MONTH May-14

ISSUE BY GAJENDER SINGH

DATES

ABS in %.

Target

Line Start Time

Line Stop Time

Linea

Punto

Manza

Vista

Manza 1st. Cycle

Vista 1st cycle

Punto 1st cycle

Spare part box

Part body

Dummy body bypass

Empty skid

Bypass pass due to defect

Repaint

Total Production

Efficency

Fresh Car Efficency

fresh car painted

T/C Strip out body count.

PTO

Production

as per SCM

PRODUCTION CONTROL FEED BACK/ INFORMATION

CONTROL

MANAGEMENT SHEET 14

Defect Target / 100

LINT 0.36

HAIR 0.10

PAINT DISTRUB 0.09

TOP COAT FOULING 0.08

UNCOVER PATCH 0.07

Thin Paint 0.15

Base Coat Rundown 0.15

Clear Rundown 0.15

Pipe Fouling 0.03

Uncover sanding patch 0.15

Visual

Visual

Visual

Visual

Visual

Check Point Std.

Booth Air Balance

Booth Temperature <QUALITY>

Booth Humidity

Manual Station Air Pressure 4 Bar ± 0.5 bar

Paint Pressure

Painting Gun & QRC Condition Visual

Jigs condition Visual MAINTENANCE

Booth Gratting Condition Visual

Top Coat 5S Condition Visual

Robot Bell Cup Condition Visual

Robot Cover Condition Visual

Both Oven condition Visual / weekly

Target

Washing Thinner / car 2.5ltrs / car

Mask & it's filters after 1700 car

Painter Dagri & Cap after 1200 car

Hand Gloves after 800 car

Robot Dangri after 1500 car

Robot Nozzole Covers after 100 car

Suggestion 1.2 / man

OPL as per req.

ABSENTISM < 5.00 %

PRODUCTION 247 / day

EFFICIENCY 93%

STOPAGE NIL

FTQ 92.00%

DEF/CAR < 2%

Top Coat DPV 1.05

Body GAP Time in Min. NIL

Dual Tone as per SCM

Quality

For FTQ

For DPV top five 1

st 5Car

Check Points

Positive at 30° ANGLE

22°C to 28°C

70% ± 5%

1.5 kg/cm² ± 0.5 kg/cm²

Cost

MAN

Morning

meeting

Ok √ Not ok ×

CRITICAL / IMPORTATANT THINGS OF MONTH

uSELF INITIATIVE POLICY BASE PLAN

MONTH May-14

ISSUE BY GAJENDER SINGH

DATES

ABS in %.

Target

Line Start Time

Line Stop Time

Linea

Punto

Manza

Vista

Manza 1st. Cycle

Vista 1st cycle

Punto 1st cycle

Spare part box

Part body

Dummy body bypass

Empty skid

Bypass pass due to defect

Repaint

Total Production

Efficency

Fresh Car Efficency

fresh car painted

T/C Strip out body count.

PTO

Production

as per SCM

PRODUCTION CONTROL FEED BACK/ INFORMATION

CONTROL

MANAGEMENT SHEET 14

Defect Target / 100

LINT 0.36

HAIR 0.10

PAINT DISTRUB 0.09

TOP COAT FOULING 0.08

UNCOVER PATCH 0.07

Thin Paint 0.15

Base Coat Rundown 0.15

Clear Rundown 0.15

Pipe Fouling 0.03

Uncover sanding patch 0.15

Visual

Visual

Visual

Visual

Visual

Check Point Std.

Booth Air Balance

Booth Temperature <QUALITY>

Booth Humidity

Manual Station Air Pressure 4 Bar ± 0.5 bar

Paint Pressure

Painting Gun & QRC Condition Visual

Jigs condition Visual MAINTENANCE

Booth Gratting Condition Visual

Top Coat 5S Condition Visual

Robot Bell Cup Condition Visual

Robot Cover Condition Visual

Both Oven condition Visual / weekly

Target

Washing Thinner / car 2.5ltrs / car

Mask & it's filters after 1700 car

Painter Dagri & Cap after 1200 car

Hand Gloves after 800 car

Robot Dangri after 1500 car

Robot Nozzole Covers after 100 car

Suggestion 1.2 / man

OPL as per req.

ABSENTISM < 5.00 %

PRODUCTION 247 / day

EFFICIENCY 93%

STOPAGE NIL

FTQ 92.00%

DEF/CAR < 2%

Top Coat DPV 1.05

Body GAP Time in Min. NIL

Dual Tone as per SCM

Quality

For FTQ

For DPV top five 1

st 5Car

Check Points

Positive at 30° ANGLE

22°C to 28°C

70% ± 5%

1.5 kg/cm² ± 0.5 kg/cm²

Cost

MAN

Morning

meeting

Ok √ Not ok ×

CRITICAL / IMPORTATANT THINGS OF MONTH

uSELF INITIATIVE POLICY BASE PLAN

UTE-2 CONTROL POINTS Month - S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1

Man

pow

erP.Booth

P.Sanding

Absentism ( % )

2 Production

3 Effieciency

4 Stoppage

5 Defect/Car

6Grey

White

7

S.Powder

S.Mark

Sealer Traces

8 Orbital sander at Roof Ditch

9

10 Royal Cars

11ICP SCORE :

Kaizen / OPL

N.B. ::

Control PointsDate

Dust Count (in primer)

Defects in Finishing

Line

DAMAGE ( SealerDelibera /PrimerDelibra )

Electricty /PropaneTarget =

UTE-2 CONTROL POINTS Month - S.No.

Major Action Points

1 Absentism

2 Production

3 Efficiency

4 Stoppages

5 Defect/Car

6Grey

White

7

S.Powder

S.Mark

S.No.

1 Absentism

2 Production

3 Efficiency

4 Stoppages

5 Defect/Car

6Grey

White

7

S.Powder

S.Mark

Control PointsDate

Dust Count (in primer)

Defects in Finishing Line

Sealer Traces

Control PointsDate

Dust Count (in primer)

Defects in Finishing Line

Sealer Traces

S.No. Activities / Kaizen / Improvements List Status

UTE-1 WATER LEAK CONTROL POINTS Month -

DATE PS WL FTQ WATER LEAK DETAILS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

UTE-1 CONTROL POINTS Month - S.No.

1

MA

NP

OW

ER

Present / Total

2 Present /Total

3 %Absentism

4 HPV

5

PR

OD

UCT

ON

PRODUCTION

6 CAGES

7 Running Time

8 % Efficiency

9 Loss time

10 Reason

11

QU

ALI

TY

CED DROP

12 CED DEFECT

13 LINE MARK / Flow mark

14 Total

15 SHOWER FTQ

16 WBSN.B. ::

Control PointsDate

Stdd / Target

UTE-1 CONTROL SHEET Month drafted by UTPAL Kr. Singh

S.NO TO DO ACTIVITIES DESCRITPTION Start Date Tar Date DOC Responsibilty Status SUGGESTIONS1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

3 TO DO LIST & SUGGESTIONS

UTE-1 CONTROL SHEET Month drafted by UTPAL Kr. Singh

S.NO TO DO ACTIVITIES DESCRITPTION Start Date Tar Date DOC Responsibilty Status SUGGESTIONS1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

2 TO DO LIST & SUGGESTIONS

UTE-1 CONTROL SHEET Month - drafted by UTPAL Kr. Singh

S.No.

1 S unsafe cond / Act

MA

NP

OW

ERTr. Absent / Total

2 App. Absent / Total

3 %Absentism

5

PR

OD

UCT

ON

PRODUCTION

6 CAGES

7 Running Time

8 % Efficiency

9 Loss time

Reason10

11

QU

ALI

TY

12 CED DEFECT

13

14 TOTAL DPV - FINISHING

Reason15

16 SHOWER FTQ / WBS

17

COST

TOTAL COST PER CAR

18 MASKING TAPE

Reason21

QUALITY ::

MAINTENANCE ::

Spec. Propject. CED DROP REDUCTION

Control PointsDate

Stdd / Target (Non - Routine) Major Activites/ Kaizens / Feedback

CED DROP = PRIMER / FINISHING

LINE MARK / FLOW MARK

(Months major) Critical Events / Points DAILY ISSUES ::: Actions / Change Point / Observation

1 DAILY MANAGEMENT