INVENTORIES AT INCOMING STORAGE , WORK IN PROGRESS ,COMPONENTS , CONSUMABLES AND FINISH GOODS STOCKS.


MRR - MATERIAL RECEIPT REPORTHOD - HEAD OF DEPARTMENTFIFO - FIRST IN FIRST OUT


FOR ORGANISATION , PLEASE REFER ORGANISATION CHART

4.1 PLANT MANAGER IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE.

4.2 HOD PURCHASE IS RESPONSIBLE FOR PROCUREMENT OF MATERIAL REQUIRED.


5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS(REFER TURTLE DIAGRAM - STORES, MATERIL HANDLING & INVENTORY)

6 DESCRIPTION

SL.NO ACTIVITY

6.1 RECEIPT STAGE

6.1.1 DECIDE THE MINIMUM & MAXIMUM LEVELS.THELEVELS IS BEING MONITORED IN THE SYSTEMON DAILY BASIS BY THE PURCHASE DEPTT.ACCORDINGLY.

NOTE : - NON CRITICAL HIGH VALUE SPARES WILL NOT BE HAVING ANY LEVEL. THESE WILLBE PROCURED AGAINST PURCHASE REQUISITION.

6.1.2 INITIATE THE ACTION FOR PROCUREMENT.

6.1.3 RECEIVE THE NECESSARY DOCUMENT OF MATERIAL RECEIPT AT SECURITY GATE OFFICE.

6.1.4 ENTER THE RELEVANT DETAIL IN THECOMPUTOR FOR SCHEDULED QTY. TO BE RECEIVE FROM VENDOR.


INTERNAL




SL.NO ACTIVITY

6.1.5 IF COMPUTOR INDICATES OVER SCHEDULED,THEN SEND BACK THE MATERIAL TO VENDOR.

6.1.6 IF WITHIN SCHEDULED NORMS, ENTER THE RE-LEVANT DETAIL IN COMPUTOR.

6.1.7 MAKE MATERIAL RECEIPT REPORT (MRR)

6.1.8 RECEIVE THE MATERIAL AND STORE IN SUCHA WAY THAT STOCK CAN BE ROTATED ON REGULAR BASIS AND FIFO CAN BE FOLLOWEDIN CASE OF SELF LIFE ITEMS.

6.1.9 DO MONTHLY PHYSICAL STOCK TAKING.

6.1.10 UPDATE THE STOCK LEVELS AND INFORM TO HOD (PURCHASE) IN CASE THE STOCK VARIESWITH RESPECT TO LEVEL DECIDED

6.1.11 BASED ON 5.1.9 ABOVE , REVIEW THE DELIVERY SCHEDULE & PASS ON NECESSARYINSTRUCTION TO THE CONCERN SUBCONTRAC-TOR AS REQUIRED.

6.1.12 ISSUE THE MATERIAL TO CONCERN USER CONSIDERING THE FIFO / STOCK ROTATION.

6.2 WORK IN PROGRESS

6.2.1 RECEIVE PRODUCTION PLAN FROM PPC DEPARTMENT

6.2.2 MAINTAIN THE PRODUCTIVITY NORM OF RESPECTIVE SHOPS

6.2.3 GET THE MATERIAL ISSUED FROM THE STORESIN ADVANCE AS PER PLANNING.

6.2.4 CARRY OUT PRODUCTION AS PER PLANNING SCHEDULE.


INTERNAL




SL.NO ACTIVITY

6.2.5 INCASE ANY REVISION IN PRODUCTION PLANFOLLOW STEP 5.2.3 TO ONWARDS.

6.2.6 TRANSFER THE MATERIAL FOR FINAL INSPECT-ION AND PACKAGING AS PER CUSTOMERREQUIREMENTS.

6.2.7 TRANSFER THE NON-CONFORMING MATERIALTO RESPECTIVE SHOP THROUGH REWORK INTIMATION SLIP OR TO SCRAP YARD THROUGHREJECTION REPORT.

6.2.8 ARRANGE TO CARRY OUT THE PHYSICAL VERIFICATION OF DOCUMENTED STOCK ON MONTHLY BASIS.

6.2.9 REVIEW THE INVENTORY REPORT AND TAKE NECESSARY CORRECTIVE / PREVENTIVEACTION TO ELIMINATE OR MINIMISE THE VARIA-TION IN DOCUMENTED AND PHYSICAL STOCK.

6.3 FINISHED GOODS STORES

6.3.1 DECIDE THE INVENTORY LEVEL TAKING CUSTOMER REQUIREMENT IN CONSULTATIONWITH PLANT MANAGER.

6.3.2 RECEIVE THE CONFORMING MATERIAL AFTERFINAL INSPECTION.

6.3.3 ARRANGE TO SEND THE MATERIAL TO CUSTOMER WITH RELEVANT DOCUMENT.

6.4 DO MONTHLY INVENTRY & FILL RG-1 FORM FORINVENTORY ANALYSIS AND EXCISE PURPOSE.

NOTE : DIRECT DATA LINK6.5 WHERE APPLICABLE AND CUSTOMER

MENDATORY REQUIREMENT, RICO WILL USEDINTERACTIVE INVENTORY MANAGEMENTSYSTEM E.G. DDL (DIRECT DATA LINK) & HOD(MP&L) WILL BE RESPONSIBLE TO ANSWERDAILY SHORTAGE AND NEW MODEL LAUNCHREQUIREMENT ACCURATELY AND INACCORDANCE TO THE FORD PROCEDURE.THIS DDL COVERAGE WILL BE PROVIDED TOCUSTOMER IN CUSTOMER OPERATING HOURS.


INTERNAL




7 DOCUMENTS :

7.1 RICO 08 QSP 01 PROCEDURE FOR PURCHASING

7.2 RICO 16 QSP 01 PROCEDURE FOR STORES

8 RECORDS :


STORE, EXCISE

MONTHLY INVENTRY DATA FOR RM / BOP, WIP & FINISH

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INTERNAL






07 25-06-2003







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ALUMINIUM PLANTS


INVENTORY CONTROL ISSUE NO 09


TO ESTABLISH A SYSTEM TO MAINTAIN OPTIMUM INVENTORY LEVEL AND STOCK

THIS PROCEDURE COVERS INVENTORIES AT INCOMING STORAGE , WORK IN PROGRESS ,

PLANT MANAGER IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE.

HOD PURCHASE IS RESPONSIBLE FOR PROCUREMENT OF MATERIAL REQUIRED.


PLANT HEAD /HOD (PURCHASE)

NOTE : - NON CRITICAL HIGH VALUE SPARES WILL NOT BE HAVING ANY LEVEL. THESE WILL

HOD (PURCHASE) /SECTION HEAD(PURCHASE)

SECTION HEAD(SECURITY)


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SECTION HEAD RICO 16 QFO 02( STORES)

HOD (STORES)

HOD (STORES)

HOD (STORES)

HOD (PURCHASE)SECTION HEAD(PURCHASE)

HOD (STORE) RICO 16 QWI 04SECTION HEAD

(STORE)

RESPECTIVE SECTION HEAD




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SECTION HEAD (QA)

PLANT MANAGER

PLANT MANAGER /HOD (PURCHASE)

HOD (MP&L)

SECTION HEAD (EXCISE)

HOD (MP&L) /SECTION HEAD(EXCISE)

SECTION HEAD(EXCISE)

HOD (MP&L) /SECTION HEAD (MP&L)

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STORE, EXCISE

6 MONTH PLANT MANAGER

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DOC. NO : RICO 01 QM 01 QUALITY MANUALCHAPTER : 7.4

PRODUCT REALIZATIONPURCHASING

A : PURPOSE

Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence.

B : SCOPE

Applicable for all purchased raw materials, bought out components, packing materials other consumable items and services which have bearing on the quality of the products made by RICO AUTODharuhera / HPDC Gurgaon

C : RESPONSIBILITY AND AUTHORITYHod (Purchase) is responsible for ensuring the requirements of this chapterHod (Q.A.) is responsible for verification and take corrective action in case of nonconformance.

D : DESCRIPTION

7.4 PURCHASING7.4.1 PURCHASING PROCESSRICO AUTO INDUSTRIES LIMITED ensures that purchased product conforms as per purchasing to specified purchase requirements. The type and extent of control applied to the supplier and the purchased product is depended upon the effect of the purchased product on subsequent product realization or the final product.The purchasing department selects suppliers on the requisites of quality, price, and delivery. The selection criteria is documented and based on one or more of the following:

A inspection of final product at the sub-contractor’s facility.B inspection of final product upon deliveryC historical performance of adherence to purchasing requirementsD sub-contractor’s conformance to an international standard

When there are mergers, acquisitions or affiliations associated with suppliers, the organization will verify the continuity of the supplier’s quality system and its effectiveness.

7.4.1.1 REGULATORY COMPLIANCEAll purchased products or materials used in product satisfy applicable regulatory requirements.

7.4.1.2 SUPPLIER QUALITY MANAGEMENT SYSTEM DEVELOPMENTRICO AUTO INDUSTRIES LIMITED has a defined procedure for development of subcontractorRICO AUTO INDUSTRIES LIMITED performs supplier quality management system development with the goal of supplier compliance to this technical specification.

7.4.1.3 CUSTOMER- APPROVED SOURCES

Where specified by the contract, RICO AUTO INDUSTRIES LIMITED purchases products, materials or services from approved sources.

The use of customer-designated sources, including tool/gauge suppliers, does not relieve the RICO AUTO INDUSTRIES LIMITED’s responsibility for ensuring the quality of purchased products




7.4.2 PURCHASING INFORMATIONPurchasing documents contain data that clearly describes the product ordered, including where applicable:Purchasing documents are reviewed and approved for adequacy of specified requirements prior to release.

A The type class, grade, requirements, or other precise identification.B The title or other positive identification applicable to the issue of specifications, drawings,

process requirements, inspection instructions, and other relevant technical data, including requirements for approval or qualification of personnel / or product.

C Quality management system requirements.

7.4.3 VERIFICATION OF PURCHASED PRODUCTRICO AUTO INDUSTRIES LIMITED has established and maintained for the verification of purchased product upon receipt. Purchased product failing to meet requirements is documented and returned to the supplier. Records of purchased product verification are maintained as quality records.

If so required by contract or agreement, the customer is afforded the right to inspect our subcontractors. The verification arrangements and product validation will be stated in purchasing documentation. The customer’s acceptance of the product does not absolve the company or the supplier from providing acceptable product or meeting specifications.

7.4.3.1 INCOMING PRODUCT QUALITYRICO AUTO INDUSTRIES LIMITED has a process to ensure the quality of purchased product utilizing one or more of the following methods:

- Receipt of, and evaluation of, statistical data by the organization.- Receiving inspection and/or testing such as sampling based on performance.- Second or third party assessments or audits of supplier sites, when coupled with records of acceptable quality performance.- Part evaluation by a designated laboratory.- Another method agreed with the customer.

7.4.3.2 SUPPLIER MONITORINGSupplier performance is monitored through the following indicators:

- Delivered part quality performance.- Customer disruptions including field returns.- Delivery schedule performance (including incidents of premium freight).- Special status customer notifications related to quality or delivery issues.

RICO AUTO INDUSTRIES LIMITED promotes supplier monitoring of the performance of there manufacturing processes.

E : RECORDS

REVISION NO. : 01ISSUE DATE : 15-12-2003

Records are maintained as described in the procedure.




F : REFERENCES

FOR ALUMINIUM DIVISIONSRICO 08 QSP 01 Procedure for PurchasingRICO 08 QSP 02 Procedure for Assessment and selection of SupplierRICO 08 QSP 03 Procedure for Supplier developmentRICO 06 QSP 01 Procedure for Incoming material inspection and testingRICO 18 QSP 01 Procedure for product realization / advanced product quality planningRICO 06 QSP 06 Procedure for control on non-conforming product.RICO 06 QSP 07 Procedure for corrective and preventive actionRICO 06 QSP 09 Procedure for control of quality records

FOR FERROUS FOUNDRY DIVISIONQSP/RICO GGN/ 06.1 Procedure for Purchase specificationQSP/RICO GGN/ 06.2 Procedure for Evaluation selection and development of sub contractorsQSP/RICO GGN/ 06.3 Procedure for Purchase document release QSP/RICO GGN/ 10.1 Procedure for Receiving inspection and testingQSP/RICO GGN/ 02.1 Procedure for Advanced product quality planning ( apqp)QSP/RICO GGN/ 13.1 Control of non conforming productQSP/RICO GGN/ 14.1 Corrective & preventive actionQSP/RICO GGN/ 16.1 Procedure for control of quality records

G : BRIEF DESCRIPTION OF AMENDMENT DETAIL

DATE NATURE OF CHANGE / DESCRIPTION W.e.f.

04 / 01 15-12-2003


EDITION NO. / REVISION NO.

Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual

15-12-2003



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DOC. NO : RICO 01 QM 01 QUALITY MANUAL

CHAPTER : 7.5

PRODUCT REALIZATION

PRODUCTION AND SERVICE PROVISION

A : PURPOSE


B : SCOPE

Covers all customer supplied product , such as components , toolings, gauges & Consumables and returnable packaging.

C : RESPONSIBILITY AND AUTHORITYPlant manager is responsible for ensuring control measures during different stages of operations.specific responsibilities are detailed in the relevant procedures

It is the responsibility of all the employees to follow the procedure laid down specific responsibilities


wherever applicable are referred to in the relevant procedures.

HOD (Q.A.) / Respective Shop Heads are responsible for maintaining inspection and test status at different stages of operations.

D : DESCRIPTION

7.5 PRODUCTIONS AND SERVICE PROVISION7.5.1 CONTROL OF PRODUCTION AND SERVICE PROVISION.A : production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence.B : documented work instructions, where necessary, define the specific methods to be used at operations where the absence of work instructions would be detrimental to product realization.C : production operations are accomplished with appropriately maintained tooling and machines, equipment.D : measuring and monitoring devices are utilized to evaluate the product in process, at various stages of production, and to evaluate the result of product realization.E : employees responsible for the individual operations as well as in-process inspection perform product monitoring by quality control personnel. Final product acceptance is the responsibility of the quality control department.F : defined processes are established, maintained, and responsibilities assigned, for product release, delivery, and applicable post-delivery activities such as customer complaint.

7.5.1.1 CONTROL PLANRICO AUTO INDUSTRIES LIMITED develops control plans for pre-launch and productions that take into account the manufacturing process fmea outputs.The control plan does

- List the controls used for the manufacturing process control- Include methods for monitoring of control exercised over special characteristics defined by both the customer and the organization,- Include the customer required information, if any, and- Initiate the specified reaction plan when the process becomes unstable or not statistically capable.



CHAPTER : 7.5

PRODUCT REALIZATION


Control plans shall be reviewed and updated when any change occurs affecting product, manufacturing process, measurements, logistics, supply sources or fmea.Customer will review control plan, if it is in agreement with customer at the time of contract

7.5.1.2 WORK INSTRUCTIONSRICO AUTO INDUSTRIES LIMITED prepares documented standard operating procedure, quality documents for various activities and works instructions for all employees having responsibilities for the operation of processes. These instructions are accessible for use of the workstation.These instructions are derived from sources such as the control plan and the product realization process.

7.5.1.3 VERIFICATION OF JOB SET-UPSJob set-ups are verified whenever performed, such as initial run of a job, material changeover, and job change.


Work instructions are available for set-up personnel. RICO AUTO INDUSTRIES LIMITED uses statistical methods or verification where applicable. Last-off-part inspection is carried out to compare the first-piece approval part.

7.5.1.4 PREVENTIVE AND PREDICTIVE MAINTENANCERICO AUTO INDUSTRIES LIMITED identifies key process equipment and provides resources for machine / equipment maintenance and has developed an effective planned total preventive maintenance system. The system includes following:

- Planned maintenance activities- Packaging and preservation of equipment, tooling and gauging,- Availability of replacement parts for key manufacturing equipment,- Documenting, evaluating and improving maintenance objectives.

RICO AUTO INDUSTRIES LIMITED utilizes predictive maintenance methods to continually improve the effectiveness and the efficiency of production equipment.

7.5.1.5 MANAGEMENT OF PRODUCTION TOOLINGRICO AUTO INDUSTRIES LIMITED provides resources for tool and gauge design, fabrication and verification and activities. RICO AUTO INDUSTRIES LIMITED has established and implements a system for production tooling management including:

- Maintenance and repair facilities and personnel.- Storage and recovery.- Set-up.- Tool-change program’s for perishable tools.- Tool design modification documentation,- Tool modification and revision to documentation- Tool identification, defining the status, such as production, repair or disposal.

RICO AUTO INDUSTRIES LIMITED has a system to monitor these activities if any work is out sources.

7.5.1.6 PRODUCTION SCHEDULINGProduction is scheduled in order to meet customer requirements, such as just in time supported by an information system that permits access to production information at key stages of the process and is order driven.

7.5.1.7 FEEDBACK OF INFORMATION FROM SERVICEThis is not applicable since after sales service not applicable

7.5.1.8 SERVICING AGREEMENT WITH CUSTOMERThis is not applicable since after sales service not applicable.



CHAPTER : 7.5

PRODUCT REALIZATION


7.5.2 VALIDATION OF PROCESSES FOR PRODUCTION AND SERVICE PROVISIONRICO AUTO INDUSTRIES LIMITED do validation of the product at periodic intervals. Validation arrangements are defined and established and include,

- Qualification of processes;- Qualification of equipment and personnel


- Use of specific methods and procedures- Requirements for records- Re-validation

7.5.3 IDENTIFICATION AND TRACEABILITYThe identification of the product is established and maintained for all products, to all applicable drawings, or other documentation during all stages of product realization and delivery.Where traceability is specified, the products have a recorded unique lot number.

7.5.4 CUSTOMER PROPERTYAt RICO AUTO INDUSTRIES LIMITED customer supplied products are verified, stored and properly maintained.Lost or unsuitable property is reported to customer and records are maintained.

7.5.4.1 CUSTOMER OWNED PRODUCTION TOOLINGAt RICO AUTO INDUSTRIES LIMITED, all customer owned toolings are permanently marked with suitable means

7.5.5 PRESERVATION OF PRODUCTRICO AUTO INDUSTRIES LIMITED has established procedure for preservation during storage, process and finished product to prevent deterioration in the product qualityRICO AUTO INDUSTRIES LIMITED has established procedure for packing, packaging , marking which also Takes care of customer packaging standard and labeling requirements.

7.5.5.1 STORAGE AND INVENTORYDesignated storage area are provided for storage of material with required facilities for preventing damages and deterioration . Receipt and issue from stores is approved by authorized personnel . Item having limited shelf life are identified and first in first out (FIFO) procedure is followed for issuing those items. Provisions are also made to assess the condition of these items at a defined frequency.

RICO AUTO INDUSTRIES LIMITED has established and implemented inventory management system at all stages and assures stock rotation. Obsolete products are also considered as non-conforming products.

E : RECORDS


PREPARED BY APPROVED BY ISSUED BYREVISION NO. : 01

ISSUE DATE : 15-12-2003


CHAPTER : 7.5

PRODUCT REALIZATION


F : REFERENCES

FOR ALUMINIUM DIVISIONSRICO 10 QSP 01 Procedure for process control & production (HPDC)RICO 11 QSP 01 Procedure for process control & production (Machine shop & F.M.)RICO 19 QSP 01 Procedure for process control & production (Paint shop)RICO 09 QSP 01 Procedure for process control & production (PPC)RICO 16 QSP 01 Procedure for StoresRICO 06 QSP 15 Procedure for Identification and traceabilityRICO 06 QSP 10 Procedure for customer complaint resolutionRICO 06 QSP 14 Procedure for Control of customer supplied productRICO 13 QSP 01 Procedure for MaintenanceRICO 12 QSP 01 Procedure for Control planRICO 14 QSP 04 Procedure for Inventory control

FOR FERROUS FOUNDRY DIVISIONQSP/RICO GGN/ 09.0 Procedure for Procedure for process controlQSP/RICO GGN/ 09.3 Procedure for Production of castings in foundry shopQSP/RICO GGN/ 09.4 Procedure for production ofcomponents in m/c shop QSP/RICO GGN/ 09.5 Procedure for paint shopQSP/RICO GGN/ 09.2 Procedure for Production planning & controlQSP/RICO GGN/ 15.1 Procedure for Handling & storage QSP/RICO GGN/ 08.1 Procedure for Product identification and traceabilityQSP/RICO GGN/ 14.2 Procedure for Customer complaint handling & dispositionQSP/RICO GGN/ 07.1 Procedure for Control of customer supplied productQSP/RICO GGN/ 09.1 Procedure for Maintenance QSP/RICO GGN/ 02.4 Procedure for Control plan ( cp ) establishmentQSP/RICO GGN/ 09.2 Procedure for Production planning & control



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15-12-2003

CHAPTER : 7.6PRODUCT REALIZATION

CONTROL OF MONITORING AND MEASURING DEVICES

A : PURPOSE


B : SCOPE

Covers all gauges & equipment used in RICO AUTO INDUSTRIES LIMITED.

C : RESPONSIBILITY AND AUTHORITY

HOD(Q.A.) is responsible for control and calibration of all equipments covered under calibration procedure.He is also responsible for measurement system analysis.

D : DESCRIPTION

7.6 CONTROL OF MEASURING AND MONITORING DEVICESAll measuring devices are maintained and established ensuring the suitability of measuring and monitoring devices. Measuring and monitoring devices are consistent with the degree of accuracy needed to evaluate conformity of the product during all phases of the manufacturing process.

Measuring and monitoring devices are controlled as a numbering system for each device in use is maintained and periodic cleaning, re-calibration is conducted and results are recorded.

accuracy and usability. Calibration activities, where applicable, are traceable to NPL / national equivalent.

handling, maintenance, and storage.

taken to validate previous results.

7.6.1 MEASUREMENT SYSTEM ANALYSISMeasurement system analysis is also carried out for all type of measurement system to analyze the variation,using statistical technique as per msa reference manual

7.6.2 CALIBRATION / VERIFICATION RECORDSRico has identified measurements to be made and the accuracy required for measurement. accordingly, the inspection, measuring & test equipments selected. hardware and software used for inspection and testing that need calibration are also identified. Unique identification numbers are allocated to these equipments.

This listing includes details of equipment type, identification number, location, frequency of check, check method and accuracy required, acceptance criteria and action taken when results are unsatisfactory.

The calibration is carried out in accordance with the laid down procedure as per in house qualified lab whichcome under lab scope or otherwise done by calibration facilities accredited to iso/iec guide or national equivalent .

A Measuring and monitoring devices are calibrated and adjusted at defined intervals to ensure continued

B Results of initial calibration and re-calibration or adjustment of measuring and monitoring devices is recorded.C All measuring and monitoring devices identify the calibration status.D All precision measuring and monitoring devices are maintained for protection from damage during

E In the event a measuring and monitoring device is found to be out of calibration, corrective action is



PRODUCT REALIZATIONCONTROL OF MONITORING AND MEASURING DEVICES

The calibration records are maintained against each of such equipment coming under the calibration activity. The equipments coming under the calibration activity are identified to show the calibration status. The persons using the calibrated equipments are adequately instructed to store and handle them in such a way that the fitness for use and accuracy are maintained. Provision to safeguard the calibrated equipments from adjustment and setting are also made as and where applicable. The calibration is carried out under standard conditions, detailed in relevant procedures.

During calibration of the equipment, if the equipment is found to be out of calibration , the validity of previousinspection and test results are assessed through the quality records /available product / customer complaint and documents. Customers are informed about the shipment of the suspected products. If an equipment is notconforming to the laid down acceptance criteria, it is identified and removed from the point of use.

matrix (calibration & testing) and laboratory quality system procedure as per lab scope. If required bycustomer RICO uses accredited lab for laboratory work perform from out side.

From time to time, an assessment is made by HOD (Q.A.) in consultation with concerned heads of department,to identify the need for any new inspection, measuring and test equipments.

RICO to ensure notification to the customer if suspect product or material has been shipped.

7.6.3 LABORATORY REQUIREMENTS7.6.3.1 INTERNAL LABORATORYRico has established and implemented all applicable laboratory requirements which come under laboratory scope. Rico has documented its policy,system procedure, of laboratory to assure that test result generatedwithin lab scope.

Rico have professionals with relevant background and experience for laboratory process decision making.

Rico has established procedure for product identification and testing, products are being kept in lab asper requirements.

Process control conditions are monitored and recorded that may influence quality. Rico has established all lab test method either agreed by customer or current issue of national / international standards.

System has been established for verification of lab capability and appropriate statistical technique is used to verify the activities where applicable.

The sampling norms for inspection if applicable, are indicated in the relevant procedures.

Before dispatch of the products, it is ensured that inspection and testing has Carried out as per the relevantprocedures and records are available clearly Indicating the authority responsible for release of product.


Calibration of inspection, measuring or test equipment is conducted in as per RICO'S laboratory scope



PRODUCT REALIZATIONCONTROL OF MONITORING AND MEASURING DEVICES

7.6.3.2 EXTERNAL LABORATORYExternal / commercial / independent laboratory (if required) facilities used for inspection, test or calibration services by RICO AUTO INDUSTRIES LIMITED has defined laboratory scope that includes the capability to perform the required inspection, test or calibration, and the laboratory accredited to iso/iec 17025 or national equivalent, or there shall be evidence that the external laboratory is acceptable to the customer

E : RECORDS


F : REFERENCES

FOR ALUMINIUM DIVISIONSRICO 06 QSP 16 Procedure for Laboratory managementRICO 06 QSP 17 Procedure for Laboratory process control & testingRICO 06 QSP 05 Procedure for Measurement system analysisRICO 06 QSP 12 Procedure for Control of inspection measuring and test equipmentRICO 06 QSP 09 Procedure for Control of quality records

FOR FERROUS FOUNDRY DIVISIONQSP/RICO GGN/ 10.5 Procedure for Laboratory management procedureQSP/RICO GGN/ 11.1 Procedure for Control of inspection, measuring and test equipmentQSP/RICO GGN/ 11.2 Procedure for Measurement system analysisQSP/RICO GGN/ 16.1 Procedure for control of quality records



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Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding

Applicable for all purchased raw materials, bought out components, packing materials other consumable items and services which have bearing on the quality of the products made by RICO AUTO

RICO AUTO INDUSTRIES LIMITED ensures that purchased product conforms as per purchasing to specified purchase requirements. The type and extent of control applied to the supplier and the purchased product is depended upon the effect of the purchased product on subsequent product realization or the

The purchasing department selects suppliers on the requisites of quality, price, and delivery. The selection

When there are mergers, acquisitions or affiliations associated with suppliers, the organization will verify the

RICO AUTO INDUSTRIES LIMITED performs supplier quality management system development with the

Where specified by the contract, RICO AUTO INDUSTRIES LIMITED purchases products, materials or

The use of customer-designated sources, including tool/gauge suppliers, does not relieve the RICO AUTO

Purchasing documents contain data that clearly describes the product ordered, including where applicable:Purchasing documents are reviewed and approved for adequacy of specified requirements prior to release.

B The title or other positive identification applicable to the issue of specifications, drawings, process requirements, inspection instructions, and other relevant technical data, including

RICO AUTO INDUSTRIES LIMITED has established and maintained for the verification of purchased product upon receipt. Purchased product failing to meet requirements is documented and returned to the supplier.

If so required by contract or agreement, the customer is afforded the right to inspect our subcontractors. The verification arrangements and product validation will be stated in purchasing documentation. The customer’s acceptance of the product does not absolve the company or the supplier from providing

RICO AUTO INDUSTRIES LIMITED has a process to ensure the quality of purchased product utilizing

- Second or third party assessments or audits of supplier sites, when coupled with records of

RICO AUTO INDUSTRIES LIMITED promotes supplier monitoring of the performance of there manufacturing

EDITION - 04SHEET 01 OF 03

Procedure for product realization / advanced product quality planning

Procedure for Evaluation selection and development of sub contractors

APPROVED BY



QEHS Corp.


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Plant manager is responsible for ensuring control measures during different stages of operations.

It is the responsibility of all the employees to follow the procedure laid down specific responsibilities


HOD (Q.A.) / Respective Shop Heads are responsible for maintaining inspection and test status at

A : production operations are planned and verified to ensure that they are proceeding under controlled

B : documented work instructions, where necessary, define the specific methods to be used at operations

C : production operations are accomplished with appropriately maintained tooling and machines, equipment.D : measuring and monitoring devices are utilized to evaluate the product in process, at various stages of

E : employees responsible for the individual operations as well as in-process inspection perform product monitoring by quality control personnel. Final product acceptance is the responsibility of the quality control

F : defined processes are established, maintained, and responsibilities assigned, for product release, delivery,

RICO AUTO INDUSTRIES LIMITED develops control plans for pre-launch and productions that take into

- Include methods for monitoring of control exercised over special characteristics defined by

- Initiate the specified reaction plan when the process becomes unstable or not statistically capable.

Control plans shall be reviewed and updated when any change occurs affecting product, manufacturing

RICO AUTO INDUSTRIES LIMITED prepares documented standard operating procedure, quality documents for various activities and works instructions for all employees having responsibilities for the operation of

These instructions are derived from sources such as the control plan and the product realization process.

Job set-ups are verified whenever performed, such as initial run of a job, material changeover, and job change.


Work instructions are available for set-up personnel. RICO AUTO INDUSTRIES LIMITED uses statistical methods or verification where applicable. Last-off-part inspection is carried out to compare the first-piece

RICO AUTO INDUSTRIES LIMITED identifies key process equipment and provides resources for machine / equipment maintenance and has developed an effective planned total preventive maintenance system.

RICO AUTO INDUSTRIES LIMITED utilizes predictive maintenance methods to continually improve the

RICO AUTO INDUSTRIES LIMITED provides resources for tool and gauge design, fabrication and verification and activities. RICO AUTO INDUSTRIES LIMITED has established and implements a system for production

RICO AUTO INDUSTRIES LIMITED has a system to monitor these activities if any work is out sources.

Production is scheduled in order to meet customer requirements, such as just in time supported by an information system that permits access to production information at key stages of the process and is


The identification of the product is established and maintained for all products, to all applicable drawings,

At RICO AUTO INDUSTRIES LIMITED customer supplied products are verified, stored and properly maintained.

At RICO AUTO INDUSTRIES LIMITED, all customer owned toolings are permanently marked with suitable means

RICO AUTO INDUSTRIES LIMITED has established procedure for preservation during storage, process and

RICO AUTO INDUSTRIES LIMITED has established procedure for packing, packaging , marking which

Designated storage area are provided for storage of material with required facilities for preventing damages and deterioration . Receipt and issue from stores is approved by authorized personnel . Item having limited shelf life are identified and first in first out (FIFO) procedure is followed for issuing those items. Provisions are also made to assess the condition of these items at a defined frequency.

RICO AUTO INDUSTRIES LIMITED has established and implemented inventory management system at all stages and assures stock rotation. Obsolete products are also considered as non-conforming products.


Procedure for process control & production (Machine shop & F.M.)

APPROVED BY

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QEHS Corp.


HOD(Q.A.) is responsible for control and calibration of all equipments covered under calibration procedure.

All measuring devices are maintained and established ensuring the suitability of measuring and monitoring devices. Measuring and monitoring devices are consistent with the degree of accuracy needed to evaluate

Measuring and monitoring devices are controlled as a numbering system for each device in use is maintained

accuracy and usability. Calibration activities, where applicable, are traceable to NPL / national equivalent.

Measurement system analysis is also carried out for all type of measurement system to analyze the variation,

Rico has identified measurements to be made and the accuracy required for measurement. accordingly, the inspection, measuring & test equipments selected. hardware and software used for inspection and testing that need calibration are also identified. Unique identification numbers are allocated

This listing includes details of equipment type, identification number, location, frequency of check, check method and accuracy required, acceptance criteria and action taken when results are unsatisfactory.

The calibration is carried out in accordance with the laid down procedure as per in house qualified lab whichcome under lab scope or otherwise done by calibration facilities accredited to iso/iec guide or national

Measuring and monitoring devices are calibrated and adjusted at defined intervals to ensure continued

Results of initial calibration and re-calibration or adjustment of measuring and monitoring devices is recorded.

All precision measuring and monitoring devices are maintained for protection from damage during

In the event a measuring and monitoring device is found to be out of calibration, corrective action is

The calibration records are maintained against each of such equipment coming under the calibration activity. The equipments coming under the calibration activity are identified to show the calibration status. The persons using the calibrated equipments are adequately instructed to store and handle them in such a way that the fitness for use and accuracy are maintained. Provision to safeguard the calibrated equipments from adjustment and setting are also made as and where applicable. The calibration is carried out under standard

During calibration of the equipment, if the equipment is found to be out of calibration , the validity of previousinspection and test results are assessed through the quality records /available product / customer complaint and documents. Customers are informed about the shipment of the suspected products. If an equipment is notconforming to the laid down acceptance criteria, it is identified and removed from the point of use.

matrix (calibration & testing) and laboratory quality system procedure as per lab scope. If required by

From time to time, an assessment is made by HOD (Q.A.) in consultation with concerned heads of department,

Rico has established and implemented all applicable laboratory requirements which come under laboratory scope. Rico has documented its policy,system procedure, of laboratory to assure that test result generated

Rico have professionals with relevant background and experience for laboratory process decision making.

Rico has established procedure for product identification and testing, products are being kept in lab as

Process control conditions are monitored and recorded that may influence quality. Rico has established

System has been established for verification of lab capability and appropriate statistical technique is

Before dispatch of the products, it is ensured that inspection and testing has Carried out as per the relevantprocedures and records are available clearly Indicating the authority responsible for release of product.


RICO'S laboratory scope

External / commercial / independent laboratory (if required) facilities used for inspection, test or calibration services by RICO AUTO INDUSTRIES LIMITED has defined laboratory scope that includes the capability to perform the required inspection, test or calibration, and the laboratory accredited to iso/iec 17025 or national

Procedure for Control of inspection measuring and test equipment

Procedure for Control of inspection, measuring and test equipment

APPROVED BY



QEHS Corp.



INTERNAL


TITLESTORES


1 PURPOSE :

TO ESTABLISH A SYSTEM FOR RECEIPT, STORAGE, PRESERVATION AND ISSUE OF MATERIAL.& FINISH GOODS STORAGE MANAGEMENT.

2 SCOPE :

APPLICABLE TO ALL MATERIAL RECEIVED , STORED AND ISSUED FROM MAIN STORE.THIS PROCEDURE ALSO INCLUDES CONTROL OF MATERIAL RETURNED FROM SHOPS.THIS PROCEDURE IS NOT APPLICABLE TO MISCELLANEOUS ITEM AND CUSTOMERSUPPLIED PRODUCT. THIS PROCEDURE IS ALSO APPLICABLE TO FINISH GOOD STORAGEMANAGEMENT.


3.1 MRR MATERIAL RECEIVED REPORT

3.2 REWORK ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT IT WILL MEET THE SPECIFIED REQUIREMENT.

3.3 REPAIR ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT THE PRODUCT WILL FUL FILL THE INTENDED USAGE, ALTHOUGH THE PRODUCT MAY NOT CONFORM TO THE ORIGINAL REQUIREMENT.

3.4 JOB-WORK ANY OPERATION DONE BY THE OUT SIDE PARTY ON THE MATERIAL BELONGING TO RICO AUTO INDUSTRIES LIMITED , DHARUHERA.

3.5 RE-OFFER OFFERING THE PREVIOUSLY REJECTED MATERIAL AFTER REWORK / REPAIR/ON CONCESSION.

3.6 MISSC. ITEM ITEM NOT UNDER INVENTORY CONTROL ( LIKE PANTRY ITMS , STATIONARY ,OFFICE EQUIPMENT AND OTHERS ) HAVING NO EFFECT ON OUT GOING PRODUCTS.


FOR ORGANISATION , PLEASE REFER ORGANISATION CHART.

4.1 OVER ALL RESPONSIBILITY TO IMPLEMENT THIS PROCEDURE LIES WITH HOD (STORES) / SECTION HEAD (EXCISE).


5 PROCESS APPROACH

PROCESS MAP AND INTERACTIONS(REFER TURTLE DIAGRAM - STORES)


INTERNAL


TITLESTORES


6 DESCRIPTION

FOR RICO DHARUHERA

SL.NO ACTIVITY

6.1 GENERATING NEW ITEM CODE 6.1.1 RECEIVE REQUEST FROM CONSUMING

DEPARTMENT FOR ALLOCATION OF " ITEMCODE" FOR NEW ITEMS.

6.1.2 GENERATE ITEM CODE AND ENTER IN THE COMPUTER.

6.2 RECEIPTS OF GOODS

6.2.1 RECEIVE THE SUB-CONTRACTOR'S DOCUMENTAT GATE AND COMPARE WITH PENDINGSCHEDULE IN COMPUTER . IF QTY EXCEED ASPER SCHEDULE , DO NOT TAKE MATERIAL AND RETURN THE DOCUMENT.

6.2.2 IF GOODS IS AS PER SCHEDULED QTY, PUTTHE RECEIVING STAMP ON SUB-CONTRACTORDOCUMENTS AND ENTER THE DETAILS IN THECOMPUTER.

6.2.3 DO PHYSICAL QUANTITY VERIFICATION AND ATTACH PRODUCT IDENTIFICATION TAG TO ALL INCOMING MATERIAL.

6.2.4 RECORD AND VALIDATE THE SUPPLIER'SDOCUMENT , DATA WITH PURCHASE ORDER ON STORE COMPUTER TERMINAL FOR THE

PREPARATION OF MRR . IF THE DOCUMENT CONFORM THE PURCHASE ORDER REQUIREMENTS , GET MRR PRINTED FOR FURTHER PROCESSING.

6.2.5 IF THE P.O. IS NOT AVAILABLE , PROVIDEUNIQUE CODE 9999 ON MRR AND SEND IT TO FURTHER PROCESS.

6.2.6 AFTER RECEIPT OF MRR FROM CONCERN DEPARTMENT APPROVAL . ARRANGE THE P.O.FROM VENDORS / PURCHASE.


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.2.7 IF STILL THE P.O. NOT AVAILABLE IN COMPUTERTHEN THESE MRR WILL BE ISSUED TO PURCH-ASE DEPARTMENT FOR THEIR ACTION.

6.2.8 OBTAIN DECISION ON QUALITY ASSURANCE /USER DEPARTMENT FOR ACCEPTANCE / RE-JECTION OF MRR

6.2.9 UP DATE INSPECTION DATA OF MRR IN STORECOMPUTER TERMINAL.

6.2.10 MOVE AND CONTROL REJECTION IN THE REJECTION STORE.

6.2.11 MOVE ACCEPTED MATERIAL TO THE MAINSTORE TO THE RESPECTIVE BAYS AND BINS ALONG WITH PRODUCT IDENTIFICATION TAG . ONCE THE MATERIAL IS KEPT ON THE IDENTIFIED LOCATION , PRODUCT IDENTIFICA-TION TAG MAY BE REMOVED.

6.2.12 AUTHORISE THE MRR AFTER APPROVAL

6.2.13 DESPATCH COPY OF MRR AND RELATEDDOCUMENT TO ACCOUNTS DEPARTMENTTHROUGH DESPATCH REGISTER.

6.3 RE - OFFER MATERIAL

6.3.1 PREPARE RE-OFFER MRR FORSEGREGATION / REWORK / REPAIR OF MATERIAL FROM PURCHASE DEPARTMENTDULY APPROVED BY HOD (QA).

6.3.2 RE-OFFER MRR WILL BE HAND OVER TO STOREDEPARTMENT AND TAKE MATERIAL ACCORDINGLY

6.3.3 TAKE ACTION AND ENTER THE DETAILS INRE-OFFER MRR AND SEND TO STORE SECTION


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.4 STORAGE

6.4.1 ENSURE THAT RELEVANT MATERIAL KEPT ATIDENTIFIED LOCATION.

6.4.2 FOR ITEMS WITH SHELF LIFE (HAVING EXPIRYPERIOD) ISSUE ON THE MATERIAL ON FIRST INFIRST OUT (FIFO) BASIS.REVIEW THE MATERIAL PERIODICALLY FOR ANY DETERIORATION AND EXPIRY, AS APPLICABLE AND FOLLOW THE WORK INSTRUCTION

6.4.3 MATERIALS WHOSE QUALITY GETS AFFECTEDDUE TO ENVIRONMENTAL CONDITIONS, ENSURESUITABLE PRESERVATIVES ARE APPLIED.

6.4.4 ENSURE THAT FRAGILE ITEMS ARE EASILY ACCESSIBLE TO AVOID DAMAGE IN HANDLING.

6.4.5 PREPARE LIST OF ITEMS WHICH ARE OVER STOCKED ON MONTHLY BASIS. CHECK THE

CONDITION OF STOCK, IF FOUND DETERIORAT-ED, APPLY SUITABLE PRESERVATIVE ONTHESE ITEMS OR INFORM TO HOD(QA) FORDISPOSAL ( IF REQUIRED ).

6.5 LINE REJECTION MATERIAL

6.5.1 RECEIVE THE LINE REJECTION ALONG WITHTHE REJECTION REPORT.

6.5.2 VERIFY THE DESCRIPTION AND QUANTITY GIVEN IN THE REJECTION REPORT

6.5.3 MOVE THE LINE REJECTION TO REJECTIONSTORE AND TAKE FURTHER ACTION WHERE APPLICABLE.

6.5.3 TREAT OBSELETE PRODUCT SIMILAR TONON-CONFIRMING PRODUCT AND KEEP INREJECRTION STORE IN PROPER MANNER.


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.6 ISSUE OF MATERIAL

6.6.1 RECEIVE ISSUE SLIP FROM CONCERNPERSON / DEPARTMENT.

6.6.2 CHECK THE ISSUE SLIP FOR DESCRIPTIONAND DETAIL DULLY FILLED.

6.6.3 ISSUE THE MATERIAL TO CONCERN PERSON /DEPARTMENT.

6.6.4 FOLLOW "FIFO SYSTEM" FOR ALUMINIUM ALLOY.

6.6.5 FOR BOUGHT OUT PART, ENSURE FIFO BY

PROVIDING SEPARATION IN BETWEEN EACHLOT AND ISSUE THE OLD LOT FIRST.

6.7 FINISH GOOD STORAGE MANAGEMENT

6.7.1 LIST OF FINISHED GOODS LYING IN STOCK ISRECEIVED BY STORES FROM EXCISEDEPARTMENT IN THE BEGININGING OF EVERYMONTH.

6.7.2 THE LIST IS RECEIVED OF FINISHED GOODS &STOCK LYING FOR MORE THAN ONE YEAR ISINTIMATED TO HOD (Q.A.)

6.7.3 HOD (Q.A.) AFTER APPROPRIATEVERIFICATION, INTIMATES STORES THROUGHINSPECTION REPORT.

6.7.4 (I) BASED ON DECISION, IF THE STOCK NEEDSTO BE REMOVED FOR 100% VERIFICATION /REPROCESSING, THE SAME IS CONVEYED TOEXCISE DEPARTMENT FOR FURTHERNECESSARY ACTION.

(II) MOVE THE SUSPECTED STOCK TOQUARNTINE SEGREGATION AREA FORSEGREGATION.

6.7.5 IF NO DETERIORATION IS REPORTED BY Q.A.,THE STOCK IS RETAINED IN THE STORAGEAREA.


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.7.6 KEEP THE FINISH GOODS IN SUCH A WAY THATSTOCK CAN BE ROTATED REGULARLY AND"FIFO" CAN BE FOLLOWED

6.7.7 REVIEW THE STORAGE PROCESS / AREA FORANY WATER LEAKS, STACKING METHOD,HEIGHT, WALL CONDITION, TEMPERATUREAND ATMOSPHERIC REQUIREMENT AND

MAINTAIN AS PER REQUIREMENT.

6.7.8 ENSURE THAT PRODUCTS / IN PROCESSPARTS / BOP AND OTHER ITEMS AREPROTECTED FROM RUST, CONTAMINATION,DUST ETC AND DO NOT STORE THE PRODUCTOUT SIDE.

6.8 DO PACKAGING VARIFICATION / INSPECTIONAT INCOMING STAGE FOR PACKAGINGREQUIREMENTS

FOR RICO HPDC GURGAON

(A) RECEIPTS 6.1 DOCUMENTS OF MATERIAL RECEIVED FROM

SUB-CONTRACTOR ARE SCRUTINISED SECURITY AGAINST MATERIAL RECEIVED AND DETAILS OF ALL THE MATERIAL RECEIVED DURING THE DAY ARE RECORDED IN COMPUTERISED GATE INWARD BOOK (GIB).

6.2 MATERIAL FROM SUB CONTRACTOR ISRECEIVED, CHECKED AGAINST SUPPLIEDDOCUMENTS FOR CORRECTNESS OF SUPPLYRECEIVED MATERIAL FOR INSPECTION AREIDENTIFIED WITH THE TAG HAVING VANDORNAME, QTY, GIB NO. & DESCRIPTION.

6.2.1 RAW MATERIAL FOR PDC STORE. RAW MATERIAL UNLOADED AFTER GIVEN TAG TOQ.A. DEPTT. PDC MRR IS GENERATED & VARIFIED BY Q.A. ACTION TAKEN ACCORDINGLY.


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.2.2 OTHER MATERIALS RECEIVED AGAINSTREQUISITION OF USERS DEPTT. MRR ISGENERATED & INTIMATED TO CONCERN

DEPARTMENT.

6.2.3 MATERIAL LIKE TOOLS, OIL PAINTS, BEARING,PACKING, HARDWARE & ELECTRICALMATERIAL KEPT IN STORES AFTER VISUALINSPECTION. MRR GENERATED & VARIFIED BYUSER, ACTION TAKEN ACCORDINGLY.

6.3 MATERIAL RECEIPT REPORT (MRR) ISGENERATED AFTER CROSS CHECKING WITHRELATED GIB. THE Q.A. & OTHER DEPARTMENTWILL VARIFY MRR IN SYSTEM THROUGH GIBNO. & CLEARING OF MRR IN THE SYSTEMONLY.

6.4 ACCEPT & REJECTED QUANTITIES AREENTERED IN COMPUTER BY THE Q.A. & USERDEPARTMENT.

6.5. BILLS IS SENT TO ACCOUNTS DEPTTS WITHMRR NO.

(B) HANDLING, STORAGE & ISSUES

6.6 ACCEPTED MATERIAL RELATED TO PDC &DIE DIVISION IS STORED IN MAIN STORE i.e. PDC.

6.7 REJECTED MATERIAL IS IDENTIFIED,RECORDED IN COMPUTER STORE INDESIGNATED AREA IN MAIN STORES,PDC, THE REJECTIONS ARE RETURNED TO SUB CONTRACTOR.

6.8 MATERIAL IS ISSUES TO USER DEPTT. AGAINSTREQUISITION SLIP & REQUISITION SLIP ISCONVERTED IN ISSUE SLIP IN THE SYSTEMONLY


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.9 EXCESS MATERIAL LEFT UNUSED IN DEPTT./MATERIAL SENT FOR JOB WORK IS RECEIVEDBACK AGAINST STORE RETURN NOTE INSYSTEM. MATERIAL SENT FOR JOB WORK,MATERIAL DESPATCH ADVICE (MDA) TO BEPREPARED EITHER FROM SHOP OR STOREBY THE USER.

6.10 MATERIAL REQUIRED FOR TEMPORARY USEARE ISSUED AGAINST SIGNATURE OFRECEIVER IN A SEPARATE LOAN REGISTER.(NIGHT LOAN REGISTER)

6.11 INVENTORY LEVELS ARE MONITORED AS PERPROCEDURE FOR INVENTORY CONTROL.

6.12 MATERIAL SENT OUTSIDE FOR REPAIRSPROCESSING ARE SENT ON RGP. RETURN OFTHESE MATERIAL IS FOLLOWED UP WITHSUBCONTRACTORS.

6.13 BASED ON GIVEN SHELF LIFE FORPRESERVATION, STOCK IS TO BE VARIFIEDAND STATEMENT TO BE PREPARED ONMONTHLY BASIS.

6.14 ENSURE THAT PRODUCTS / IN PROCESSPARTS / BOP AND OTHER ITEMS AREPROTECTED FROM RUST, CONTAMINATION,DUST ETC AND DO NOT STORE THE PRODUCTOUT SIDE.

(C) FINISH GOOD STORAGE MANAGEMENT

6.13.1 LIST OF FINISHED GOODS LYING IN STOCK ISRECEIVED BY STORES FROM EXCISEDEPARTMENT IN THE BEGININGING OF EVERYMONTH.

6.13.2 THE LIST IS RECEIVED OF FINISHED GOODS &STOCK LYING FOR MORE THAN ONE YEAR ISINTIMATED TO HOD (Q.A.)

6.13.3 HOD (Q.A.) AFTER APPROPRIATEVERIFICATION, INTIMATES STORES THROUGHINSPECTION REPORT.


INTERNAL


TITLESTORES


SL.NO ACTIVITY

6.13.4 (I) BASED ON DECISION, IF THE STOCK NEEDSTO BE REMOVED FOR 100% VERIFICATION /REPROCESSING, THE SAME IS CONVEYED TOEXCISE DEPARTMENT FOR FURTHERNECESSARY ACTION.

(II) MOVE THE SUSPECTED STOCK TOQUARNTINE SEGREGATION AREA FORSEGREGATION.

6.13.5 IF NO DETERIORATION IS REPORTED BY Q.A.,THE STOCK IS RETAINED IN THE STORAGEAREA.

6.13.6 KEEP THE FINISH GOODS IN SUCH A WAY THATSTOCK CAN BE ROTATED REGULARLY AND"FIFO" CAN BE FOLLOWED

6.13.7 REVIEW THE STORAGE PROCESS / AREA FORANY WATER LEAKS, STACKING METHOD,HEIGHT, WALL CONDITION, TEMPERATUREAND ATMOSPHERIC REQUIREMENT ANDMAINTAIN AS PER REQUIREMENT.

6.13.8 ENSURE THAT PRODUCTS / IN PROCESSPARTS / BOP AND OTHER ITEMS AREPROTECTED FROM RUST, CONTAMINATION,DUST ETC AND DO NOT STORE THE PRODUCTOUT SIDE.

6.14 DO PACKAGING VARIFICATION / INSPECTIONAT INCOMING STAGE FOR PACKAGINGREQUIREMENTS


INTERNAL


TITLESTORES


7 DOCUMENTS :

7.1 RICO 06 QSP 06 PROCEDURE FOR CONTROL OF NON - CONFORMING PRODUCT

RICO DHARUHERA7.2 RICO 16 QWI 01 WORK INSTRUCTION FOR HANDLING OF SHELF LIFE ITEMS.

7.3 RICO 16 QWI 02 WORK INSTRUCTION FOR STORAGE OF MATERIAL IN STORES.

7.4 RICO 16 QWI 03 WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT SECTION.

7.5 RICO 16 QWI 04 WORK INSTRUCTION FOR FIFO SYSTEM OF RAW MATERIAL

RICO HPDC GURGAON7.6 RICO 16 QWI 01 WORK INSTRUCTION FOR HANDLING OF SHELF LIFE ITEMS.

7.7 RICO 16 QWI 02 WORK INSTRUCTION FOR STORAGE OF MATERIAL IN STORES.

7.8 RICO 16 QWI 03 WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT SECTION.

8 RECORDS


GOODS RECEIPT REPORT (GR)---------

REQUISITION SLIP---------

TRANSFER POSTING---------

RETURNABLE GATE PASS (RGP)---------

NON RETURNABLE GATE PASS (NRGP)---------

RICO 06 QFO 13 RETURN DELIVERY ( M/C SHOP)

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

(LINE REJECTION)

RICO 10 QFO 02 RETURN DELIVERY ( HPDC)(LINE REJECTION)


INTERNAL


TITLESTORES




07 25-06-2003



ON LINE SAP SYSTEM

ON LINE SAP SYSTEM




HOME

ALUMINIUM PLANTS


STORES ISSUE NO 09


TO ESTABLISH A SYSTEM FOR RECEIPT, STORAGE, PRESERVATION AND ISSUE OF MATERIAL.

APPLICABLE TO ALL MATERIAL RECEIVED , STORED AND ISSUED FROM MAIN STORE.THIS PROCEDURE ALSO INCLUDES CONTROL OF MATERIAL RETURNED FROM SHOPS.THIS PROCEDURE IS NOT APPLICABLE TO MISCELLANEOUS ITEM AND CUSTOMERSUPPLIED PRODUCT. THIS PROCEDURE IS ALSO APPLICABLE TO FINISH GOOD STORAGE

ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT IT WILL MEET THE

ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT THE PRODUCT WILL FUL FILL THE INTENDED USAGE, ALTHOUGH THE PRODUCT MAY NOT CONFORM

ANY OPERATION DONE BY THE OUT SIDE PARTY ON THE MATERIAL BELONGING TO RICO AUTO INDUSTRIES LIMITED , DHARUHERA.

OFFERING THE PREVIOUSLY REJECTED MATERIAL AFTER REWORK / REPAIR/

ITEM NOT UNDER INVENTORY CONTROL ( LIKE PANTRY ITMS , STATIONARY ,OFFICE EQUIPMENT AND OTHERS ) HAVING NO EFFECT ON OUT GOING

OVER ALL RESPONSIBILITY TO IMPLEMENT THIS PROCEDURE LIES WITH HOD (STORES) /

COPY STATUS SHEET

01 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09



HOD (STORES)

HOD (STORES)


SECTION HEAD RICO 16 QWI 03(SECURITY)

SECTION HEAD RICO 16 QFO 03(STORES)




COPY STATUS SHEET

02 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09





CONCERN HOD



HOD(STORES) HOD(STORES)




COPY STATUS SHEET

03 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09




SECTION HEAD RICO 16 QWI 02(STORES) RICO 16 QFO 01

SECTION HEAD RICO 16 QWI 01(STORES)







COPY STATUS SHEET

04 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09






SECTION HEAD RICO 16 QWI 04(STORES)

SECTION HEAD

(STORES)



HOD (Q.A.)

HOD (EXCISE)

HOD (EXCISE)

HOD (EXCISE)

COPY STATUS SHEET

05 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09




HOD (EXCISE)

PLANT HEAD / HOD (EXCISE)

SECURITY INCHARGE

STORES ASST.

STORES ASST.

COPY STATUS SHEET

06 OF 10

ALUMINIUM PLANTS


STORES ISSUE NO 09



STORE ASSTT.

STORE ASSTT.

STORE ASSTT.

STORE OFFICER

STORE OFFICER

STORE ASSTT.

STORE ASSTT.

STORE ASSTT.

COPY STATUS SHEET

07 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09



STORE ASSTT.

STORE ASSTT.

STORE INCHARGE

STORE INCHARGE

STORES OFFICER

PLANT HEAD / STORE INCHARGE



HOD (Q.A.)

COPY STATUS SHEET

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ALUMINIUM PLANTS


STORES ISSUE NO 09



HOD (EXCISE)

HOD (EXCISE)

HOD (EXCISE)


HOD (EXCISE)

PLANT HEAD / HOD (EXCISE)

COPY STATUS SHEET

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ALUMINIUM PLANTS


STORES ISSUE NO 09


PROCEDURE FOR CONTROL OF NON - CONFORMING PRODUCT

WORK INSTRUCTION FOR HANDLING OF SHELF LIFE ITEMS.

WORK INSTRUCTION FOR STORAGE OF MATERIAL IN STORES.

WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT SECTION.

WORK INSTRUCTION FOR FIFO SYSTEM OF RAW MATERIAL

WORK INSTRUCTION FOR HANDLING OF SHELF LIFE ITEMS.

WORK INSTRUCTION FOR STORAGE OF MATERIAL IN STORES.

WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT SECTION.


AS PER SAP SYSTEM HOD (STORES)






ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM

ON LINE SAP SYSTEM



COPY STATUS SHEET

10 OF 11

ALUMINIUM PLANTS


STORES ISSUE NO 09



25-06-2003



ON LINE SAP SYSTEM

ON LINE SAP SYSTEM




QEHS Corp.


QEHS Corp.

COPY STATUS SHEET

11 OF 11


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DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

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