Hm Auto Bench Mark Gap Analysis Report 19.09.08

1. DATE OF AUDIT : 19 SEP 2008

2. AUDITOR :

HMI: SARAVANAKUMAR

3. IMPROVEMENT PLAN SUBMISSION DATE :

4. SIGNATURE

BENCH MARK GAP ANALYSIS - HM AUTO INDUSTRIES (SL Lumax)

BENCH MARK GAP ANALYSIS - HM AUTO INDUSTRIES (SL Lumax)

HM AUTO SL LUMAX HMI

SL

NOCategory

Plan

Completed Remaining

Monthly Completion

Trend

Initial Added Total 09/08 10/08 11/08 12/08

1 Material

2 Machine

3 Method

4 Man

5 3C / 5S

Total

IMPROVEMENT STATUS

BENCHMARK COMPANY H. M Auto Industries

Functional Layout, no back and forth movement

Subsequent operations not linked

0101 FUNCTIONAL LAYOUTArea SHOP FLOOR

Resp Vijayakumar / Magesh

Target Date 15/11/08


Painted shop floor with effective 3C/5S activities

3C/5S (Press shop standards

not available)

0202 SHOP FLOOR PAINTINGArea SHOP FLOOR

Resp Vijayakumar/ Magesh/ Saleem



Incoming Inspection area with trends display

Area not identified for Incoming Inspection

0303 SUPPLIER CONTROLArea INCOMING INSP.

Resp Magesh/ Saleem


BENCHMARK COMPANY H.M AUTO INDUSTRIES

Incoming inspection flow chart displayedIncoming inspection flow chart

not available

0404 RECEIVING INSPECTIONArea INCOMING INSP.

Resp MAGESH

Target Date 20.10.08


Incoming Inspection as per Inspection Std

AOI not available with the sub supplier, Regular inspection not carried out

0505INCOMING INSPECTION

– CHILD PARTS

Area INCOMING INSP.

Resp MAGESH



Raw material, child part master sample with validity

Master samples not available for

sub supplier parts

0606 MASTER SAMPLEArea INCOMING INSP.

Resp SALEEM / MAGESH

Target Date 1.11.08

MASTER SAMPLES


Packing standardized for incoming partsPacking not standardized for raw

material / sub supplier parts


Resp MAGESH



Supplier rejections analyzed and

counter measures verifiedSupplier rejection reporting system and

proper procedure not available

0808 SUPPLIER REJ. ANALYSISArea INCOMING INSP.

Resp Magesh / Vijayakumar



Storage area with FIFO racks for child parts

Storage area identified, FIFO not in practice

0909 CHILD PART STORAGEArea R/M STORES

Resp Vijayakumar / Magesh/ Saleem



R/m stock status with FIFO system FIFO Board displayed with alerts

1010INCOMING MATERIAL

STOCK WITH FIFO

Area R/M STORES

Resp Vijayakumar



Coils stored properly with identification Keeping coils on to the floor

1111 R/M STORAGEArea R/M STORES

Resp Vijayakumar



Chowel photo

Storage racks available for steel strips, location identified, stock monitored

Raw Material storage and FIFO system not in proper


Resp Vijayakumar



Material identification well definedIdentification tag available for some raw materials, basic information not covered in tags





Wooden support to eliminate damage Chances of scratch is more

1515 COIL STORAGEArea R/M STORES

Resp Vijayakumar



Fork lift operator can move around easily

1717 MIRROR FOR SAFETYArea R/M GANG WAY

Resp Saleem



Welding line organized with functional layout & visual controls

Welding line not organized properly

1818 WELDING LINE SET UPArea WELDING LINE

Resp Vijayakumar / Magesh/ Saleem



Enough lighting, proper ventilation to avoid operator fatigue

Additional lighting & ventilation, proper ventilation to avoid operator

fatigue

1919 SAFETY MEASURESArea WELDING LINE

Resp Vijayakumar / Saleem



My Machine Concept will be introduced

2020 MY MACHINE CONCEPTArea Incoming Storage

Resp Vijayakumar



Detailed machine preventive maintenance check sheet

Preventive maintenance check sheet not available

2121 MACHINE MAINTENANCEArea M/C TABLE

Resp Vijayakumar/ MAGESH



Machine check points highlighted on the machine

2222 CHECK POINTS ON M/CArea MACHINE


Target Date 5.11.08


Critical spares list prepared and maintained

2323 M/C CRITICAL SPARESArea MACHINE

Resp Vijayakumar



2424PROCESS PARAMETER MONITORING

Area Machine

Resp Magesh




Area Machine

Resp Magesh



Work instruction and process parameters not displayed


Area Machine

Resp Magesh



Recommend to replace a single tank to parallel connection


Area Incoming Storage

Resp Saleem



Electrode coil not protected from atmosphere


Area Machine

Resp Vijayakumar



Unit description different

litre / min flow rate



Resp Magesh

Target Date 7.10.08


3030MACHINE STATUS – VISUAL DISPLAY

Area Machine

Resp Vijayakumar


MACHINE STATUS DISPLAY


Welder certificate not available

3131 WELDER CERTIFICATIONArea Welding




Welding parameter specification not available, refer to STD

3232 WELDER CERTIFICATIONArea Welding

Resp Magesh



3333 GRAVITY CHUTEArea Welding




Recommended to install a gravity chute

3434 PRODUCTION LINE UPArea Welding



CHUTE


All types of safety wearing provided Poor man safety

3535 PERSONAL SAFETYArea Welding

Resp Saleem / Vijayakumar



3636 HANDLING OF WIP PARTArea Welding

Resp Vijayakumar



Rubber sleeve provided at goose neck area

3737 WELDING – JOB REPORTArea Welding

Resp Vijayakumar


RUBBER SLEEVE


3838 NOZZLE CLEANINGArea Welding

Resp Vijayakumar



Periodic jig maintenance, Inspection

(Plan Vs Actual)

3939 JIG MAINTENANCEArea MACHINE




4040 WIRE FEEDER GUIDEArea Welding

Resp Vijayakumar



Poorly routed cable

4141 EARTH CABLE ROUTINGArea Welding

Resp Vijayakumar


POOR EARTHING


4242PROCESS MONITORING –

GAS FLOW METER

Area Welding

Resp Magesh


GAS FLOW METER



Resp Magesh


PARTITION


4444CHIP REMOVAL

PROCEDURE

Area Welding

Resp MAGESH



Master samples and defective samples not displayed

4545MASTER, DEFECTIVE, F/M/L SAMPLES DISPLAY


Resp Magesh/ Saleem




Resp Magesh


JOB REPORT


4747REJECTION TREND DISPLAY – CELL WISE

Area Quality

Resp Magesh



1818 NC PART CONTROLArea Quality

Resp Magesh



Poor 3C & 5S of rejected part bin

4949 REJECTION STORAGEArea Rejection

Resp Maesh



5050 NC PART HANDLINGArea Incoming Storage




5151 Q ALERT DISPLAY ON M/C Area Incoming Storage

Resp Magesh


Q ALERTDISPLAY


5252INSPECTION TABLE FOR ALL MACHINES


Resp Magesh / Saleem



Clamping screw length oversize

5353INSPECTION TABLE FOR ALL MACHINES


Resp Vijauakumar

Target Date 30.9.08


Break down status monitored

5454 BREAK DOWN STATUSArea PRODUCTION




Idle time monitored for all machines

5555MACHINE IDLE TIME

MONITORING

Area PRODUCTION




Direction of flow marking with colour coding

5656FLOW MEDIUM / DIRECTION MARKING

Area WATER LINE

Resp Vijayakumar / SALEEM



Material over stacking (WIP)

5757 IN-PROCESS STORAGEArea WIP

Resp Vijayakumar



Material over stacking (WIP)

5858 IN-PROCESS STORAGEArea WIP

Resp Vijayakumar



Big sized wooden bins used for

in-process

5959 WIP STORAGE & HANDLINGArea WIP

Resp Vijayakumar



Over stacking, more chances of component damage

6060 WIP STORAGE & HANDLINGArea WIP

Resp Vijayakumar



Rust on the component (awaiting for inspection)

6161DUST COVER FOR PLATED PARTS

Area WIP

Resp Vijayakumar


Transparent LDPE Lid to avoid Dust


TROLLIES WITH CASTERS FOR EASY HANDLING - WIP

6262TROLLIES FOR EASY

HANDLING

Area SHOP FLOOR




Fork lift for material handling to avoid fatigue

6363FORK LIFT FOR LOADING /

UNLOADING

Area SHOP FLOOR




RED LINE PROVIDED IN TROLLIES FOR MAX. STACK HEIGHT

6464STACKING LEVEL IN

TROLLIES

Area SHOP FLOOR

Resp Vijayakumar



Traceability not available from raw material incoming stage to F/G dispatch

6565 LOT TRACEABILITYArea Incoming Storage

Resp Magesh



6666 ASSY SHOP SET UPArea Incoming Storage

Resp Saleem / Vijayakumar / Magesh



6767 FINAL INSP. STANDARDArea Incoming Storage

Resp Magesh


FINAL INSP STD


Inspection area needs more light

7070 FINAL INSP. AREA LIGHTINGArea Incoming Storage

Resp Saleem / Vijayakumar



Master samples to be prepared with master list / due date /

location

6868 MASTER SAMPLESArea Incoming Storage


Target Date 1.11.08

MASTER SAMPLES


FINISHED GOODS STOCK STATUS WITH VISUAL CONTROLS

6969 F/G STOCK STATUSArea F/G STORAGE




Inspection area needs more light





Rack of Weld bead width

7272 FINAL INSP. AREA LIGHTINGArea Welding

Resp Vijayakumar



NG parts out going without any proper check


Resp Magesh



7474 REJECTION TREND DISPLAYArea Incoming Storage

Resp Magesh



7575INSPECTION TABLE FOR DESTRUCTIVE TEST

Area Welding




7676 SAMPLES RETAININGArea Incoming Storage

Resp Magesh



7777 TRANING ROOMArea Incoming Storage




7878 CALIBRATION STICKERArea Incoming Storage

Resp Magesh



7979 CHECKER, JIG STORAGEArea Incoming Storage




Testing facilities not sufficient (Hardness testing, welding penetration

testing & roughness testing not available)

8080 INSPECTION & TESTINGArea Incoming Storage




8181 TOOL STORAGEArea Incoming Storage




Tooling rack to be modified to minimize the area of contact bet. the tool and the rack


Resp

Target Date 7.10.08


There is no place / identification for tools





Finished goods storage area not organized

8484 FINISHED GOODS STORAGEArea Incoming Storage




No QC identification tag on the pallet

8585 FINISHED GOODS STORAGEArea Incoming Storage

Resp Magesh



Improper bin leads more people to handle, Needs to improve size and type of bins


Resp MAGESH



Sensors provided between ram & bed

to avoid accidentSensors Provided

8787 SAFETY MEASURESArea WATER LINE




First, middle, last samples - top

Master, defective samples –second

Checker – bottom

8888 SAMPLES DISPLAYArea INSP. TABLE




Tool daily preventive maintenance

check sheet

8989 TOOL CHECK SHEETArea M/C TABLE




OPERATORS PROPERLY TRAINED AND CERTIFIED

9090 WELDER CERTIFICATIONArea MACHINE




Cover provided for welding coil to isolate it from surrounding

9191COVER FOR WELDING COIL

(MIG WELDING)

Area MACHINE




Tool maintenance schedule displayed & followed

9292TOOL MAINTENANCE

SCHEDULE

Area MOULD STORAGE




Tool layout display for traceability

9393 TOOL LAYOUTArea MOULD STORAGE




Tool name plate provided on all tools

9494 TOOL IDENTIFICATIONArea MOULD STORAGE




9595TOOLING TABLE WITH

RUBBER MAT

Area MOULD STORAGE

Resp SALEEM / Vijayakumar



9696TOOL PAINTING – MODEL

WISE COLOUR

Area MOULD STORAGE

Resp SALEEM / Vijayakumar



Critical spares list prepared and maintained

9797 TOOLING CRITICAL SPARESArea MACHINE

Resp Vijayakumar



Detailed mould history card

9898 TOOL HISTORY CARDArea MOULD STORAGE

Resp MAGESH



All components revalidated periodically to monitor the process / tooling consistency

9999COMPONENT

REVALIDATION

Area SHOP FLOOR

Resp MAGESH



CHOWEL PHOTO

Weld penetration tested samples displayed

100100 FMEA SAMPLES DISPLAYArea SHOP FLOOR

Resp MAGESH



Inspection plan based on quality issues

101101SAMPLING INSPECTION PLAN

Area FINAL INSP.

Resp MAGESH



Inspection standard prepared with all quality check points

102102FINAL INSPECTION

STANDARD

Area FINAL INSP.

Resp MAGESH



Control plan & work instruction in line with AOI

103103 INSPECTION AGREEMENTArea SHOP FLOOR

Resp MAGESH



Quality check points for all parts

104104 PDI STANDARDArea PDI

Resp MAGESH



Customer approved packing standard displayed in PDI area

Packing standards not available

105105 PACKING STANDARD AT PDIArea PDI

Resp MAGESH



Trend charts displayed in shop floor

106106 PERFORMANCE DISPLAYSArea SHOP FLOOR

Resp MAGESH



Customer complaint free days monitored

107107CUSTOMER COMPLAINT

MONITORING

Area SHOP FLOOR

Resp MAGESH



Finished parts stored & identified properly

Proper location (layout) not yet identified for F/G storage

108108FINISHED PART FIFO/

IDENTIFICATION

Area F/G STORAGE




NC parts located on the customer complaint review area

Customer complaints not reviewed properly through daily meeting

109109CUSTOMER COMPLAINT

REVIEW

Area SHOP FLOOR


Target Date 30.9.08


Plant safety status displayed Safety visual control not displayed

Area SHOP FLOOR

Resp Vijayakumar/ Saleem

Target Date 20.11.08110110

PLANT SAFETY STATUS DISPLAY

Hm Auto Bench Mark Gap Analysis Report 19.09.08

Business

Transcript of Hm Auto Bench Mark Gap Analysis Report 19.09.08