Department Check points

Environmental Records should be available in plant (Discharges, Emissions, etc)

Safety Records in plant (Accidents, Incidents, Productive man hours lost etc) should be available
The sound levels should be checked in the plant and ear plugs should be provided in high sound zones
There should be an emergency evacuation plan - Deployment and its awareness among workers
Deployment of fire hydrant system and its operational training to employees
Use of PPE (hand gloves, helmets, safety goggles, safety shoes)
Deployement of safety measures (precautionary measures walk ways, grid around electrical panel, hand rails, safety instructions etc)
Safety training to workers
HSE Colour coding for safety & Order
The Hazardous and Non Hazardous wastes should be properly marked and stored in respective locations
All Eye-washers should be Functional
The First Aid boxes should identified and easily accessible
The best Safety practices (Daily Tool Box Talk,Contractor Safety Management,LOTO,HIRA,Work Permit)should be followed in the Plant
Accident frequency rates (%) should be measured
Fire Extinguisher Inspection Date display
The Cranes, Tanks, Tools & Tackles must be inspected and recorded
Emergency Contact Nos.should be displayed across the plant

There should be a forum for communication for Employee suggestion scheme etc
Workers should be Involved in kaizen and other improvement projects
Workers should be active members of formal work teams, quality teams or problem solving teams
Manpower requirement should be scientifically studied and deployed accordingly
Employee Satisfaction Surveys should be conducted
The annual personnel turnover (%) should be captured
There should be a defined training calender and employees should be trained accordingly
There should be a policy to conduct the exit interviews and monitor the reasons for leaving the organisation
HR The basic SPC trainings should be provided to manufacturing employees
There should be a policy deployment tool for (Balance score card - Key deliverables, KRA)
There should be a multi skilling program in place (Operations and Maintenance)
Skill Matrix should be developed and competency to be done
Training Man-days per employee per year Data
Employee Attrition Rate (%) Data
Visibility of Company Goal & Individual Goal to all employees
Procedure to record Headcount & No. of Vehicles in the plant premises
SWOT analysis for the organization

The supplier delievery compliance should be tracked and OTIF(on time in fulls ) to be maintained
The supplier certification process to be adopted
Supplier performance should be measured and reported back to them
Purchase A portion of raw material & purchased parts should come from qualified suppliers with no need for incoming inspection (%)
Suggestions from suppliers for alternate designs, processes, etc.. for cost reduction / process improvements.
A proceedure should be in place to improve the supplier performance(delivery & quality)
Supplier Delivery Reliability (%)

Inventory turnover should be mapped for (FG,WIP & RM) and people should be made aware about it
Dead stock should be tracked and disposed regularly
A system should bethere to track materials with limited shelf life
Mechanism should be there in place to count and verify Inventory in the stores (specified lot sizes) easily
Reconciliation of Physical and system Stock
FIFO should befollwed for all relevant (shelf life) materials
The materials under should be storage free of dirt/dust, leakage or contaminants
The Raw Materials and Packing Materials storage norms should be defined and adhered in Stores and Warehouse
Place for everything and everything in its place
Store
Non-moving Inventory Data
Define Material Issue Process & Material Incoming Process(SOP)
There should be a system to inspect the in coming material
Identification of OK/Not OK Materials
Procedure to rejected material (return to vendor/debit)
There should be SOP's for Handling/Disposal of scrap generated
All materials should be clearly identified
The vertical space should be effectively utilised in all storage areas
Space utilisation and goals for space use reduction
 Department Check points
Measuring instruments being used should be appropriate and calibrated
First time right in percentage should be implemented
Finished Goods be tracked into its components/batch
Scrap & rework should be measured at each process & for each product and reduction mechanism should be there
Structured problem solving process (5 Why/RCA, etc) should be in place
Cost of Quality must be understood & documented .Aproper analysis should carried out for reduction
There a should be a defined sampling plan and its compliance should be ensured
The incoming components should conform to drawings / specifications
Inspection status should be displayed on all In-process and Finished Goods
Quality and Possession of Quality certifications and ratings
despatch The inspection time should be monitored & efforts to reduce it
Procedure to dispose chemicals used in tests
Action taken on Customer Complaints
Monitoring of delivery time & Analysis of delays in delivery
Identification of Goods corresponding to customers
Weigh Bridge Claibration Status
A defined procedure should be followed during development of a lab process into a successful commercial manufacturing process
There should energy management system in place for optimal consumption of power
There should be no of kaizens,Visual management,SOP's ,RCA done
A system should be in place to analyse review the Area owners observations and and their completion status

Material Handling from receiving to shipment should be continually reviewed to eliminate non-value added activities
The Operators should be involved in carrying out Autonomous Maintenance
A changeover time reduction program should be established and time reduction to be noted
The percentage of downtime due to changeover should be noted
Ensure that production does not stops due to non availability of material
There should visibility of labeling & coding of product lines, inventory
The Process Flow Diagrams should be displayed prominently
Yield should be calculated in percentage and compared the benchmark across the processes
Resource Recovery and Recycling should be done
Production scheduling balances product mix and volume to optimize performance of all manufacturing cells
Product Line versus Shop floor Layout
Operations The OEE of the bottleneck equipment should be calculated
Process control and capability studies should be conducted
Batch/ Product changeover time should be noted for improvement
A program for Material Reconciliation through conversion should be established
Technology and processes should be bench marked across similar industry
Breakthrough products in company
Display of Production Plan v/s Actual
Awareness of Production Target to all concerned manpower
There should energy management system in place for optimal consumption of power
There should be no of kaizens,Visual management,SOP's ,RCA done
A system should be in place to analyse review the Area owners observations and and their completion status

Truck turnaround time (TAT)

Heavy Vehicles
Evaluation of logistics efficiency
IT Effective usage of Information Technology in the plant
Finance Percentage of revenue generated from new products needs to be calculated
Finance The overall inventory turnover, including FG, WIP and RM should be calculated
Employee knowledge & support of customers & business and willingness to talk about it.

All visitors, casual workers, drivers and cleaners seen wearing appropriate badges
Security system, facilities (phone, emergency nos, first aid, fire fighting system)personal attitude and behavior should be ensured
Visitor / Contract personnel gate pass, visitor tag, maintenance of visitor details should be ensured
SOP's for Entrance Procedure at gate for vehicles & people should prepared and implemented
Procedure to record Headcount & No. of Vehicles in the plant should be in place
Security
PUC, Driving Licenses & Other relevant papers of Vehicles inside the factory should be ensured
Deployment of Security Manpower in right places should be ensured
The un-authorised access to plant through boundary wall should be secured
There should be no of kaizens,Visual management,SOP's ,RCA done
A system should be in place to analyse review the Area owners observations and and their completion status