Production Shift Report Ref No.

: - F: PRD: 7509

Issue Date 15/09/08 Revision No. 1 Revision Date 1/3/2013 Manpower deployment Columns Added Resp.: Engg. Prod.

BASE REAR TEAM LEADER DATE SHIFT B ISO/TS 16949

Target Execution
INPROCESS / PLANNED
PURCHASE STORE/ POWER FAILURE MAINT PED QA MAN POWER STOPPAGE
FIXT /Mc SETTING
Difference (+/-)
Time
Cum-ulative Actual Pieces / Actual Cum- Hourly Target
Rework Scrap Description of Issue, Actions & Root Cause
Hourly Target
Target Hour ulative LOSS LOSS LOSS LOSS LOSS LOSS LOSS LOSS
INITIAL INITIAL INITIAL INITIAL INITIAL INITIAL INITIAL INITIAL TIME
TIME TIME TIME TIME TIME TIME TIME TIME

3.30

– 300 300

4.30

4.30

273 573

5.30

5.30

– 327 900

6.30

6.30

– 327 1227

7.30

7.30

164 1391

8.30

8.30

– 327 1718

9.30

9.30

– 327 2045

10.30

10.30

– 273 2318

11.30

11.30

– 327 2645

12.30

12.30

137 2782

1.00

TOTAL
2782 2782 TOTAL BREAKDOWN

TOTAL PLANNED OPERATOR BOTTELNECK OPERATION PLANNED NO. OF CHANGEOVER CHANGEOVER TARGET TIME Min.

ACTUAL NO. OF OPERATOR BOTTELNECK CYCLE TIME ACTUAL NO. OF CHANGEOVER ACTUAL CHANGEOVER TIME Min. TOTAL SUM BREAKDOWN MANPOWER DEPLOYMENT

MACHINE NAME PROBLEM REPORTED TO Machine Name OPERATOR Ref No. : - F: PRD: 7507

S. No. MODEL PLANNED TOTAL BUILT QA TEST REJECTION BUILT OK FOR SAP

NAME ROLLING& Resp.: Prod.

FLARING

1 YV4 SEAM WELDING

2 YP8 LOOP WELDING

3 YL8 LEAKAGE TESTING

SPATTER REMOVAL
Total
 Production Shift Report Ref No. : - F: PRD: 7509

Issue Date 15/09/08 Revision No. 1 Revision Date 1/3/2013 Manpower deployment columns Added Resp.: Engg. Prod.

FRONT MODULAR TEAM LEADER DATE SHIFT B ISO/TS 16949

Target Execution
POWER INPROCESS / FIXT PLANNED
PURCHASE STORE MAINT PED QA MAN POWER
FAILURE /Mc SETTING STOPPAGE
Difference (+/-)
Time
Cum-ulative Actual Pieces / Actual Cum- Hourly Target
Rework Scrap Description of Issue, Actions & Root Cause
Hourly Target
Target Hour ulative LOSS LOSS LOSS
LOSS TIME INITIAL LOSS TIME INITIAL LOSS TIME LOSS TIME INITIAL INITIAL LOSS TIME INITIAL INITIAL INITIAL TIME
TIME TIME TIME

3.30

– 157 157
4.30

4.30

– 171 329
5.30

5.30

– 143 471
6.30

6.30

– 171 643
7.30

7.30

171 814
8.30

8.30

– 86 900
9.30

9.30

– 171 1071
10.30

10.30

– 143 1214
11.30

11.30

– 171 1386
12.30

12.30

– 71 1457
1.00

TOTAL 1457 1457

TOTAL BREAKDOWN

TOTAL PLANNED OPERATOR BOTTELNECK OPERATION PLANNED NO. OF CHANGEOVER CHANGEOVER TARGET TIME Min.

ACTUAL NO. OF OPERATOR BOTTELNECK CYCLE TIME ACTUAL NO. OF CHANGEOVER ACTUAL CHANGEOVER TIME Min. TOTAL SUM BREAKDOWN MANPOWER DEPLOYMENT
MACHINE NAME PROBLEM REPORTED TO MANPOWER DEPLOYMENT
S. No. MODEL PLANNED TOTAL BUILT QA TEST REJECTION BUILT OK FOR SAP
MACHINE NAME OPERATOR NAME Ref No. : - F: PRD: 7507

1 401 Resp.: Prod.

MODULAR ASSY.
2 501

3 601 REWORK

4 701

5 YP8 D LH

6 YP8 D RH

7 YP8 D LH (NB)

8 YP8 D RH(NB)

9 YP8 P LH

10 YP8 P RH

TOTAL
 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER REAR TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
2:30 CYLINDER WASHING

- 125 125 MATERIAL FEEDING

3:00 ROD WASHING

3:00 P.ROD VISUAL INSPECTION

- 300 425 CRIMPING

4:00 PISTON VALVING

4:00

- 250 675 COMPRESSION VALVING

5:00

5:00 GREASING

- 300 975 LOCKTITE APPLICATION

6:00 NUT TIGHTENING

NUT TIGHTENING
6:00 VERIFICATION

- 300 1275 C.V PRESSING

7:00 OIL FILLING

7:00 OUTER TUBE WASHING

- 150 1425

8:00 D/F TESTING

8:00 STICKER PAISTING

- 300 1725 SEALING

9:00 SEALING INSPECTION

9:00 GASFILLING

- 250 1975 P.ROD PLAY

10:00 NOISE TESTING

10:00 BUMP CAP PRESSING

- 275 2250 MARKING

11:00

TOTAL 2250

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER REAR TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00 CYLINDER WASHING

- 275 275 MATERIAL FEEDING

7:00 ROD WASHING

7:00 P.ROD VISUAL INSPECTION

- 300 575 CRIMPING

8:00 PISTON VALVING

8:00

- 250 825 COMPRESSION VALVING

9:00

9:00 GREASING

- 300 1125 LOCKTITE APPLICATION

10:00 NUT TIGHTENING

NUT TIGHTENING
10:00 VERIFICATION

- 300 1425 C.V PRESSING

11:00 OIL FILLING

11:00 OUTER TUBE WASHING

- 150 1575

12:00 D/F TESTING

12:00 STICKER PAISTING

- 300 1875 SEALING

13:00 SEALING INSPECTION

13:00 GASFILLING

- 250 2125 P.ROD PLAY

14:00 NOISE TESTING

14:00 BUMP CAP PRESSING

- 125 2250 MARKING

14:30

TOTAL 2250

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501A

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell:NEW BASE FRONT TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution PLANNED ACTUAL

p
ra
Difference OPERATOR OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME PROCESS

k
Target NAME SAP CODE LEVEL

or
Target Hour ulative NAME

w
Re
6:00 NOTCHINE

- 347 347 NAME ROLLING

7:00 HORIZENTEL 1

7:00 HORZINTEL 2

- 379 726 PRESSING

8:00 APEENA 1

8:00 APEENA 2

- 316 1042 SIZING

9:00 PIERCING

9:00 SENSOR PROJ

- 379 1421 BHB PROJ

10:00 STABI

10:00 TAG 1

- 379 1800 TAG 2

11:00 TAG 3

11:00 LEAK TESTING

- 189 1989 FINAL INSPECTION

12:00 OILING

12:00

- 379 2368 SKILL ACTION

13:00 LEVEL 1

13:00 LEVEL 2

- 316 2684 LEVEL 3

14:00 LEVEL 4

14:00
QTY.(IN PCS.)
- 150 2834 REWORK

14:30 SCRAP

TOTAL 2834

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME

1
TIR COTTON ARM SLEEVE/PCS. START TIME

TCR COTTON OLD DHOTI/PCS. C/O ISSUE

2
STOP CALL WAIT CHEMICAL HAND GLOVES/PAIR MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN TIP 24KD/PCS. TOLLING ISSUE

TIP 36 KD/PCS. GAUGES ISSUE

4
PAINT MARKER/PCS. CYCLE TIME INCREASE ISSUE

GAS DEFUSER 36KD/PCS. SAFETY ISSUE

5
LATHER APRAN/PCS. OTHER ANY ISSUE

GAS DEFUSER 24KD/PCS. END TIME

6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

LATHER ARM SLEEVE/PAIR.

7
TIP HOLDER 36KD (M₆ₓ₁)

WIRE ROLL (/KG)

8
LATHER HAND GLOVES/PAIR.

SILICON SPRAY/PCS.
9
WELDING NOZZEL 24 KD/PCS.

LATHER SHOE GUARD/PAIR.

10
WELDING HELMET FRONT GLASS

WELDING MASK 3M/PCS.

11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.

RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.

GAS NOZZEL 36KD CONOAL SPLIT PUSH FIT

13
WELDING CURTAIN/PCS.

WELDING FACE SHIELD INNER GLASS/PCS.

14
WELDING TORCH 24KD/PCS. (45⁰BEND)

LINNER 42.04001047 1.2LEN STEELINSD

TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX

MANUAL WELDING
without name rolling puncher
half name rolling gas fault
double name rolling sapatter on hole of piercing abd bhb
NAME ROLLING
reverse name rolling {block wrong over weld
fitment or wrong tubr fitt}
date fall down then date and shift print weld miss
miss
dent mark problem stabi cut
low impression
dimension out of spec.
other model tube name rolling pin hole
weld miss
penetration high gas fault
under cut half welding
HORIZONTAL WELDING

gas fault under cut

pin hole puncher
half welding over weld

STABI BKT. WELDING

welding shift up and down stabi.bkt cut
k.bkkt weld wrong side on tube weld shift
name rolling shift { front of operator } low and high penertation
over weld thin beed of weld
puncher spatter on stabi.bkt
stabi weld wrong postion
depth varation gap problem
lss dim .varation stabi tapper
base cup to bkt and tube dim. Varation gauage not qualify
base cup taper Dimensions out
PRESSING M/C

dent mark on tube end leakage

reverse k.bkt assemble
name roliling position shift
double base cup leakage from base cup
LEAKAGE TESTING

base cup tilled reverse leakage from k.bkt

wrong lsss press leakage from r. tube
k.bkt damage due to alingement issue leakge from stabi
base cup not insert leakage from lss

pin hole
weld miss
gas fault reverse notching in yl8
half welding
NOTCHING

notching dia undersize

under cut notching crack
puncher double notching
over weld
APEENA

k.bkt cut
weld shift
low and high penertation
thin beed of weld
spatter on k.bkt
lss fall down loose
leakage
welding out due to run out

size not maintain

dent mark
SIZING

flatness not ok

concntricicty out
46 dim out
PIERCING

total length dim out

burr
flatness not ok
coining not ok

nugget issue
spark mark on bkt
child part wrong weld
PROJECTION

gauage not qualify

dimensions not ok
gap issue
part melt
child part nut miss
 Daily Production Shift Report
Ref. No. : - F:PRD:8501A
Resp. : TL - Production
Std.
Format
Issue
Date
01/07/17 Revision No.
0 - Revision Date 00/00/00 IATF 16949 : 2016
Bottleneck CT & Process
Cell : NEW BASE FRONT TEAM LEADER:- DATE:- SHIFT B
Name
Changeover Target Time

Target Execution ACTUAL

PLANNED OPERATOR OPERATOR
OTHER
Difference (+/-)
Time Hourly Cumulative Actual Pieces / Actual Cum- Hourly Target Description of Issue, Actions & Root Cause Total Loss
Time
PUR STR
POWER
CUT
MAINT PED
SETTING
& ADJ.
NPD C/O
MANPOW TRAINING
ER / AUDIT
Q.A LOSS
TIME
Target Target Hour ulative PROCESS NAME NAME SAP CODE LEVEL

14:30 NOTCHING
- 150 150 NAME ROLLING
15:00 HORIZONTAL 1
15:00 HORIZONTAL 2
- 360 510 PRESSING
16:00 APEENA 1
16:00 APEENA 2
- 300 810 SIZING
17:00 PIERCING
17:00 SENSOR PROJ
- 360 1170 BHB PROJ
18:00 STABI
18:00 TAG 1
- 300 1470 TAG 2
19:00 TAG 3
19:00 LEAK TESTING
- 360 1830 FINAL INSPECTION
20:00 OILING
20:00
- 180 2010 SKILL ACTION
21:00 LEVEL 1

21:00 LEVEL 2

- 360 2370 LEVEL 3

22:00 LEVEL 4

22:00 QTY.(IN PCS.)

- 330 2700 REWORK

23:00 SCRAP

TOTAL 2700

REWORK SAP
Sr. No. MODEL PLAN BUILT QA TEST REJECTION FOR SAP
DOC. NO
EHS DETAIL CONSUMABLE DETAILS NEW DEVELOPMENT DETAILS

NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME

1
TIR COTTON ARM SLEEVE/PCS. START TIME

TCR COTTON OLD DHOTI/PCS. C/O ISSUE

2
STOP CALL WAIT SURGICAL HAND GLOVES/PAIR M/C SPECIFIC ISSUE
BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
3
NAME NO.OF OBS.TIME TAKENTIP 24KD/PCS. TOLLING ISSUE

TIP 36 KD/PCS. GAUGES ISSUE

4
PAINT MARKER/PCS. CT INCREASE ISSUE
GAS DEFUSER 36KD/PCS. SAFETY ISSUE
5
LATHER APRAN/PCS. OTHER ANY ISSUE

GAS DEFUSER 24KD/PCS. END TIME

6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

1 LATHER ARM SLEEVE/PAIR.

7
2 TIP HOLDER 36KD (M₆ₓ₁)

3 WIRE ROLL (/KG)

8
4 LATHER HAND GLOVES/PAIR.

5 SILICON SPRAY/PCS.
9
6 WELDING NOZZEL 24 KD/PCS.

7 LATHER SHOE GUARD/PAIR.

10
8 WELDING HELMET FRONT GLASS

9 WELDING MASK 3M/PCS.

11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.
RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.
GAS NOZZEL 36KD CONOAL SPLIT PUSH
13
WELDING CURTAIN/PCS.
WELDING FACE SHIELD INNER GLASS/P
14
WELDING TORCH 24KD/PCS. (45⁰BEND)

LINNER 42.04001047 1.2LEN STEELINSD

TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX
without name rolling puncher
half name rolling gas fault
double name rolling sapatter on hole of piercing abd bhb
MANUA
reverse name rolling {block wrong fitment or wrong tube fitt} L over weld
NAME date fall down then date and shift print miss WELDIN weld miss
ROLLING dent mark problem G stabi cut
low impression
dimension out of spec.
other model tube name rolling pin hole
weld miss
penetration high gas fault
under cut half welding
gas fault under cut
pin hole puncher
HORIZONTAL half welding over weld
WELDING welding shift up and down stabi.bkt cut
k.bkkt weld wrong side on tube STABI weld shift
name rolling shift { front of operator } BKT. low and high penertation
over weld WELDIN thin beed of weld
Puncture G spatter on stabi.bkt
stabi weld wrong postion
depth varation gap problem
lss dim .varation stabi tapper
base cup to bkt and tube dim. Varation gauage not qualify
base cup taper Dimensions out
dent mark on tube end leakage
PRESSING reverse k.bkt assemble
M/C name roliling position shift
double base cup leakage from base cup
base cup tilled reverse leakage from k.bkt
wrong lsss press LEAKA leakage from r. tube
k.bkt damage due to alingement issue GE leakge from stabi
base cup not insert TESTIN leakage from lss
G
pin hole
weld miss
gas fault reverse notching in yl8
half welding notching dia undersize
under cut notching crack
NOTCHING
puncher double notching
over weld
APEENA k.bkt cut
weld shift
low and high penertation
thin beed of weld
spatter on k.bkt
lss fall down loose
leakage
welding out due to run out

size not maintain

dent mark
SIZING flatness not ok

concntricicty out
46 dim out
total length dim out
PIERCING
burr
flatness not ok
coining not ok

nugget issue
spark mark on bkt
child part wrong weld
gauage not qualify
dimensions not ok
PROJECTION
gap issue
part melt
child part nut miss
 Daily Production Shift Report Ref. No. : - F:PRD:8501A

Std.Issue Date :01/07/2017 Formate Revision No. 0 Revision Date 00/00/00 BOTTEL Manpower Deployment columns added Resp. : TL - Production
NECK CT
Cell:NEW BASE FRONT TEAM LEADER:- DATE:- SHIFT C AND CHANGEOVER TARGET TIME IATF 16949 : 2016
PROCESS
Target Execution r ap PLANNED OPERAT ACTUAL OPERATOR
Difference (+/-) Sc NAME PURCHAS POWER INPROCESS
NEW PARTS
MANPOWE TRAINING / OTHER
Time
Hourly Target
Cum-ulative Actual Pieces / Actual Cum-
Hourly Target k
Description of Issue, Actions & Root Cause LOSS TIME
E
STORE
FAILURE
MAINT PED
SETTING
SETUP & C/O
R AUDIT
Q.A
LOSS TIME Details
Target Hour ulative w or LOSS TIME PROCESS NAME SAP CODE LEVEL
Re
23:00 NOTCHINE

- 360 360 NAME ROLLING

0:00 HORIZENTEL 1

0:00 HORZINTEL 2

- 300 660 PRESSING

1:00 APEENA 1

1:00 APEENA 2

- 360 1020 SIZING

2:00 PIERCING

2:00 SENSOR PROJ

- 300 1320 BHB PROJ

3:00 STABI

3:00 TAG 1

- 360 1680 TAG 2

4:00 TAG 3

4:00 LEAK TESTING

- 360 2040 FINAL INSPECTION

5:00 OILING

5:00 SKILL ACTION

- 330 2370 LEVEL1

6:00 LEVEL2

LEVEL3

TOTAL 2370
LEVEL 4

SAP
S. No. MODEL PLAN BUILT QA TEST REJECTION REWORK FOR SAP DOC. EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS
NO
NEAR
MISS COTTON HAND GLOVES/PAIR MODEL NAME
1
TIR COTTON ARM SLEEVE/PCS. START TIME
TCR COTTON OLD DHOTI/PCS. C/O ISSUE
2
STOP CA SURGICAL HAND GLOVES/PAIR MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE

3
NAMENO.OF OBS.
TIME TAKEN
TIP 24KD/PCS. TOLLING ISSUE
TIP 36 KD/PCS. GAUGES ISSUE
4
PAINT MARKER/PCS. CYCLE TIME INCREASE ISSUE
GAS DEFUSER 36KD/PCS. SAFETY ISSUE
5
LATHER APRAN/PCS. OTHER ANY ISSUE
GAS DEFUSER 24KD/PCS. END TIME
6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)
LATHER ARM SLEEVE/PAIR.
7
TIP HOLDER 36KD (M₆ₓ₁)
WIRE ROLL (/KG)
8
LATHER HAND GLOVES/PAIR.
SILICON SPRAY/PCS.
9
WELDING NOZZEL 24 KD/PCS.
LATHER SHOE GUARD/PAIR.
10
WELDING HELMET FRONT GLASS
WELDING MASK 3M/PCS.
11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.
RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.
GAS NOZZEL 36KD CONOAL SPLIT PUSH
13
WELDING CURTAIN/PCS.
WELDING FACE SHIELD INNER GLASS/P
14
WELDING TORCH 24KD/PCS. (45⁰BEND)
LINNER 42.04001047 1.2LEN STEELINSD
TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX
without name rolling puncher

MANUAL WELDING
half name rolling gas fault
NAME ROLLING

double name rolling sapatter on hole of piercing abd bhb

reverse name rolling {block wrong fitment or over weld
date fall down wrong tubrand
then date fitt}shift print miss weld miss
dent mark problem stabi cut
low impression
dimension out of spec.
other model tube name rolling pin hole
weld miss
penetration high gas fault
under cut half welding
gas fault under cut
HORIZONTAL

STABI BKT. WELDING

pin hole puncher
WELDING

half welding over weld

welding shift up and down stabi.bkt cut
k.bkkt weld wrong side on tube weld shift
name rolling shift { front of operator } low and high penertation
over weld thin beed of weld
puncher spatter on stabi.bkt
stabi weld wrong postion
depth varation gap problem
lss dim .varation stabi tapper
base cup to bkt and tube dim. Varation gauage not qualify
PRESSING M/C

base cup taper Dimensions out

dent mark on tube end leakage
reverse k.bkt assemble
name roliling position shift
double base cup leakage from base cup
base cup tilled reverse leakage from k.bkt
LEAKAGE
wrong lsss press TESTING
leakage from r. tube
k.bkt damage due to alingement issue leakge from stabi
base cup not insert leakage from lss
pin hole
weld miss
gas fault reverse notching in yl8
NOTCHING

half welding notching dia undersize

under cut notching crack
puncher double notching
over weld
APEENA

k.bkt cut
weld shift
low and high penertation
thin beed of weld
spatter on k.bkt
lss fall down loose
leakage
welding out due to run out
size not maintain
SIZING

dent mark
flatness not ok

concntricicty out
PIERCING

46 dim out
total length dim out
burr
flatness not ok
coining not ok

nugget issue
spark mark on bkt
child part wrong weld
gauage not qualify
PROJECTION

dimensions not ok
gap issue
part melt
child part nut miss
 Daily Production Shift Report Ref. No. : - F:PRD:8501B

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production

Cell :OLD BASE FRONT TEAM LEADER: DATE: SHIFT: BOTTEL NECK CT
PROCESS NAME
AND
CHANGEOVER TARGET TIME IATF 16949 : 2016
Target Execution PLANNED OPERATOR ACTUAL OPERATOR

Difference (+/-) Rework NEW PARTS

PURCHAS POWER INPROCESS MANPOWE TRAINING / OTHER
Time Cum-ulative Actual Pieces / Actual Cum- Hourly Target Scrap Description of Issue, Actions & Root Cause LOSS TIME
E
STORE
FAILURE
MAINT PED
SETTING
SETUP & C/O
R AUDIT
Q.A
LOSS TIME Details
Hourly Target LOSS TIME PROCESS
Target Hour ulative SAP CODE LEVEL
NAME

6:00 NOTCHINE

- 275 275 NAME ROLLING

7:00 HORIZENTEL 1

7:00 HORZINTEL 2

- 300 575 PRESSING

8:00 APEENA 1

8:00 APEENA 2

- 250 825 SIZING

9:00 PIERCING

9:00 SENSOR PROJ

- 300 1125 BHB PROJ

10:00 STABI

10:00 TAG 1

- 300 1425 TAG 2

11:00 TAG 3

11:00 LEAK TESTING

- 150 1575 FINAL INSPECTI

12:00 OILING

12:00
ROBOTIC
WELDING
- 300 1875

13:00

13:00

- 250 2125

14:00 SKILL
ACTION
14:00 LEVEL 1

- 125 2250 LEVEL 2

14:30 LEVEL 3

TOTAL 2250 2250 LEVEL 4

REWORK
S. No. MODEL PLAN BUILT QA TEST REJECTION FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME

1
TIR COTTON ARM SLEEVE/PCS. START TIME
TCR COTTON OLD DHOTI/PCS. C/O ISSUE
2
STOP CALL WA SURGICAL HAND GLOVES/PAIR MACHINE SPECIFIC ISSUE
BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
3
NAME NO.OF OBS. TIME TAKEN
TIP 24KD/PCS. TOLLING ISSUE
TIP 36 KD/PCS. GAUGES ISSUE
4
PAINT MARKER/PCS. CYCLE TIME INCREASE ISSUE
GAS DEFUSER 36KD/PCS. SAFETY ISSUE
5
LATHER APRAN/PCS. OTHER ANY ISSUE
GAS DEFUSER 24KD/PCS. END TIME
6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)
LATHER ARM SLEEVE/PAIR.
7
TIP HOLDER 36KD (M₆ₓ₁)
WIRE ROLL (/KG)
8
LATHER HAND GLOVES/PAIR.
SILICON SPRAY/PCS.
9
WELDING NOZZEL 24 KD/PCS.
LATHER SHOE GUARD/PAIR.
10
WELDING HELMET FRONT GLASS
WELDING MASK 3M/PCS.
11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.
RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.
GAS NOZZEL 36KD CONOAL SPLIT PUSH FIT
13
WELDING CURTAIN/PCS.
WELDING FACE SHIELD INNER GLASS/PCS.
14
WELDING TORCH 24KD/PCS. (45⁰BEND)
LINNER 42.04001047 1.2LEN STEELINSD
TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX
without name rolling puncher
half name rolling gas fault
double name rolling MANU sapatter on hole of piercing abd bhb
reverse name rolling {block wrong fitment or wrong tubr fitt} over weld
AL
date fall down then date and shift print miss WELDI weld miss
NAME ROLLING
dent mark problem NG stabi cut
low impression
dimension out of spec.
other model tube name rolling pin hole
weld miss
penetration high gas fault
under cut half welding
gas fault under cut
pin hole puncher
half welding over weld
HORIZONTAL
welding shift up and down stabi.bkt cut
WELDING
k.bkkt weld wrong side on tube STABI weld shift
name rolling shift { front of operator } BKT. low and high penertation
over weld WELDI thin beed of weld
puncher NG spatter on stabi.bkt
stabi weld wrong postion
depth varation gap problem
lss dim .varation stabi tapper
base cup to bkt and tube dim. Varation gauage not qualify
base cup taper Dimensions out
dent mark on tube end leakage
reverse k.bkt assemble
PRESSING M/C name roliling position shift
double base cup leakage from base cup
base cup tilled reverse leakage from k.bkt
wrong lsss press LEAK leakage from r. tube
k.bkt damage due to alingement issue AGE leakge from stabi
base cup not insert TESTI leakage from lss
NG
pin hole
weld miss
gas fault reverse notching in yl8
half welding notching dia undersize
under cut notching crack
NOTCHING
puncher double notching
over weld
k.bkt cut
APEENA
weld shift
low and high penertation
thin beed of weld
spatter on k.bkt
lss fall down loose
leakage
welding out due to run out

size not maintain

dent mark
SIZING flatness not ok

concntricicty out
46 dim out
PIERCING
total length dim out
burr
flatness not ok
coining not ok

nugget issue
spark mark on bkt
child part wrong weld
gauage not qualify
dimensions not ok
PROJECTION
gap issue
part melt
child part nut miss
 Bottleneck CT & Process Changeover
Cell : NEW BASE FRONT TEAM LEADER:- DATE:- SHIFT B
Name Target Time
Target Execution PLANNED OPERATOR ACTUAL OPERATOR
OTHER
Difference (+/-)
Time Hourly Cumulative Actual Pieces / Actual Cum- Hourly Target Description of Issue, Actions & Root Cause Total Loss
Time
PUR STR
POWER
CUT
MAINT PED
SETTING
& ADJ.
NPD C/O
MANPOW TRAINING
ER / AUDIT
Q.A LOSS
TIME
Target Target Hour ulative PROCESS NAME SAP CODE LEVEL

14:30 NOTCHING
- 125 125 NAME ROLLING
15:00 HORIZONTAL 1
15:00 HORIZONTAL 2
- 300 425 PRESSING
16:00 APEENA 1
16:00 APEENA 2
- 250 675 SIZING
17:00 PIERCING
17:00 SENSOR PROJ
- 300 975 BHB PROJ
18:00 STABI
18:00 TAG 1
- 300 1275 TAG 2
19:00 TAG 3
19:00 LEAK TESTING
- 300 1575 FINAL INSPECTION
20:00 OILING
20:00 ROBOTIC WELDING
- 150 1725
21:00
21:00
- 300 2025
22:00 SKILL ACTION
22:00 LEVEL 1
- 225 2250 LEVEL 2
23:00 LEVEL 3

TOTAL 2250 LEVEL 4

REWORK SAP
Sr. No. MODEL PLAN BUILT QA TEST REJECTION FOR SAP
DOC. NO
EHS DETAIL CONSUMABLE DETAILS NEW DEVELOPMENT DETAILS

NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME

1
TIR COTTON ARM SLEEVE/PCS. START TIME

TCR COTTON OLD DHOTI/PCS. C/O ISSUE

2
STOP CALL WAIT SURGICAL HAND GLOVES/PAIR M/C SPECIFIC ISSUE
BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
3
NAME NO.OF OBS.TIME TAKENTIP 24KD/PCS. TOLLING ISSUE
TIP 36 KD/PCS. GAUGES ISSUE
4
PAINT MARKER/PCS. CT INCREASE ISSUE
GAS DEFUSER 36KD/PCS. SAFETY ISSUE
5
LATHER APRAN/PCS. OTHER ANY ISSUE
GAS DEFUSER 24KD/PCS. END TIME
6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

1 LATHER ARM SLEEVE/PAIR.

7
2 TIP HOLDER 36KD (M₆ₓ₁)
3 WIRE ROLL (/KG)
8
4 LATHER HAND GLOVES/PAIR.

5 SILICON SPRAY/PCS.
9
6 WELDING NOZZEL 24 KD/PCS.

7 LATHER SHOE GUARD/PAIR.

10
8 WELDING HELMET FRONT GLASS

9 WELDING MASK 3M/PCS.

11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.
RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.
GAS NOZZEL 36KD CONOAL SPLIT PUSH
13
WELDING CURTAIN/PCS.
WELDING FACE SHIELD INNER GLASS/P
14
WELDING TORCH 24KD/PCS. (45⁰BEND)

LINNER 42.04001047 1.2LEN STEELINSD

TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX
without name rolling puncher
half name rolling gas fault
double name rolling sapatter on hole of piercing abd bhb
MANUA
reverse name rolling {block wrong fitment or wrong tube fitt} L over weld
NAME date fall down then date and shift print miss WELDIN weld miss
ROLLING dent mark problem G stabi cut
low impression
dimension out of spec.
other model tube name rolling pin hole
weld miss
penetration high gas fault
under cut half welding
gas fault under cut
pin hole puncher
HORIZONTAL half welding over weld
WELDING welding shift up and down stabi.bkt cut
k.bkkt weld wrong side on tube STABI weld shift
name rolling shift { front of operator } BKT. low and high penertation
over weld WELDIN thin beed of weld
Puncture G spatter on stabi.bkt
stabi weld wrong postion
depth varation gap problem
lss dim .varation stabi tapper
base cup to bkt and tube dim. Varation gauage not qualify
base cup taper Dimensions out
dent mark on tube end leakage
PRESSING reverse k.bkt assemble
M/C name roliling position shift
double base cup leakage from base cup
base cup tilled reverse leakage from k.bkt
wrong lsss press LEAKA leakage from r. tube
k.bkt damage due to alingement issue GE leakge from stabi
base cup not insert TESTIN leakage from lss
G
pin hole
weld miss
gas fault reverse notching in yl8
half welding notching dia undersize
under cut NOTCHIN notching crack
puncher G double notching
over weld
APEENA k.bkt cut
weld shift
low and high penertation
thin beed of weld
spatter on k.bkt
lss fall down loose
leakage
welding out due to run out

size not maintain

dent mark
SIZING flatness not ok

concntricicty out
46 dim out
total length dim out
PIERCING
burr
flatness not ok
coining not ok

nugget issue
spark mark on bkt
child part wrong weld
gauage not qualify
dimensions not ok
PROJECTION
gap issue
part melt
child part nut miss
 Daily Production Shift Report Ref. No. : - F:PRD:8501C
Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production

Cell:BASE REAR TEAM LEADER:- DATE: Shift: A BOTTEL NECK CT

AND PROCESS NAME
CHANGEOVER TARGET TIME IATF 16949 : 2016
Target Execution
PLANNED

rap
NEW ACTUAL
INPRO OPERATOR OPERATOR

Sc
Difference POWER PARTS TRAINI OTHER
LOSS PURCH CESS MANPO
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause STORE FAILUR MAINT PED SETUP C/O NG / Q.A LOSS Details
Hourly TIME ASE SETTIN WER

k
ulative Pieces / Cum- Target E & LOSS AUDIT TIME

or
Target G

w
Target Hour ulative TIME PROCESS NAME SAP CODE LEVEL

Re
6:00 FLARING

- 391 391 NAME ROLLING

7:00 SEAM WELDING

7:00 LOOP WELDING

- 427 819 LEAK TESTING

8:00 FINAL INSPECTION

8:00 SWAGING

- 356 1174 LSS WELDING

9:00 N/R-2

9:00 FLARING-2

- 427 1601 LEAK TESTING -2

10:00 OILING

10:00
- 427 2028
11:00
11:00
- 214 2242
12:00
12:00
- 427 2669
13:00
13:00
- 356 3025
14:00 SKILL ACTION

14:00 LEVEL 1

- 178 3203 LEVEL 2

14:30 LEVEL 3

TOTAL 3203 LEVEL 4

REWORK SAP DOC.
S. No. MODEL PLAN BUILT QA TEST REJECTION FOR SAP
NO
EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

1 NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME

2 TIR COTTON ARM SLEEVE/PCS. START TIME

3 TCR COTTON OLD DHOTI/PCS. C/O ISSUE

MACHINE SPECIFIC
4 STOP CALL WA SURGICAL HAND GLOVES/PAIR
ISSUE

5 BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE

6 NAME NO.OF OBS. TIME TAKEN CHEMICAL GLOVES/PAIR TOLLING ISSUE

7 TIP 36 KD/PCS. GAUGES ISSUE

CYCLE TIME
8 PAINT MARKER/PCS.
INCREASE ISSUE

TOTAL GAS DEFUSER 36KD/PCS. SAFETY ISSUE

4M CHANGE DETAILS LATHER APRAN/PCS. OTHER ANY ISSUE

 DEFECT MATRIX TORCH 36KD/PCS. END TIME

LEATHER PAD/PAIR
Machine name
LATHER ARM SLEEVE/PAIR.

tube damage/ Dent TIP HOLDER 36KD (M₆ₓ₁)

flaring over and under size WIRE ROLL (/KG)

Flaring scretch WELDING LINER/PCS.

flaring miss one side SILICON SPRAY/PCS.

Tube Crack PU-PAD/PAIR

LATHER SHOE GUARD/PAIR.

REST PREVINTIVE OIL/LIT.

without name rolling

half name rolling
double name rolling
reverse name rolling {block wrong
Name Rolling datefitment or wrong
fall down tubrand
then date fitt} shift
print miss
dent mark problem
low impression/ High impression
dimension out of spec.
other model tube name rolling

pill off fail

base cup taper
depth varation
welding thin
Vertical seam
spark
knurling impression low
half weld
perpedicularty

offset
puncher
weld miss
gas fault
under cut
loop cit
Loop welding pin hole
over weld
welding up and down
loop position shift
wrong loop weld
spatter
nugget fail

leakage from seam weld

Leakage Testing
leakage from tube
Lekage from L.S.S

tube bend
tube dent
swaging dia over size
swaging id over size and under
Swaging size
swaging langhth dim. Not ok
runout
length short
Tube Crack
 Daily Production Shift Report Ref. No. : - F:PRD:8501C

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production

Cell:Base rear Target Execution

TEAM LEADEAR: Date: Shift:B BOTTEL NECK CT
NAME
AND PROCESS
CHANGEOVER TARGET TIME IATF 16949 : 2016
ACTUAL
NEW PLANNED

p
OPERAT

ra
Difference INPROCE PARTS TRAININ OTHER OPERATOR

Sc
LOSS PURCHA POWER MANPO OR
Time Actual
Hourly Cum-ulative Actual Cum- (+/-) Hourly Description of Issue, Actions & Root Cause
TIME SE
STORE
FAILURE
MAINT PED SS SETUP & C/O
WER
G/ Q.A LOSS Details

k
Pieces / Target SETTING LOSS AUDIT TIME

or
Target Target ulative

w
Hour TIME PROCESS NAME NAME / SAP CODE LEVEL

Re
14:30 FLARING

- 168 168 NAME ROLLING

15:00 SEAM WELDING

15:00 LOOP WELDING

- 400 568 LEAK TESTING

16:00 FINAL INSPECTION

16:00 SWAGING

- 333 901 LSS WELDING

17:00 N/R-2

17:00 FLARING-2

- 400 1301 LEAK TESTING -2

18:00 OILING

18:00
- 400 1701
19:00
19:00
- 400 2101
20:00
20:00
- 200 2301
21:00
21:00
- 333 2634
22:00 SKILL
ACTION

22:00 LEVEL 1

- 370 3004 LEVEL 2

23:00 LEVEL 3

TOTAL 3004 LEVEL 4

SAP DOC.
S. No. MODEL PLAN BUILT QA TEST REJECTION REWORK FOR SAP
NO
EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS
NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME
1 TIR COTTON ARM SLEEVE/PCS. START TIME
TCR COTTON OLD DHOTI/PCS. C/O ISSUE
2 MACHINE SPECIFIC
STOP CALL WAI SURGICAL HAND GLOVES/PAIR
ISSUE
BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
3 NAME NO.OF OBS. TIME TAKEN TIP 24KD/PCS. TOLLING ISSUE
TIP 36 KD/PCS. GAUGES ISSUE
4 CYCLE TIME
PAINT MARKER/PCS.
INCREASE ISSUE
GAS DEFUSER 36KD/PCS. SAFETY ISSUE
5
LATHER APRAN/PCS. OTHER ANY ISSUE
GAS DEFUSER 24KD/PCS. END TIME
6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

LATHER ARM SLEEVE/PAIR.

7
TIP HOLDER 36KD (M₆ₓ₁)

WIRE ROLL (/KG)

8
LATHER HAND GLOVES/PAIR.

SILICON SPRAY/PCS.
9
WELDING NOZZEL 24 KD/PCS.
LATHER SHOE GUARD/PAIR.
10
WELDING HELMET FRONT GLASS

WELDING MASK 3M/PCS.

11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.

RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.
GAS NOZZEL 36KD CONOAL SPLIT PUSH FIT
13
WELDING CURTAIN/PCS.
WELDING FACE SHIELD INNER GLASS/PCS.
14
WELDING TORCH 24KD/PCS. (45⁰BEND)
LINNER 42.04001047 1.2LEN STEELINSD
TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX
Machine name

tube damage/ Dent

flaring over and under size
Flaring scretch
flaring miss one side
Tube Crack

without name rolling

half name rolling
double name rolling
reverse name rolling {block wrong
Name Rolling date fallfitment
down or wrong
then datetubr
andfitt}
shift print
miss
dent mark problem
low impression/ High impression
dimension out of spec.
other model tube name rolling

pill off fail

base cup taper
depth varation
welding thin
Vertical seam
spark
knurling impression low
half weld
perpedicularty

offset
puncher
weld miss
gas fault
under cut
loop cit
Loop welding pin hole
over weld
welding up and down
loop position shift
wrong loop weld
spatter
nugget fail

leakage from seam weld

Leakage Testing
leakage from tube
Lekage from L.S.S

tube bend
tube dent
swaging dia over size
swaging id over size and under size
Swaging
swaging langhth dim. Not ok
runout
length short
Tube Crack
 Daily Production Shift Report Ref. No. : - F:PRD:24A

Std.Issue Date :01/11/2019 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : Production

PART NAME/NO:- TEAM LEADER:- DATE: SHIFT:GEN BOTTEL NECK CT

AND PROCESS NAME CHANGEOVER TARGET TIME ISO 9001:2008
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR

Sc
Difference NEW PARTS OPERATOR
POWER INPROCES MANPOWE TRAINING / OTHER
Actual Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE MAINT PED C/O Q.A Details

k
Time (+/-) Hourly SETUP &

or
Hourly Cum-ulative Actual Cum- FAILURE S SETTING R AUDIT LOSS TIME

w
Pieces / Target LOSS TIME

Re
Target Target ulative PROCESS NAME NAME / SAP CODE LEVEL
Hour

8:30 FLARING

- NAME ROLLING

9:30 SEAM WELDING

9:30 LOOP WELDING

- LEAK TESTING

10:30 FINAL INSPECTION

10:30 SWAGING

- LSS WELDING

11:30 N/R-2

11:30 FLARING-2

- LEAK TESTING -2

12:30 OILING

13:00
-
14:00
14:00
-
15:00
15:00

16:00
16:00

17:00
17:00

18:00
18:00

19:00
19:00
SKILL ACTION

20:30 LEVEL 1

LEVEL 2

TOTAL 0 0 LEVEL 3

LEVEL 4
REJECTIO REWORK SAP DOC.
S. No. MODEL PLAN BUILT QA TEST
N
FOR SAP
NO
EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS
NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME
1 TIR COTTON ARM SLEEVE/PCS. START TIME
TCR COTTON OLD DHOTI/PCS. C/O ISSUE
2 MACHINE SPECIFIC
STOP CALL WA SURGICAL HAND GLOVES/PAIR
ISSUE
BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
3
NAME NO.OF OBS. TIME TAKEN TIP 24KD/PCS. TOLLING ISSUE
TIP 36 KD/PCS. GAUGES ISSUE
4 CYCLE TIME INCREASE
PAINT MARKER/PCS.
ISSUE
GAS DEFUSER 36KD/PCS. SAFETY ISSUE
5
LATHER APRAN/PCS. OTHER ANY ISSUE
GAS DEFUSER 24KD/PCS. END TIME
6
4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

LATHER ARM SLEEVE/PAIR.

7
TIP HOLDER 36KD (M₆ₓ₁)
WIRE ROLL (/KG)
8
LATHER HAND GLOVES/PAIR.

SILICON SPRAY/PCS.
9
WELDING NOZZEL 24 KD/PCS.

LATHER SHOE GUARD/PAIR.

10
WELDING HELMET FRONT GLASS

WELDING MASK 3M/PCS.

11
KAIZENS DETAILS WATER BASED RUST CHEMICAL/LTR.

RUSTLICK/PCS.
12
WELDING NOZZEL 36KD/PCS.
GAS NOZZEL 36KD CONOAL SPLIT PUSH FIT
13
WELDING CURTAIN/PCS.
 WELDING FACE SHIELD INNER GLASS/PCS.
14
WELDING TORCH 24KD/PCS. (45⁰BEND)
LINNER 42.04001047 1.2LEN STEELINSD
TOTAL
CONTACT TIP 1.2*M₆ 42.0001.4464
 DEFECT MATRIX
Machine name

tube damage/ Dent

flaring over and under size
Flaring scretch
flaring miss one side
Tube Crack

without name rolling

half name rolling
double name rolling
reverse name rolling {block
wrong
date fallfitment or wrong
down then date tubr fitt}
and shift
Name Rolling
print miss
dent mark problem
low impression/ High impression
dimension out of spec.
other model tube name rolling

pill off fail

base cup taper
depth varation
welding thin
Vertical seam
spark
knurling impression low
half weld
perpedicularty

offset
puncher
weld miss
gas fault
under cut
loop cit
Loop welding pin hole
over weld
welding up and down
loop position shift
wrong loop weld
spatter
nugget fail

leakage from seam weld

Leakage Testing
leakage from tube
Lekage from L.S.S

tube bend
tube dent
swaging dia over size
swaging id over size and under
Swaging size
swaging langhth dim. Not ok
runout
length short
Tube Crack
 Daily Production Shift Report Ref. No. : - F:PRD:8501D

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER FRONT TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00 CYLINDER WASHING

- 351 351 MATERIAL FEEDING

7:00 ROD WASHING

7:00 P.ROD VISUAL INSPECTION

- 383 733 CRIMPING

8:00 PISTON VALVING

8:00

- 319 1052 COMPRESSION VALVING

9:00

9:00 GREASING

- 383 1434 LOCKTITE APPLICATION

10:00 NUT TIGHTENING

NUT TIGHTENING
10:00 VERIFICATION

- 383 1817 C.V PRESSING

11:00 OIL FILLING

11:00 OUTER TUBE WASHING

- 191 2008

12:00 D/F TESTING

12:00 STICKER PAISTING

- 383 2391 SEALING

13:00 SEALING INSPECTION

13:00 GASFILLING

- 319 2709 P.ROD PLAY

14:00 NOISE TESTING

14:00 BUMP CAP PRESSING

- 159 2869 MARKING

14:30

TOTAL 2869

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501D

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER FRONT TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly Cum-ulative FAILURE SETTING AUDIT LOSS TIME
Pieces / Cum- Target LOSS TIME

k
Target Target PROCESS NAME NAME / SAP CODE LEVEL

or
Hour ulative

w
Re
2:30 CYLINDER WASHING

- 159 159 MATERIAL FEEDING

3:00 ROD WASHING

3:00 P.ROD VISUAL INSPECTION

- 383 542 CRIMPING

4:00 PISTON VALVING

4:00

- 319 861 COMPRESSION VALVING

5:00

5:00 GREASING

- 383 1243 LOCKTITE APPLICATION

6:00 NUT TIGHTENING

NUT TIGHTENING
6:00 VERIFICATION

- 383 1626 C.V PRESSING

7:00 OIL FILLING

7:00 OUTER TUBE WASHING

- 319 1944

8:00 D/F TESTING

8:00 STICKER PAISTING

- 255 2199 SEALING

9:00 SEALING INSPECTION

9:00 GASFILLING

- 319 2518 P.ROD PLAY

10:00 NOISE TESTING

10:00 BUMP CAP PRESSING

- 351 2869 MARKING

11:00

TOTAL 2869

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen inside Sticker reverse/ wrinkle on sticker
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen inside

Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage during oil seal bulging

Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin damage dent/scrach on rod
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage

Pressure tube dent and damage

cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501D

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER FRONT TEAM LEADER:- DATE:- SHIFT:C PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
11:00 CYLINDER WASHING

- 351 351 MATERIAL FEEDING

12:00 ROD WASHING

12:00 P.ROD VISUAL INSPECTION

- 383 733 CRIMPING

1:00 PISTON VALVING

1:00

- 319 1052 COMPRESSION VALVING

2:00

2:00 GREASING

- 383 1434 LOCKTITE APPLICATION

3:00 NUT TIGHTENING

NUT TIGHTENING
3:00 VERIFICATION

- 383 1817 C.V PRESSING

4:00 OIL FILLING

4:00 OUTER TUBE WASHING

- 319 2136

5:00 D/F TESTING

5:00 STICKER PAISTING

- 351 2486 SEALING

6:00 SEALING INSPECTION

GASFILLING

P.ROD PLAY

NOISE TESTING
TOTAL 2486 REWORK/TROLLEY
MOVEMENT

BUMP CAP PRESSING

MARKING

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS
NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3
LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER REAR TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00 CYLINDER WASHING

- 440 440 MATERIAL FEEDING

7:00 ROD WASHING

7:00 P.ROD VISUAL INSPECTION

- 480 920 CRIMPING

8:00 PISTON VALVING

8:00

- 400 1320 COMPRESSION VALVING

9:00

9:00 GREASING

- 480 1800 LOCKTITE APPLICATION

10:00 NUT TIGHTENING

NUT TIGHTENING
10:00 VERIFICATION

- 480 2280 C.V PRESSING

11:00 OIL FILLING

11:00 OUTER TUBE WASHING

- 240 2520

12:00 D/F TESTING

12:00 STICKER PAISTING

- 480 3000 SEALING

13:00 SEALING INSPECTION

13:00 GASFILLING

- 400 3400 P.ROD PLAY

14:00 NOISE TESTING

14:00 BUMP CAP PRESSING

- 200 3600 MARKING

14:30

TOTAL 3600

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER REAR TEAM LEADER:- DATE:- SHIFT:C PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
11:00 CYLINDER WASHING

- 440 440 MATERIAL FEEDING

12:00 ROD WASHING

12:00 P.ROD VISUAL INSPECTION

- 480 920 CRIMPING

1:00 PISTON VALVING

1:00

- 400 1320 COMPRESSION VALVING

2:00

2:00 GREASING

- 480 1800 LOCKTITE APPLICATION

3:00 NUT TIGHTENING

NUT TIGHTENING
3:00 VERIFICATION

- 480 2280 C.V PRESSING

4:00 OIL FILLING

4:00 OUTER TUBE WASHING

- 240 2520

5:00 D/F TESTING

5:00 STICKER PAISTING

- 440 2960 SEALING

6:00 SEALING INSPECTION

GASFILLING

P.ROD PLAY

NOISE TESTING
TOTAL 2960 REWORK/TROLLEY
MOVEMENT

BUMP CAP PRESSING

MARKING

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS
NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3
LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER REAR TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
2:30 CYLINDER WASHING

- 200 200 MATERIAL FEEDING

3:00 ROD WASHING

3:00 P.ROD VISUAL INSPECTION

- 480 680 CRIMPING

4:00 PISTON VALVING

4:00

- 400 1080 COMPRESSION VALVING

5:00

5:00 GREASING

- 480 1560 LOCKTITE APPLICATION

6:00 NUT TIGHTENING

NUT TIGHTENING
6:00 VERIFICATION

- 480 2040 C.V PRESSING

7:00 OIL FILLING

7:00 OUTER TUBE WASHING

- 240 2280

8:00 D/F TESTING

8:00 STICKER PAISTING

- 480 2760 SEALING

9:00 SEALING INSPECTION

9:00 GASFILLING

- 400 3160 P.ROD PLAY

10:00 NOISE TESTING

10:00 BUMP CAP PRESSING

- 440 3600 MARKING

11:00

TOTAL 3600

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501G

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: MODULAR REAR TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00 BUSH FIXING

- 440 440 SLEEVE COCKING

7:00 DIRT SHIELD ASSY.

7:00

- 480 920

8:00

8:00

- 400 1320

9:00

9:00

- 480 1800

10:00

10:00

- 480 2280

11:00

11:00

- 480 2760

12:00

12:00

- 240 3000

13:00

13:00

- 480 3480

14:00

14:00

- 400 3880

14:30

TOTAL 3880

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS
SKILL LEVEL MATRIX
SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Bush Out

Dent/Paint Fault On Loop

Bush Bush Mixup

Fixing
Bush Bonding Fail

caulking loose

caulking surface damage

Sleeve Retainer /Sleve MIXUP
Caulking
Thread Damage

Polygon Damage

Metal Cap Mixup

Metal Cap Sleave Mixup

Assy. / Retainer Mixup
Tata Pre
assy.
 Daily Production Shift Report Ref. No. : - F:PRD:8501G

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: MODULAR REAR TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
2:30 BUSH FIXING

- 200 200 SLEEVE COCKING

3:00 DIRT SHIELD ASSY.

3:00

- 480 680

4:00

4:00

- 400 1080

5:00

5:00

- 480 1560

6:00

6:00

- 480 2040

7:00

7:00

- 480 2520

8:00

8:00

- 480 3000

9:00

9:00

- 240 3240

10:00

10:00

- 400 3640

11:00

TOTAL 3640

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS
SKILL LEVEL MATRIX
SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3
LEVEL 4
9

10

11
KAIZENS DETAILS

12
 12

13

14

TOTAL
 Daily Production Shift Report Ref. No. : - F:PRD:8501G

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: MODULAR REAR TEAM LEADER:- DATE:- SHIFT:C PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
11:00 BUSH FIXING

- 440 440 SLEEVE COCKING

12:00 DIRT SHIELD ASSY.

12:00

- 480 920

1:00

1:00

- 400 1320

2:00

2:00

- 480 1800

3:00

3:00

- 480 2280

4:00

4:00

- 400 2680

5:00

5:00

- 440 3120

6:00

TOTAL 3120
p

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS
NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS
SKILL LEVEL MATRIX
SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3
LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Bush Out

Dent/Paint Fault On Loop

Bush Bush Mixup

Fixing
Bush Bonding Fail

caulking loose

caulking surface damage

Sleeve Retainer /Sleve MIXUP
Caulking
Thread Damage

Polygon Damage

Metal Cap Mixup

Metal Cap Sleave Mixup

Assy. / Retainer Mixup
Tata Pre
assy.
 Daily Production Shift Report Ref. No. : - F:PRD:8501F

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: MODULAR FRONT TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00
MODULAR ASSY.
- 118 118

7:00 REWORK

7:00 FINAL INSPECTION

- 129 246 PDI INSPECTION

8:00 TORQUING

8:00 GAUGING

- 107 354

9:00

9:00

- 129 482

10:00

10:00

- 129 611

11:00

11:00

- 64 675

12:00

12:00

- 129 804

13:00

13:00

- 107 911

14:00

14:00

- 54 964

14:30

TOTAL 964

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

1 NEAR MISS HAND GLOVES MODEL NAME

2 TIR CHEMICAL GLOVES START TIME

3 TCR SURGICAL GLOVES C/O ISSUE

4 STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

5 BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

6 NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

7 DHOTI GAUGES ISSUE

8 FOSECLEAN CYCLE TIME INCREASE ISSUE

9 PAINT MARKER SAFETY ISSUE

10 PAINT SPRAY OTHER ANY ISSUE

11 RUST LICK END TIME

12 4M CHANGE DETAILS
SKILL LEVEL MATRIX
13 SKILL ACTION
14 LEVEL 1
15 LEVEL 2
LEVEL 3

LEVEL 4

KAIZENS DETAILS

TOTAL
DEFECT MATRIX
NUT DAMAGE

PAINT FAULT

STICKER REWORK

THREAD DAMAGE

TOP MOUNT DAMAGE

KNUCKLE TIGHT PROBLEM

DIRT SHIELD CUT

GAP IN LSS RUBBER

WASHAR/NUT MIXUP

BEARING DAMAGE

BAR CODE ON STICKER NOT SCAN

SPRING MIXUP

DAMPER MIXUP

TOP MOUNT MIXUP

BHB NUT RUSTY

OVER WELDING

WELDING MISS

HEX ROUND OFF

 Daily Production Shift Report Ref. No. : - F:PRD:8501F

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: MODULAR FRONT TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
2:30
MODULAR ASSY.
- 54 54

3:00 REWORK

3:00 FINAL INSPECTION

- 129 182 PDI INSPECTION

4:00 TORQUING

4:00 GAUGING

- 107 289

5:00

5:00

- 129 418

6:00

6:00

- 129 546

7:00

7:00

- 64 611

8:00

8:00

- 129 739

9:00

9:00

- 107 846

10:00

10:00

- 118 964

11:00

TOTAL 964

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

1 NEAR MISS HAND GLOVES MODEL NAME

2 TIR CHEMICAL GLOVES START TIME

3 TCR SURGICAL GLOVES C/O ISSUE

4 STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

5 BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

6 NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

7 DHOTI GAUGES ISSUE

8 FOSECLEAN CYCLE TIME INCREASE ISSUE

9 PAINT MARKER SAFETY ISSUE

10 PAINT SPRAY OTHER ANY ISSUE

11 RUST LICK END TIME

12 4M CHANGE DETAILS
SKILL LEVEL MATRIX
13 SKILL
ACTION
14 LEVEL 1

15 LEVEL 2

TOTAL LEVEL 3

LEVEL 4

KAIZENS DETAILS
 DEFECT MATRIX
NUT DAMAGE

PAINT FAULT

STICKER REWORK

THREAD DAMAGE

TOP MOUNT
DAMAGE

KNUCKLE TIGHT PROBLEM

DIRT SHIELD CUT

DIRT SHIELD CUT
DIRT SHIELD CUT

GAP IN LSS RUBBER

GAP IN LSS RUBBER
GAP IN LSS RUBBER

WASHAR/NUT MIXUP
WASHAR/NUT MIXUP
WASHAR/NUT MIXUP

BEARING DAMAGE
BEARING DAMAGE
BEARING DAMAGE

BAR CODE ON STICKER

BAR CODE
NOT
ONSCAN
STICKER
BAR CODE
NOT
ONSCAN
STICKER NOT SCAN

SPRING MIXUP SPRING MIXUP SPRING MIXUP

DAMPER MIXUP DAMPER MIXUP DAMPER MIXUP

TOP MOUNT MIXUP

TOP MOUNT MIXUP
TOP MOUNT MIXUP

BHB NUT RUSTYBHB NUT RUSTYBHB NUT RUSTY

OVER WELDING OVER WELDING OVER WELDING

WELDING MISS WELDING MISS WELDING MISS

HEX ROUND OFFHEX ROUND OFFHEX ROUND OFF

 Daily Production Shift Report Ref. No. : - F:PRD:8501F

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: MODULAR FRONT TEAM LEADER:- DATE:- SHIFT:C PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
11:00
MODULAR ASSY.
- 118 118

12:00 REWORK

12:00 FINAL INSPECTION

- 129 246 PDI INSPECTION

1:00 TORQUING

1:00 GAUGING

- 107 354

2:00

2:00

- 129 482

3:00

3:00

- 129 611

4:00

4:00

- 107 718

5:00

5:00

- 118 836

6:00

TOTAL 836

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS
NEW DOVELOPMENT DETAILS

1 NEAR MISS HAND GLOVES MODEL NAME

2 TIR CHEMICAL GLOVES START TIME

3 TCR SURGICAL GLOVES C/O ISSUE

4 STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

5 BBS OBSERVATION DETAIL DHOTI Q.A APPROVAL LATE

6 NAME NO.OF OBS. TIME TAKEN PAINT MARKER TOLLING ISSUE

7 PAINT SPRAY GAUGES ISSUE

8 RUST LICK CYCLE TIME INCREASE ISSUE

9 SAFETY ISSUE

10 OTHER ANY ISSUE

11 END TIME

12 4M CHANGE DETAILS
SKILL LEVEL MATRIX
13 SKILL ACTION
14 LEVEL 1
15 LEVEL 2

LEVEL 3
LEVEL 4

KAIZENS DETAILS

TOTAL
DEFECT MATRIX
NUT DAMAGE

PAINT FAULT

STICKER REWORK

THREAD DAMAGE

TOP MOUNT DAMAGE

KNUCKLE TIGHT PROBLEM

DIRT SHIELD CUT

GAP IN LSS RUBBER

WASHAR/NUT MIXUP

BEARING DAMAGE

BAR CODE ON STICKER NOT SCAN

SPRING MIXUP

DAMPER MIXUP

TOP MOUNT MIXUP

BHB NUT RUSTY

OVER WELDING

WELDING MISS

HEX ROUND OFF

 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER ARMSTRONG TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
2:30 COMPONENT WASHING

- 150 150 PRESSUER TUBE WASHING

3:00
ROD WASHING
3:00

- 450 600 OUTER TUBE WASHING

4:00
PISTON VALVING
4:00

- 375 975
COMPRESSION
VALVING+COINNING
5:00

5:00 TOP CAP ASSY REAR

- 450 1425 DIMPLING

6:00 CV FIXING

6:00 NUT TIGHTNING

- 450 1875 OIL FILLING

7:00 DF TESTING

7:00 SEALING

- 450 2325 FINAL INSPECTION

8:00 DUSTCOVER SEAM WELDING

8:00 PISTON ROD CRIMPING

- 225 2550 PISTON ROD LOAD TESTING

9:00 TOP CAP ASSY FRONT

9:00 DU BUSH FIXING

- 450 3000 VERTICAL SEAM WELDING

10:00 GLIND SCREW TOUQUING

10:00 TOURQUE CHECKING

- 338 3338 DATE CODE PUNCHING

11:00 TOLLEY MOVEMENT

TOTAL 3338 REWORK

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

1 NEAR MISS HAND GLOVES MODEL NAME

2 TIR CHEMICAL GLOVES START TIME

3 TCR SURGICAL GLOVES C/O ISSUE

4 STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

5 BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

6 NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

7 DHOTI GAUGES ISSUE

8 FOSECLEAN CYCLE TIME INCREASE ISSUE

9 PAINT MARKER SAFETY ISSUE

10 PAINT SPRAY OTHER ANY ISSUE

11 RUST LICK END TIME

12 4M CHANGE DETAILS STICKER ROLL

TEAM MEMBER KAIZENS DETAILS
13 RIBBEN TEAM LEADER
14 OE
15 DET
INTRIM

SKILL ACTION
LEVEL 1
LEVEL 2
LEVEL 3

LEVEL 4
 Daily Production Shift Report Ref. No. : - F:PRD:8501E

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: DAMPER ARMSTRONG TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00 COMPONENT WASHING

- 413 413 PRESSUER TUBE WASHING

7:00
ROD WASHING
7:00

- 450 863 OUTER TUBE WASHING

8:00
PISTON VALVING
8:00

- 375 1238
COMPRESSION
VALVING+COINNING
9:00

9:00 TOP CAP ASSY REAR

- 450 1688 DIMPLING

10:00 CV FIXING

10:00 NUT TIGHTNING

- 450 2138 OIL FILLING

11:00 DF TESTING

11:00 SEALING

- 225 2363 FINAL INSPECTION

12:00 DUSTCOVER SEAM WELDING

12:00 PISTON ROD CRIMPING

- 450 2813 PISTON ROD LOAD TESTING

13:00 TOP CAP ASSY FRONT

13:00 DU BUSH FIXING

- 375 3188 VERTICAL SEAM WELDING

14:00 GLIND SCREW TOUQUING

14:00 TOURQUE CHECKING

- 150 3338 DATE CODE PUNCHING

14:30 TOLLEY MOVEMENT

TOTAL 3338 REWORK

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

1 NEAR MISS HAND GLOVES MODEL NAME

2 TIR CHEMICAL GLOVES START TIME

3 TCR SURGICAL GLOVES C/O ISSUE

4 STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

5 BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

6 NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

7 DHOTI GAUGES ISSUE

8 FOSECLEAN CYCLE TIME INCREASE ISSUE

9 PAINT MARKER SAFETY ISSUE

10 PAINT SPRAY OTHER ANY ISSUE

11 RUST LICK END TIME

12 4M CHANGE DETAILS STICKER ROLL TEAM MEMBER KAIZENS DETAILS

13 RIBBEN TEAM LEADER
14 OE
15 DET

INTRIM

SKILL ACTION
LEVEL 1

LEVEL 2

LEVEL 3

LEVEL 4
 Daily Production Shift Report Ref. No. : - F:PRD:8501C

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production

Cell:ARMSTRONG BASE TEAM LEADER:- DATE: Shift: A BOTTEL NECK CT

AND PROCESS NAME
CHANGEOVER TARGET TIME IATF 16949 : 2016
Target Execution

p
NEW PLANNED ACTUAL

ra
INPRO OPERATOR OPERATOR

Sc
Difference POWER PARTS TRAINI OTHER
LOSS PURCH CESS MANPO
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause STORE FAILUR MAINT PED SETUP C/O NG / Q.A LOSS Details
Hourly TIME ASE SETTIN WER

k
ulative Pieces / Cum- Target E & LOSS AUDIT TIME

or
Target G

w
Target Hour ulative TIME PROCESS NAME SAP CODE LEVEL

Re
6:00 FLARING

- 413 413 NAME ROLLING

7:00 SEAM WELDING

OT PROJECTION
7:00 AND MIG

- 450 863 LEAK TESTING

8:00 P R MIG

8:00 P R LINER
P ROD CRIMPING
- 375 1238 AND PROJECTION

9:00
9:00
- 450 1688
10:00
10:00
- 450 2138
11:00
11:00
- 450 2588
12:00
12:00
- 225 2813
13:00
13:00
- 375 3188
14:00 SKILL ACTION

14:00 LEVEL 1

- 150 3338 LEVEL 2

14:30 LEVEL 3

TOTAL 3338 LEVEL 4

REWORK SAP DOC.
S. No. MODEL PLAN BUILT QA TEST REJECTION FOR SAP
NO
EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS
1 NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME
2 TIR COTTON ARM SLEEVE/PCS. START TIME
3 TCR COTTON OLD DHOTI/PCS. C/O ISSUE
MACHINE SPECIFIC
4 STOP CALL WA SURGICAL HAND GLOVES/PAIR
ISSUE
5 BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
6 NAME NO.OF OBS. TIME TAKEN TIP 24KD/PCS. TOLLING ISSUE
7 LINNER 42.04001047 1.2LEN STEELINSD GAUGES ISSUE
CYCLE TIME
8 CONTACT TIP 1.2*M₆ 42.0001.4464
INCREASE ISSUE
9 GAS DEFUSER 36KD/PCS. SAFETY ISSUE
10 LATHER APRAN/PCS. OTHER ANY ISSUE
11 GAS DEFUSER 24KD/PCS. END TIME
12 4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

13 LATHER ARM SLEEVE/PAIR.

14 TIP HOLDER 36KD (M₆ₓ₁)

15 WIRE ROLL (/KG)

LATHER HAND GLOVES/PAIR.
SILICON SPRAY/PCS.
WELDING NOZZEL 24 KD/PCS.
LATHER SHOE GUARD/PAIR.
WELDING MASK 3M/PCS.

p RUSTLICK/PCS.
 Daily Production Shift Report Ref. No. : - F:PRD:8501C

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production

Cell:ARMSTRONG BASE TEAM LEADEAR: Date: Shift:B BOTTEL NECK CT

NAME
AND PROCESS
CHANGEOVER TARGET TIME IATF 16949 : 2016
Target Execution ACTUAL
NEW

ap
PLANNED OPERATOR OPERAT

r
Difference INPROCE PARTS TRAININ OTHER

Sc
LOSS PURCHA POWER MANPO OR
Time Actual
Hourly Cum-ulative Actual Cum- (+/-) Hourly Description of Issue, Actions & Root Cause
TIME SE
STORE
FAILURE
MAINT PED SS SETUP & C/O
WER
G/ Q.A LOSS Details

k
Pieces / Target SETTING LOSS AUDIT TIME

or
Target Target ulative

ew
Hour TIME PROCESS NAME NAME / SAP CODE LEVEL

R
14:30 FLARING

- 150 150 NAME ROLLING

15:00 SEAM WELDING

OT PROJECTION AND
15:00 MIG

- 450 600 LEAK TESTING

16:00 P R MIG

16:00 P R LINER

P ROD CRIMPING AND

- 375 975 PROJECTION

17:00
17:00
- 450 1425
18:00
18:00
- 450 1875
19:00
19:00
- 450 2325
20:00
20:00
- 450 2775
21:00
21:00
- 225 3000
22:00 SKILL
ACTION

22:00 LEVEL 1

- 338 3338 LEVEL 2

23:00 LEVEL 3

TOTAL 3338 LEVEL 4

SAP DOC.
S. No. MODEL PLAN BUILT QA TEST REJECTION REWORK FOR SAP
NO
EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS
1 NEAR MISS COTTON HAND GLOVES/PAIR MODEL NAME
2 TIR COTTON ARM SLEEVE/PCS. START TIME
3 TCR COTTON OLD DHOTI/PCS. C/O ISSUE
MACHINE SPECIFIC
4 STOP CALL WAIT SURGICAL HAND GLOVES/PAIR
ISSUE
5 BBS OBSERVATION DETAIL EAR PLUG/PAIR Q.A APPROVAL LATE
6 NAME NO.OF OBS. TIME TAKEN TIP 24KD/PCS. TOLLING ISSUE
7 LINNER 42.04001047 1.2LEN STEELINSD GAUGES ISSUE
CYCLE TIME
8 CONTACT TIP 1.2*M₆ 42.0001.4464
INCREASE ISSUE
9 GAS DEFUSER 36KD/PCS. SAFETY ISSUE
10 LATHER APRAN/PCS. OTHER ANY ISSUE
11 GAS DEFUSER 24KD/PCS. END TIME
12 4M CHANGE DETAILS TIP HOLDER 24KD (M₆ₓ₁)

13 LATHER ARM SLEEVE/PAIR.

14 TIP HOLDER 36KD (M₆ₓ₁)

15 WIRE ROLL (/KG)

LATHER HAND GLOVES/PAIR.
SILICON SPRAY/PCS.
WELDING NOZZEL 24 KD/PCS.
LATHER SHOE GUARD/PAIR.
WELDING MASK 3M/PCS.
RUSTLICK/PCS.
 Daily Production Shift Report Ref. No. : - F:PRD:8501D

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: NEW DAMPER FRONT TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly Description of Issue, Actions & Root Cause LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00 CYLINDER WASHING

- 312 312 MATERIAL FEEDING

7:00 ROD WASHING

7:00 P.ROD VISUAL INSPECTION

- 340 652 CRIMPING

8:00 PISTON VALVING

8:00

- 285 937 COMPRESSION VALVING

9:00

9:00 GREASING

- 340 1277 LOCKTITE APPLICATION

10:00 NUT TIGHTENING

NUT TIGHTENING
10:00 VERIFICATION

- 340 1617 C.V PRESSING

11:00 OIL FILLING

11:00 OUTER TUBE WASHING

- 340 1957

12:00 D/F TESTING

12:00 STICKER PAISTING

- 170 2127 SEALING

13:00 SEALING INSPECTION

13:00 GASFILLING

- 285 2412 P.ROD PLAY

14:00 NOISE TESTING

14:00 BUMP CAP PRESSING

- 142 2554 MARKING

14:30

TOTAL 2554

REJECTIO
S. No. MODEL PLAN BUILT QA TEST
N
REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
OT 2
ROD 1
PRES TU 1
CRIMP 1
GRES 1
NUT 2
C.V PRS 1
OIL 1
D.F 1
STICKR 1
SELNG 1
GAS 1
BUMP C 1
C.V ASSY 2 2185.714
P.V 2
REWORK 1
MAT 1
21
 Daily Production Shift Report Ref. No. : - F:PRD:8501D

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: NERKON TEAM LEADER:- DATE:- SHIFT:A PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Cum- Actual Actual (+/-) Hourly CONVEYOUR 1 CONVEYOUR 2 LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly FAILURE SETTING AUDIT LOSS TIME
ulative Pieces / Cum- Target LOSS TIME

k
Target PROCESS NAME NAME / SAP CODE LEVEL

or
Target Hour ulative

w
Re
6:00
PRE WASHING
- 825 825

7:00
LOADING
7:00

- 900 1725
UNLOADING
8:00

8:00
MOVEMENT
- 750 2475

9:00

9:00

- 900 3375

10:00

10:00

- 900 4275

11:00

11:00

- 450 4725

12:00

12:00

- 900 5625

13:00

13:00

- 750 6375

14:00

14:00

- 375 6750

14:30

TOTAL 6750

S. No. MODEL PLAN BUILT REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen

Sticker reverse/ wrinkle on sticker
inside
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen

inside
Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage oil seal bulging

during Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin dent/scrach on rod
damage
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage
Pressure tube dent and
damage
cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling
 Daily Production Shift Report Ref. No. : - F:PRD:8501D

Std.Issue Date :01/07/2017 Revision No. 0 Revision Date 00/00/00 Manpower Deployment columns added Resp. : TL - Production
BOTTEL NECK CT AND
Cell: NERKON TEAM LEADER:- DATE:- SHIFT:B PROCESS NAME
CHANGEOVER TARGET
TIME IATF 16949 : 2016
Target Execution

p
ACTUAL

ra
PLANNED OPERATOR
Difference OPERATOR

Sc
NEW PARTS
Time Actual Actual (+/-) Hourly CONVEYOUR 1 CONVEYOUR 2 LOSS TIME PURCHASE STORE
POWER
MAINT PED
INPROCESS
SETUP & C/O MANPOWER
TRAINING /
Q.A
OTHER
Details
Hourly Cum-ulative FAILURE SETTING AUDIT LOSS TIME
Pieces / Cum- Target LOSS TIME

k
Target Target PROCESS NAME NAME / SAP CODE LEVEL

or
Hour ulative

w
Re
2:30
PRE WASHING
- 375 375

3:00
LOADING
3:00

- 900 1275
UNLOADING
4:00

4:00
MOVEMENT
- 750 2025

5:00

5:00

- 900 2925

6:00

6:00

- 900 3825

7:00

7:00

- 450 4275

8:00

8:00

- 900 5175

9:00

9:00

- 750 5925

10:00

10:00

- 750 6675

11:00

TOTAL 6675

S. No. MODEL PLAN BUILT REWORK FOR SAP SAP DOC. NO EHS DETAIL CONSUMABLE DETAILS NEW DOVELOPMENT DETAILS

NEAR MISS HAND GLOVES MODEL NAME

1
TIR CHEMICAL GLOVES START TIME

TCR SURGICAL GLOVES C/O ISSUE

2
STOP CALL WAIT EAR PLUG MACHINE SPECIFIC ISSUE

BBS OBSERVATION DETAIL LINT FREE CLOTH Q.A APPROVAL LATE

3
NAME NO.OF OBS. TIME TAKEN LINT FREE GLOVES TOLLING ISSUE

DHOTI GAUGES ISSUE

4
FOSECLEAN CYCLE TIME INCREASE ISSUE

PAINT MARKER SAFETY ISSUE

5
PAINT SPRAY OTHER ANY ISSUE

RUST LICK END TIME

6
4M CHANGE DETAILS STICKER ROLL
SKILL LEVEL MATRIX
RIBBEN SKILL ACTION
7
LEVEL 1
LEVEL 2
8
LEVEL 3

LEVEL 4
9

10

11
KAIZENS DETAILS

12

13

14

TOTAL
 DEFECT MATRIX
Dent / Damage miss print issue
Ot
wrong sticker role
Washing
Dent / Damage wrong part number selected

Pressure Rust due component Fallen inside Sticker reverse/ wrinkle on sticker
Tube
damage sticker
Washing
Dent / Damage scaning problem

Piston Rust due component Fallen inside

Rod
sealing flat
Washing
Eddy
Scrap / rej oil seal bulging
Current
sealing margin more/less

Dent Damage on OD imprint NOK

Dent Damage on Top Threads Rod play

RSP Loose dent/scrach on rod

RSP Crack Sealing dent/scrach on tube

Crimping
oil seal cutting problem
1
Dent Damage on OD seam crack

Dent Damage on Top Threads Q.A Testing

RSP Loose det on sealing surface

RSP Crack chattring on sealing surface

Crimping
2
Seal damage during Insertion sealing flat

Rod guide Bush Damage during oil seal bulging

Insertion
Greasing R.B Miss/R.B problem sealing margin more/less
&
chattring on sealing surface
insertiion
Wrong Assy. Sequence Rod play

Disc Damage/ bend dent/scrach on rod

Sealing dent/scrach on tube

PV Assy. Check
wrong assy. Sequence oil seal cutting problem

disc damage/bend seam crack

backup washar mixup det on sealing surface

CV Assy.
Spring Damage

Intake pin damage

Intake valve disc damage high/low gas force

Flaring
oil seal damage
M/C
Revating of intake pin damage dent/scrach on rod
Gass Filling
Cylinder end damage sticker tear out

Less /More Tourque

Q.A Testing

rversre backup washar Rod play

backup washar damage Rod Play

Revating
M/C
Less /More Tourque Noise

nut damage problem Thread Damage

Teflone damage Paint Fault

disc bend issue Dent/scrach on Rod

Noise
pistion post brakage
Testing M/C
Nut
Tightening
eylinder end damage

Pressure tube dent and damage

cylinder end crack problem less bump cap press

cylinder end less press Bump cap crack peoblem

CV Pressing Taper pressing of bump cap

less oil volume passon Knuckle/LSS damage proble

more oil volume

Bump Cap paint fault on part
Pressing
contaminated oil passon wrong bump cap press problem

Oil Filling loose bump cap

dent/scrach passon

teflone damage

reverse bump stopper

Rod
Insertion Bumper wrong bump stopper
Stopper
thread damage Insertion
Compression Ng

Rebound NG part/rod mixup

Major DF fault therad damage

dent/scrach on rod Rework / hex round of

Trolley
less/more sealing margin Movement reject / contaminated material pass on

noise in parts dent & paint fault

DF Test rod guide less press problem

part mixup

disc mixup

Material rusty materialloading

Handling