Sr. No.

Check Points Responsibility

Procedure for product development from receipt of order to SOP at customer
1 end (preferably as per AIAG guidelines) to be available MR/NPD HOD

APQP matrix for deciding development activities based on categorization of

parts (for new and modifications). Roles and Responsibilities defined in APQP
matrix. Activities matching with procedure(minimum NPD, ECN, PCN, Plant
2 location change, Supplier change, RM Change to be addressed in the matrix, MR/NPD HOD
critical activities e.g. Tool development, supplier development etc, to be
identified)

3 Understanding of Team
MR/NPD HOD
Customer events (sample approval, trial dates, SOP at customer end) and
4 vendor's events (sample submission, pilot lot submission, SOP) to be NPD HOD
mentioned in timing plan
5 Activities matching with procedure and APQP matrix
NPD HOD
6 Evidence of review by project leader and top management in the timing plan
NPD HOD
7 MOM or record of reviews (for evidence)
NPD HOD
8 Micro timing plan matching with MACRO plan (wrt timing)
NPD HOD
9 Capturing delays in plan v/s actual in timing plans
NPD HOD
RFQ register (status of the enquiries to be checked) /Part handover sheet from
10 marketing to NPD(For Developent) NPD HOD

11 Timing plan approved by top management

NPD HOD
12 Evidences of activities
NPD HOD
13 Procedure for FMEA with CFT approach
NPD HOD
List of problems reported in past at customer end , in-house , development
14 and supplier (Things gone Wrong) (lessons learnt from past NPD HOD
experience/kakotora sheet)
Rating of FMEA as per AIAG guidelines and having back up data for rating.
15 Allocation of severity, occurrence & detection as per AIAG manual NPD HOD

16 Cut off criteria for taking action as per latest AIAG manual
NPD HOD
Review plan for FMEA and evidence of review as per decided criteria and at
17 decided frequency NPD HOD

18 Evidence of implementation (FMEA)

NPD HOD
19 Summary in PDCA sheet
NPD HOD
20 Summary in Adequacy pf analysis
NPD HOD
21 Effectiveness of countermeasures
NPD HOD
2. Regulation for Initial Production Control NPD HOD
22 Scope (for new parts, part & process modifications and restart of part after
long duration) NPD HOD
23 Special controls (increased inspection, increased sample size etc. at all stages
- incoming, in-process & final) NPD HOD
24 Frequent process audit
NPD HOD
25 Initial production control start date (from SOP at vendor's end) and end date
(after completion of period of IPC after SOP at customer end) NPD HOD
26 Initial production control period
NPD HOD
27 Minimum quantity to be produced during IPC period
NPD HOD
28 Persons responsible for start/end
NPD HOD
29 Finish conditions (including following): - Targets of customer complaints,
rejection at customer end, in-house rejection, supplier parts rejection, process
capability, defect rate, process audit c/ms closure, effectiveness of
NPD HOD
countermeasures taken for problems reported during development and
effectiveness of countermeasures taken for problems reported during initial
production control.
30 Meeting above targets for 3 months for new products and as per timelines for
ECN/PCN/Modification and results should have improving trend NPD HOD
31 Action to be taken in case targets are not met(to be extended)
NPD HOD
32 Evidence of implementation of special controls as defined in the IPC
procedure: - Increased sample size and/or inspection frequency (special
control plan for IPC) - Process audit for verification of Standards, operation
NPD HOD
standards, facility etc. - Stricter visual inspection (100% inspection/ 200%
inspection) - Stricter gauging with GO/NG gauges (100% inspection/ 200%
inspection)
33 Sticker targets for IPC and evidence of monthly monitoring them
NPD HOD
34 Analysis of quality problems reported during IPC and their summary in PDCA
sheet NPD HOD
35 Special color tags on the packing/bin/trolley on the parts produced during
initial production control period NPD HOD
36 Termination sheet with evidence of production quantity in IPC period and
Extension of IPC period in case termination criteria is not met NPD HOD
37 Evidence of communication of start and end of IPC
NPD HOD
38 Identification of parameters for which process capability study and defect rate
(for critical defects) is to be done NPD HOD
39 Set target for Cpk (Cpk > 1.33)
NPD HOD
40 Process capability study reports
NPD HOD
41 Defect rate monitoring record (for critical non-measureable defects)
NPD HOD
42 Action plan to improve Cpk and reduce defect rate in case of not meeting
target NPD HOD
43 Definition of initial part (Upto pilot lot)
NPD HOD
44 Initial part control - separate locked area, identification tags
NPD HOD
45 Initial part control - log of initial parts
NPD HOD
46 Separate tags to identify initial parts
NPD HOD
47 Inspection report of initial parts
NPD HOD
48 Separate locked area
NPD HOD
49 Summary of initial parts prepared, sent to customer and balance quantity.
Action taken of balance quantity after customer feedback. NPD HOD
Sr. No. Check Points Responsibility
1 Condition of material in RM Store ( to be kept in covered condition away from
dust, rust, scratches) Store HOD
2 Condition of material in shop floor ( to be kept in covered condition away from
dust, rust, scratches) Store HOD
3 Designated area for RM material storage
Store HOD
4 Designated area for BOP material storage
Store HOD
5 Availability of system to ensure FIFO (software or ledger) FIFO followed for
incoming, WIP Store HOD
6 Evidence of FIFO implementation at RM/ BOP store Store HOD
7 Avaiility of identification tags on RM/ BOP parts, (route card no/ batch no /lot
no/ heat code/ production date & shift) Store HOD
8 Avaiility of identification tags on WIP parts, (route card no/ batch no /lot no/
heat code/ production date & shift) Store HOD
9 Working as per control plan in incoming inspection
Store HOD
Sr. No. Check Points Responsibility
1 Procedure for new supplier selection: Y/N MR
Acceptance criteria / dropping criteria (Individual Selection e.g. Quality, top
2 management) for new supplier selection based on system audit available: Y/N
MR
(to be checed for RM/BOP/Jobwork/Consumables) one example for above
procedure:
3 Evidence of implementation
Purchase HOD
Sr. No. Check Points Responsibility
1 Display of 4M change WI on shop floor in proper way Press Shop/Weld
Shop/Dispatch HOD's
2 Actions to be taken at change point as per WI Press Shop/Weld
Shop/Dispatch HOD's
3 Visual control of changes (4M change indication) on machine Press Shop/Weld
Shop/Dispatch HOD's
4 Awareness of change management among the shop floor personnel Press Shop/Weld
Shop/Dispatch HOD's
5 Traceability system (traceability through invoice no, lot no, route card, etc.) Press Shop/Weld
Shop/Dispatch HOD's
6 Evidences of implementation of actions: - Record of changes (4M change
record), evidence of signatures of quality and production head Press Shop/Weld
Shop/Dispatch HOD's
7 approval of quality head during 4M changes
Press Shop/Weld
Shop/Dispatch HOD's
8 Evidence of implementation Press Shop/Weld
Shop/Dispatch HOD's
9 Check record of parts produced after change Press Shop/Weld
Shop/Dispatch HOD's
10 Retroactive check record in case of unplanned (unexpected) changes (criteria
for checking dimensional check - how many parts to be checked dimensionally Press Shop/Weld
in case of retroactive check) How to handle the parts untill the dispatch. Shop/Dispatch HOD's
11 Traceability to invoice : Yes/No
Press Shop/Weld
Shop/Dispatch HOD's
12 Procedure for training available or not
Dinesh

13 Training need identification done; Y/N

Press Shop/Weld
Shop/Dispatch HOD's
14 Training plan made as per above need (TNI): Y/N
Press Shop/Weld
Shop/Dispatch HOD's
15 Training Plan vs Actual is following
Press Shop/Weld
Shop/Dispatch HOD's
16 Training content is to be checked
Press Shop/Weld
Shop/Dispatch HOD's
17 Effectiveness of training is checked; Y/N (Effectiveness for Operators/ Staff) Press Shop/Weld
Shop/Dispatch HOD's
18 New operator training given / Induction Training Record: Y/N (standard
induction training program available and followed) (above requirements must
be checked with one example for operator and staff wherever applicable) Press Shop/Weld
Shop/Dispatch HOD's

19 Training Plan for operators for awareness trainings Press Shop/Weld

Shop/Dispatch HOD's
20 For each operator, skill evaluation is done: Y/N (applicable for Production,
Tool Room and Inspection) Press Shop/Weld
Shop/Dispatch HOD's
21 For each skill level (e.g. defining a operator at Level 1,2,3,4), specific criteria is
made and followed. (implementation check) Press Shop/Weld
Shop/Dispatch HOD's
22 Minimum skill level to perform any operation : defined and followed check Press Shop/Weld
Shop/Dispatch HOD's
23 Availability of Skill Matrix in shop floor (all operators to be included) Press Shop/Weld
Shop/Dispatch HOD's
24 Skill evaluation frequency using criteria followed above (clause no 5.1.2) Press Shop/Weld
Shop/Dispatch HOD's
25 Quarterly/half yearly (skill evaluation must be done at least 2 time/year) Press Shop/Weld
Shop/Dispatch HOD's
26 For QA inspector, Poisson test done: Y/N (Frequency) Press Shop/Weld
Shop/Dispatch HOD's
27 Skill upgradation plan for Operators (in case the skill level is reduced) (plan to
be available in skill matrix) Press Shop/Weld
Shop/Dispatch HOD's
28 Definition of abnormal situations (Detail as per Annexure) Press Shop/Weld
Shop/Dispatch HOD's
29 Display of abnormal situations in shop floor Press Shop/Weld
Shop/Dispatch HOD's
30 Awareness of abnormal situations among the shop floor personnel Press Shop/Weld
Shop/Dispatch HOD's
31 Criteria to estimate suspected quantity produced during abnormal situations
and system to trace suspected lot produced based upon the criteria Press Shop/Weld
Shop/Dispatch HOD's
32 Check record of parts produced during abnormal situations Press Shop/Weld
Shop/Dispatch HOD's
33 Traceability Press Shop/Weld
Shop/Dispatch HOD's
34 Lux value is defined and maintain as per IS Standard at Incoming, WIP and
Final Inspection table and area.(minimum 500 lux for gauging, minimum 700
for visual inspection, minimum 300 for other areas) Press Shop/Weld
Shop/Dispatch HOD's

35 Noise level : Are the persons in High noise level wearing PPE's? Y/N Press Shop/Weld
Shop/Dispatch HOD's
36 Condition and height of Working / Inspection table Press Shop/Weld
Shop/Dispatch HOD's
37 Tool/Jig/Fixture storage in racks Press Shop/Weld
Shop/Dispatch HOD's
38 Daily maintenance check sheet filled by operator: Y/N Press Shop/Weld
Shop/Dispatch HOD's
39 Cross checking of above check sheet by supervisor: Y/N Press Shop/Weld
Shop/Dispatch HOD's
40 List of Pokayoke available: Y/N Press Shop/Weld
Shop/Dispatch HOD's
41 Cross checking of Pokayoke: Y/N Press Shop/Weld
Shop/Dispatch HOD's
42 Poka Yoke failure analysis (to be defined in procedure, analysis to be checked) Press Shop/Weld
Shop/Dispatch HOD's
43 press: trimming, blanking & hole punching punches
Press Shop HOD's
44 Welding electrodes dressing frequency
Weld Shop HOD's
45 Display of Work Instruction (Operation Standard) for easy assess ability to Press Shop/Weld
operator Shop/Dispatch HOD's
46 Press Shop/Weld
Display of critical process parameters and quality parameters
Shop/Dispatch HOD's
47 Understanding of WI & quality check points by operator (WI to be In local
language/ operator's langage so that operator can read and understand it) Press Shop/Weld
Shop/Dispatch HOD's
48 Operator wise operator monitoring plan for all production areas (shift wise)
(Inspectors to be covered or not?) Press Shop/Weld
Shop/Dispatch HOD's
49 Check record of operator monitoring as per check sheet covering all the
activities to be done by operator during working time Press Shop/Weld
Shop/Dispatch HOD's
50 Training plan for operators for weak areas Press Shop/Weld
Shop/Dispatch HOD's
51 Condition of packing (bin/trolley) used in WIP Press Shop/Weld
Shop/Dispatch HOD's
52 Guidelines for repairing of bins/trolley Press Shop/Weld
Shop/Dispatch HOD's
53 safety standards available? Press Shop/Weld
Shop/Dispatch HOD's
54 Awareness of safety to operators Press Shop/Weld
Shop/Dispatch HOD's
55 PPEs as per standard Press Shop/Weld
Shop/Dispatch HOD's
Sr. No. Check Points Responsibility
1 General condition of machines are proper like wiring condition, cover and dust. Jitender/Bipul
2 Oil/water/coolant leakage around the machine Jitender
3 Procedure for preventive and breakdown maintenance of machines and tools. Jitender/Bipul
4 PM of machine : frequency, plan, plan vs actual, history card, check sheet filled
or not, breakdown analysis, break down points covered in PM check Jitender/Bipul
sheet or not, Spares (list and availability)
5 PM of Tool: frequency, plan, plan vs actual, history card, check sheet filled or
not, breakdown analysis, break down points covered in PM check sheet or not, Jitender/Bipul
Spares (list and availability)
6 List of Pokayoke available: Y/N
Jitender/Bipul
7 Cross checking of Pokayoke: Y/N
Jitender/Bipul
8 Poka Yoke failure analysis (to be defined in procedure, analysis to be checked)
Jitender/Bipul
9 Door sensors on machines
Jitender
10 Double hand operation
Jitender
11 Insulating jacket on barrel, Jam bar/drop bar (in plastic molding General -
Machine guards, Photo guard sensors, emergency switch :
Jitender

12 Safety in material movement : Lifters, hydraulic forklifts, stackers, corner

guards, - Not Available.
Jitender
Sr. No. Check Points Responsibility
Internal audit, process audit and product audit procedure defining audit
1 method, audit frequency & check sheet to be used for audit, internal auditor
Dinesh/Abhinav
criteria, NC Closure time limit (internal audit to be done by internal auditors
only)
2 Plan for internal audit, product and process audit covering all manufacturing
processes and all working shifts. Dinesh/Abhinav

3 Evidence of conducting audits as per plan (check sheet records) (in all shifts) Dinesh/Abhinav
4 Evidence of improvement in case of issues identified (NC's reported) Dinesh/Abhinav
5 NC summary report (for internal audits) Dinesh/Abhinav
6 Evidence of conducting audit as per control plan during process audit. Abhnav
Evidence of checking actual working as per operation standard during process
7 audit Abhnav
8 Evidence of coducting audit ( genuineness of record) Abhnav
Evidence of checking effectiveness of countermeasures of customer and
9 horizontal deployment Abhnav
10 Evidence of checking effectiveness of countermeasures of in-house defects
during process audit & horizontal deployment Abhnav
11 Last audit NC closure Abhnav
12 Procedure for handling customer complaints, in-process failure and supplier
defects
Abhnav

Criteria for raising QPCR's (internal QPCR's to be raised in case of daily

13 abnormal rejection and monthly top rejections) Abhnav
14 Customer complaint register, QPCR control registers (for in-house and
supplier defects) Abhnav
Analysis sheet for analyzing customer complaints, in-house defects and
15 supplier defects Abhnav
16 Monthly in-house rejection analysis (defect wise pareto and analysis)
Abhnav
17 Quality of analysis (root cause analysis)
Abhnav
18 Non conforming parts produced due to defects (Reported at customer end,
inhouse defects or supplier defects) checked or not.
Abhnav

19 Countermeasures detail for root cause/causes

Abhnav
20 Standardisation (Control Plan, WI/OS Inspection standard, check sheets, list
of abnormal situations etc.)
Abhnav

21 Updation of PFMEA
Abhnav
22 Evidence of onsite verification of countermeasures (to checked for min three
months) Abhnav

23 Horizontal deployment of countermeasures

Abhnav
24 Effectiveness of countermeasure (to checked for min three months)
Abhnav
25 Storage of inspection Equipments when not in use: in boxes or in open
Abhnav
26 Damages of instruments
Abhnav
27 Condition of GO/ NG gauges
Abhnav
28 Calibration plan
Abhnav
29 Plan vs actual
Abhnav
30 History card of measuring instruments
Abhnav
31 Delayed calibration
Abhnav
32 In case of in-house: procedure, soaking: Y/N, frequency, master calibration
Abhnav

33 Acceptance certificate/acceptance criteria (Reference detail)

Abhnav
34 Validation of rec gauge/welding fixture .
Abhnav
35 NABL logo to be checked on certificate
Abhnav
36 Lab to be NABL Approved for instruments to be checked
Abhnav
37 Expiry date of limit sample
Abhnav
38 Visual display of OK and NG process/part at WIP/FG stage
Abhnav
39 Limit sample availability (should be available in front of operator)
Abhnav
40 Availability of alarm at critical operations for confirmation of completion of
work Abhnav
Availability of Visualizers at critical operations for confirmation of completion
41 of work Abhnav
42 Condition of visualizers and alarms
Abhnav
Judgement criteria and checking method should be mentioned on check record
43 sheet of product and process checks (e.g..- Upper/ Lower tolerance)
Abhnav

44 Space for giving judgment and proper judgment after check

Abhnav
Evidence of check at each inspection stage (set up and in-process inspection)
45 Abhnav
46 Do you have Special checks/Inspection for Maru A parameters of Maru A part
are available.
Abhnav

47 Do you have Identification of Maru A Process/Operator on Shop Floor.

Abhnav
48 Do you keep the repair history when repairing & using Maru A items
Abhnav
49 Availability of Test standards
Abhnav
50 Availability of Test equipments as per drg/control plan/inspection standards in
shop floor
Abhnav

Availability of Test equipments as per drg/control plan/inspection standards in

51 Test Lab
Abhnav

52 Other observations during process audit

Abhnav
53 Closure of observations of previous audit
Abhnav
 Responsibility
Availability of documents (control plans, operation standard, inspection
1 standards) for all parts under supply Abhinav
Procedure for preparation and control of documents defining following: -
department in charge of making, person in charge of making, a person in
charge of authorizing - revision rule & revision history (internal & customer) -
2 Document Control Numbering - retention period; - Distribuion matrix - Chandan/Abhinav
Obselete documents handling

3
Master copies of the controlled documents Chandan/Abhinav
Master list of documents (control plans, operation standard, inspection
4 standards) with latest revision nos Chandan/Abhinav
5
All Product and process parameters are mentioned in the control plan Chandan
Reference of WI, sample size, checking frequency, checking method, boundary
6 samples & Poka Yoke are defined in the control plan Chandan

7 Consistency among documents (process control standards/control plans,

operation standards, inspection standards and customer inspection standards) Chandan
Sr. No. Check Points Responsibility
1 Condition of material in FG store ( to be kept in covered condition away from
dust, rust, scratches) Rajender
2 Designated area for FG material storage
Rajender
3 Lux value is defined and maintain as per IS Standard at Incoming, WIP and
Final Inspection table and area.(minimum 500 lux for gauging, minimum 700 Rajender
for visual inspection, minimum 300 for other areas)
4 Condition and height of Working / Inspection table Rajender
5 List of Pokayoke available: Y/N
Rajender
6 Cross checking of Pokayoke: Y/N
Rajender
7 Poka Yoke failure analysis (to be defined in procedure, analysis to be checked)
Rajender
8 Availability of system to ensure FIFO (software or ledger) FIFO followed for
FG material Rajender
9 Evidence of FIFO implementation at shop and FG store Rajender
10 Availability of identification tags on FG parts, (route card no/ batch no /lot no/
heat code/ production date & shift) Rajender
11 WI for similar part management Rajender
12 Similar part management (WI) in WIP area (different color of I tags/ Bins/
packings) Rajender
13 Similar part management (WI) in FG area (different color of I tags/ Bins/
packings) Rajender
14 NG part identification should be defined and evident. Each NG part and part on
hold should be identified properly by tag with defect details. Rajender
15 Color of bin for keeping NG parts to be identified and bin should be accessible
& near to station. Rajender
16 Decision for scrap, rework or salvage of part should be done by QA.
Rajender
17 Approved packing norms with customer
Rajender
18 Display of packing standards at packing station
Rajender
19 Evidence of implementation
Rajender
20 Condition of packing (bin/trolley) used in FG material
Rajender
21 Bin cleaning area available
Rajender
22 Do you have Special checks/Inspection for Maru A parameters of Maru A part
are available. Rajender
23 Do you have Identification of Maru A Process/Operator on Shop Floor. Rajender
24 Do you keep the repair history when repairing & using Maru A items Rajender
25 Availability of inspection instruments as per drg/control plan/inspection
standards at incoming inspection Rajender
26 Availability of inspection instruments as per drg/control plan/inspection
standards in standard room Rajender
27 Availability of inspection instruments as per drg/control plan/inspection
standards in in-process inspection Rajender
28 Availability of Test standards Rajender
29 Availability of Test equipments as per drg/control plan/inspection standards in
shop floor Rajender
30 Availability of Test equipments as per drg/control plan/inspection standards in
Test Lab Rajender
31 Availability of trained manpower to operate the inspection instruments and
test Rajender
equipments in incoming inspection
32 Availability of trained manpower to operate the inspection instruments and
test Rajender
equipments in shop floor
33 Availability of trained manpower to operate the inspection instruments and
test Rajender
equipments in Lab
34 Bin trolley stacking height defined or not :
Rajender
35 Safety in tool room :
Rajender
Sr. No. Check Points Responsibility
1 Procedure for training available or not
Dinesh
2 Training need identification done; Y/N
Neelam
3 Training plan made as per above need (TNI): Y/N Collection Resp.
Neelam
4 Training Plan vs Actual is following
Neelam
5 Training content is to be checked
Neelam
6 Effectiveness of training is checked; Y/N (Effectiveness for Staff)
Neelam
7 Monitoring of noise level in case of product quality is affected (during
production or inspection) Raghunandan
1 Adequate organization structure : available with all requirement
Raghunandan
2 Roles and responsibilities
Raghunandan
3 All positions filled (no position vacant)
Raghunandan
1 Noise level in shop floor
Raghunandan
2 Air quality in shop floor
Raghunandan
3 Rest area available at shop floor.
Raghunandan
4 Condition of toilet
Raghunandan
5 Adequate space for movement of material and tools
Raghunandan
6 Layout and escape routes availability
Raghunandan
1 Usage of PPEs by operators:
Raghunandan
2 Accident reporting mechanism :
Raghunandan
3 Countermeasures against accidents:
Raghunandan
4 Periodic verification of countermeasures:
Raghunandan
1 Fire safety audit report by reputed 3rd part agency :
Raghunandan
1 Consent to operate (CTO) certificate :
Raghunandan
1 Enrolment of all operators for ESI :
Raghunandan
2 Enrolment of all employees to PF :
Raghunandan
3 Check Management review status for direct enrolment or for 3rd part
enrolment : Raghunandan
1 Waste segregation system :
Raghunandan
2 Awareness among operators :
Raghunandan
3 Segregation facility on shop floor.
Raghunandan
4 Check disposal system and implementation for last 1 year .
Raghunandan
Sr. No. Check Points Responsibility
1 Top management visit frequency at shop floor Anil Thomas
2 Monitoring of KPI by Management Dinesh
3 Evidence of review (Minutes of Meeting for MRM) Dinesh