RML Product Development Manual- 031108
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Transcript of RML Product Development Manual- 031108
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8/22/2019 RML Product Development Manual- 031108
1/21
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
1.0
1.1
1.2
1.3
1.4
1.5
1.6
SELECTION OF PROJECT
Products development RML are classified into 3 classes of design as listed below:
- Advanced Engineering Design Engg. Project Note (AED - EPN)
- Advanced Engineering Design - Technical Sales Note (AED TSN)
- Standard Prototype - Technical Sales Note
On receipt of Technical Sales Note from Marketing the design classification based on the guidelinesE,R&D WI 01, is done as AED-TSN or Standard Prototype and it is taken up for design and development inthe respective product group.
AED-EPN design and development is identified through the Policy Deployment of Head of ENGG
Products classified as AED-EPN and AED-TSN are designed & developed through 7 Stage Design Review
process
Design and Development of Standard Prototype is done through Standard Prototype development flow
chart
Based on the Technical Sales Note issued by marketing or discussion had with OE customer the development
activities for new product is started.
NPD Flow
Chart
Std.
Prototype
Flow
Chart
Technical
Sales Note /
MOM withCustomer
Marketing
Page No: 1 / 20 Revision No: 3 Date : NOV 07 Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED document.
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTD
Chennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
1.7
1.8
2.0
2.1
2.2
The new product development process consists of 5 phases:
- Product Concept Specification Development Phase
- Detail Design Phase
- Prototype Development & Testing Phase
- Initial Production Phase
-Mass Production Phase
Each phase consist of inter-linked activities as given in the NPD Flow chart. The NPD flow chart shows the
flow of various activities, Design & Development Review at various stages and interfaces of departments
PRODUCT CONCEPT SPECIFICATION DEVELOPMENT PHASE:
Marketing forwards the Technical Sales Note / specification / drawing received from customer to ENGG. to
decide the feasibility of Product design and manufacturing.
Risk Assessment is performed during contract stage for the product / project considering the following
factors:
- Risk in completion of project as per customer agreed timing plan
- Risk in meeting the Product Quality Requirements
- Risk in investment to be made on this project
- Return on investment and
- Risk in meeting the volume requirement of the customer
Alternate plan / Contingency Plan will be made in case of high risk, to meet the eventuality.
Risk
Assessment
Engineer / Head
of MKTG
-Do-
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
2.3
2.3.1
2.3.2
2.4
2.5
2.5.1
2.5.2
2.6
2.6.1
Design Input Adequacy checklist is used to ensure adequate input data is collected and available for product
design and development. If required, customer will be interacted to understand / obtain necessary information
and to resolve any ambiguous and conflict requirement of customer. For standard prototype Design Input /
Output checklist is used to ensure the adequacy.
Engineering Project Note constitute the design input in the case of AED-EPN type projects.
The Design Input Adequacy Checklist is reviewed by Head of ENGG.
Cross Function Team is formed that comprises persons from Engineering, Marketing, Quality,
Materials, Production and MED.
Project timing plan is prepared by project team members and reviewed by Head of ENGG. Timing Plan is
consistent with customer program dates.
The timing plan is used by the team to monitor the progress of implementation of various activities and theplan is updated by entering the start and completion dates of activities.
In case of any delay in activities, the details are informed to Head of ENGG and the timing plan is revised
if required. If the change in the timing plan affects the customer program date, the same is intimated tocustomer through Marketing.
Product Design Inputs:
During the Development phase the following inputs as appropriate are obtained from customers and internal
functions:
Design
Input
Adequacy
Check List
Project Note
CFT Team
Project
Timing Plan
ENGG
ENGG
Head of ENGG
Head of ENGG.
CFT / Head of
ENGG
Head of ENGG /
Marketing
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
2.6.2
2.6.3
2.6.4
- Customer Requirements: These are the technical details / drawings obtained from customer or
marketing during initial stage. In addition customer requirements are identified through review had
with customer.
- Information from Internal Functions: These are data on learning of previous design projects,
information from supplier, Line Complaints and Field Failures.
-Learning of previous design projects are captured through the Things Gone Right (TGR) and ThingsGone Wrong (TGW) records.
-The information from suppliers are captured during the review meeting with suppliers at the time of
development of component and the suppliers feedback on previous projects are obtained through
TGR and TGW Records.
-Line Complaints and Field Failures: Data on customer Line complaints, Field failures and corrective
preventive actions initiated for those are collected from QA department
- Targets for Product Quality, Reliability, Durability, Maintainability and Cost:
- The target for product quality is expressed as Attractive Quality in QFD matrix.
The target for Reliability is expressed as ratio of probability of failure at 90% and 10% running timeat 3 times of the specified test cycle. The ratio shall not exceed 1:4. Alternatively Reliability target is
taken as 100% of all 5 samples has to meet the test cycle with out any failure.
GM
Guidelines
TGR / TGWReports
QFD
Product
Concept
Report
ENGG / MKT
ENGG
ENGG
ENGG/QA/ME
D
ENGG
ENGG
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP 02
Ref.
No.ACTIVITY Document Record Responsibility
2.6.5
2.7
2.7.1
- The target for Life and Durability is expressed in terms of no. of test cycles the product will
withstand.
- The maintainability is expressed as time taken to replace the inner parts (Mean Time To Repair
MTTR) in case of any field failures and it is expressed in matrix chart. This is applicable for SGPproduct only since the SSLP products are non-serviceable in nature.
- The target cost is expressed as target material cost and it is arrived based on the individual cost of the
components the product comprises.
Bench Marking and Quality Function Deployment (QFD):
Quality Function Deployment is used to convert the technical inputs into Attractive Quality.
Wherever competitor products are available, they are evaluated for performance and features. These data are
bench marked in QFD to derive attractive quality.
After arriving the specifications and targets, the feasibility of design and manufacturing is studied
If any bottleneck in engineering / technology arise the same is reviewed with Head of ENGG for
infrastructure planning.
Product Concept:
The product concept report is finalized incorporating all the technical details and is reviewed by Head
of ENGG.
Target Cost
Report
QFD Matrix
ProductConcept
ENGG
ENGG
ENGG / MMD
ENGG / MKT/CFT
ENGG
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Page No: 5 / 20Revision No: 3 Date : NOV 07 Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED document.
Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
2.8.1
2.8.2
3.0
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
After finalization of product concept, CFT with Head of ENGG reviews the Development Phase-I using
the checklist of Design Review-I.
The action points arising out of the review meeting is recorded in the Minutes of review and follow-up
activities are reviewed during the next review meeting .
DETAIL DESIGN PHASE:
Detail design phase includes the product design outputs and manufacturing process design inputs.
Based on the Product Concept report, product concept drawing is prepared.
Preliminary Parts lists and Bill of materials, list of standard and non-standard parts are prepared and reviewed.This is used to estimate the material cost.
Design for manufacturability and assembly is evaluated. This is carried out by analysis on Standard parts,
Standard Manufacturing Process. The Design Efficiency and Material Cost are analyzed against the targetedlevels.
After completion of the above activities, the CFT with Head of ENGG / Head of MFG and Head of
Materials reviews the activities of Detail Design phase using the checklist of Design Review-II.
The action points arising out of the review meeting is recorded in the Minutes of review and follow-up
activities are reviewed during the next review meeting. The previous minutes points are reviewed for
completion status.
DR-I Check
List
Minutes of
Meeting
DFM / DFA
Report
DR-II
Check List
Minutes of
Meeting
CFT / Head of
ENGG
Respective
Depts(ENGG / MED /
MMD)
Leader / Headof
ENGG/MFG/
MMD
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
3.2.1
3.3.1
3.3.2
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
Upon Completion of the Design Review-II detailed technical proposal is made which is submitted to customer
after review with Head of ENGG.
The Technical proposal is submitted to customer for approval and any clarification raised by customer isreviewed and addressed. The final approval from customer for technical proposal is obtained for product as well
as process development.
Assembly drawings submitted to customer are identified with suffix C and the approved drawing is kept asrecord.
The following documents are prepared and reviewed as Product Design outputs:
Drawings / Specifications: General Assembly Drawings and subsequently detailed drawings are prepared
which includes Material Specification, Specific Inspection/Test requirement wherever required.
Special Characteristics are identified in the drawings at assembly, sub-assembly and component levels usingRML symbol. The Design Guidelines are referred while preparing the detailed drawings.
The detailed drawings are prepared for new components only and for standard / common parts existing
drawings will be used.
DFMEA: After preparation of detailed drawings, Design FMEA is carried out for Assembly, Sub-assembly and
component level. It is performed by CFT and reviewed by team leader. The recommended actions proposed by
the team are to be implemented and progress of implementation shall be reviewed by the team.
The AIAG Manual of DFMEA is used for reference. The output of FMEA is recorded in FMEA Record.
Technical
Proposal
Design
Guide lines
FMEA
Manual
DR-III
Check List
DFMEA
Record
ENGG
ENGG
ENGG
ENGG
ENGG
ENGG
ENGG
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP 02
Ref.
No.ACTIVITY Document Record Responsibility
3.4.6
3.5.0
Safety Consideration: Products manufactured in RML are safety related The following approach is
considered to enhance the safety aspects in products
- Product liability and other Statutory and Regulatory requirements are obtained from customer and designpersonnel are made aware of the requirements.
-DFMEA aims at reducing the Occurrence & Improving Detection levels for critical parts.
Manufacturing Process Design Input:
The following details are taken as input to the design and development of manufacturing process
- General Assembly, Sub-assembly and component drawings issued by ENGG.
- Design FMEA
-
Learning of previous design projects are captured through the Things Gone Right (TGR) and ThingsGone Wrong (TGW) records.
- Line Complaints and Field Failures: Data on internal line rejections, customer line complaints, field
failures and corrective preventive actions initiated for those are collected from QA department
- Specific Requirement if any from customer and from Quality System Review had with customer
- Targets for Productivity, Process Capability and Cost
ProcessDesign
Input Data
ENGG
MED / MFG
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
3.5.1
3.5.2
3.5.3
3.5.4
- The target for productivity is captured based on customer requirement as mentioned in the TSN or
expected market demand. The target is expressed as Per Man Per Day of Steering Gear / SSLP
(PMPD).
- The target for Process Capability expressed as Rejection / Rework level of the process, Process
Capability Indices and Measurement Analysis System
- The target for Rejection / Rework levels are expressed in parts per millions (ppm) for the wholeprocess.
- The target for process capability is expressed Cp and Cpk indices. This is attributed for list of Special
Characteristics identified in the drawings and the default target for the capability indices is: Cp 1.67
and Cpk 1.33
The target for Measurement System Analysis is expressed as no. of capable measurement systems to be
adopted in the manufacturing process. MSA plan is made for the particular manufacturing process and the
plan covers the Bias, Linearity, Stability, Repeatability and Reproducibility studies.
The target cost of manufacturing is captured based on the process costing and estimation and expressed in
terms of cost in Rs. / product.
The target for uptime of Critical machines/equipments if any is set at 95%. The target tool life for critical
tools are identified as input to the process design.
Manufacturing Process Design Input Adequacy Check list is used to ensure that all the relevant input details is
captured for the design and development of manufacturing process. Any clarification in the identification of
Process
Input
AdequacyChecklist
MED / MFG
MED / QA
MED / QA
MED / QA
QA
MED / MFG
MED
MED
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
3.6.0
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
input requirement is reviewed with Head of MED to avoid ambiguity.
Manufacturing Process Design Outputs:
The manufacturing process design outputs are expressed as per the following documents:
Floor Plan Layout: The Floor Plan layout is prepared by MED on the basis of information provided by CFT.
The inputs for the floor plan layout is described in Infrastructure Provisioning Process procedure.
Process Flow Charts: The Process Flow chart is prepared by MED on the basis of information provided by
CFT.
Process FMEA: Process FMEA is carried for all new processes. For existing process the in-house quality
issues and customer complaints relevant to similar products / process are collected and revisited.
Process Controls are implemented to aim to reduce Occurrence / Improve Detection during PFMEA.
Control Plan: Control Plan or Quality Control Process Charts (QCPC) are prepared by CFT. AIAG Manual
of Control Plan is used for reference. The development of control plan is described in Manufacturing ProcessProcedure. The format provided in the AIAG manual is used for development of control plan.
Standard Operating Procedure: Standard Operating Procedures are prepared by CFT.
Process Special Characteristics: Process Special Characteristics are identified as Process SignificantCharacteristics in Control Plans and Standard Operating Procedures. The designation of process significant
characteristics is as per RML symbol.
Floor Plan
Layout
Process
Flow
ChartsFMEA
Manual
Manufactu
ringProcess
Procedure
SOP
PFEMA
Record
MED
MED
MED
QA /MFG /
MED
MED
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
3.6.7
3.6.8
3.6.9
3.7.1
3.7.2
4.0
4.1
4.1.1
Packaging Specifications: The Packaging Specifications are derived as per the requirement of customer or on
the basis of experience and knowledge.
Mistake Proofing: Wherever possible mistake proofing methodologies are employed in the manufacturingprocess.
Rapid Detection: This is implemented in product / process involving heat treatment operations. The existing
traceability practice is incorporated for new products.
After finalization of manufacturing process outputs, CFT reviews the Development Phase-II using the
checklist of Design Review-IV
The action points arising out of the review meeting is recorded in the Minutes of review and follow-up
activities are reviewed during the next review meeting.
PROTOTYPE DEVELOPMENT & TESTING PHASE:
Development of Tooling and Gauges: For new Tooling / Jigs / Fixtures, drawings are prepared for
manufacturing/fabrication either at In-house or at subcontractor. MED provides technical leadership tosubcontractors in the development of new tooling. The development, subcontracting and inspection of tooling
is detailed in Infrastructure Provisioning Procedure.
The new inspection gauges / instruments are planned by QA. Special Gauges / Receiving gauges are designedby MED and subcontracted outside.
Packaging
Specificati
on
Infrastruct
ureProvisioni
ngProcedure
DR Check
List IV
NewTooling
InspectionReport
New Gauge
Insp. Report
QA/MKT/
MMD
MED/ QA /
MFG
QA/ MED
/MFG
QA/MED/MFG/
CFT
MED
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QA
Page No: 11 / 20Revision No: 3 Date : NOV 07 Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED document.
Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEMPROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
Prototype Program:
If any customer requires prototype program for product development, a Prototype Plan will be developed. Thenumber of samples to be developed and timing plan for testing will be jointly decided by RML and Customer.
The prototype is built using the Prototype drawings. Both in-house and subcontractor facilities are used for
developing prototype.
Wherever possible, the same supplier, tooling and processes will be used for prototype as will be used in
production.
The completion of prototype testing activities will be monitored as per the timing plan and incase any delay in
progress of timing plan it will be intimated to customer.
If the development of prototype is subcontracted, RML will provide the necessary infrastructure and technicalinputs to supplier and is responsible for their activities.
The design verification and validation are carried out on prototype samples.
The bought-out / subcontractor machined / in-house manufactured components are subjected to initial sample
inspection and the results are reviewed for acceptance.
PrototypePlan
SampleInsp. Report
MED
MED
QA
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEMPROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
4.3
4.3.1
4.3.2
4.3.3
4.3.5
4.3.6
4.3.7
4.4
4.4.1
4.4.2
Design Verification:
The Design Verification & Validation Plan is prepared. The test are derived from Customer Test / EngineeringSpecification or RML Test / Engineering Specifications.
Design verification tests are carried out on Prototype samples as per Design Verification & Validation Plan.
Design verification is considered to be completed only if the samples pass the verification test satisfactorily.
Alternate method of Design Verification is carried out by Alternate Calculations and Comparing with similar
proven designs
The targets set for Durability and Life is verified during design verification stage.
The Reliability Test is carried out as per Test Guidelines given by General Motors and MTTR data is capturedby calculating the time taken in replacing the inner parts.
Design Validation:
Design Validation Tests are to be carried-out on the final product, under actual operating condition to ensure
the product confirms to defined requirements. This is done by fitting the product on vehicle and carrying out
Road Testing.
Validation Test can be combined with Verification Test and carried out during verification program or
prototype testing program. However if vehicles are not available at this stage, then customer may be requested
DVVP
Test Report
ReliabilityTest and
MTTRRepors
Design
Validation
Reports
ENGG
ENGG
ENGG
ENGG
ENGG
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
4.4.4
4.4.5
4.4.6
4.5
4.5.1
4.5.2
5.0
5.1
5.1.1
to provide vehicle for fitment & field Testing. Such Tests can be carried out by customer or jointly by RML
before launching the product.
If the validation is carried out at customers end ENGG will co-ordinate with customer and all validation testreports will be obtained from customer. If any design failures are reported then corrective / preventive actions
have to be taken.
Activities carried out for Prototype Building and results of Verification and Validation Testing are reviewedusing checklist of Design Review-V
The action points arising out of the review meeting is recorded in the Minutes of review and follow-up
activities are reviewed during the next review meeting.
Samples to Customer for Fitment and Approval:
Prototype samples are submitted to customer for Customer Engineering approval.
The samples will be completely checked for Dimensional & Performance aspects as given in the drawing andcopy of reports are forwarded to customer along with samples.
INITIAL PRODUCTION PHASE:
Review of Process Control Documents:
The Process Flow Charts, Control Plans, Standard Operating Procedures and Packaging Specification are
Validation
Reports
Customer
DR Check
List V
DimensionalReports
ENGG
CFT / Leader
ENGG.
QA
.
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
reviewed for any updation based on the feedback / results of activities carried out in previous phases.
Validation of Manufacturing Process outputs:
During the initial / pilot production, data are captured and evaluated for the following parameters.
- Measurement System analysis
- Process Capability Indices (Cp and Cpkfor Special Characteristics)
- Productivity Levels
- Rejection / Rework levels and
- Manufacturing Cost
- Uptime of Critical Machines / Equipments
- Tool Life of Critical Tools
The data obtained during the initial production for the above are compared with Targets assigned for the
above parameters during identification of inputs for Manufacturing Process Design.
The results of above Process outputs are monitored for initial production of 3 months. If any of parameterdeviates from targets, necessary corrective and preventive actions wil l be initiated and implemented.
Samples taken from the Initial Production are subjected to complete dimensional inspection and performance
tests if prototype sample was not build for that model.
The Samples and necessary documents as mentioned in the Part Approval Process are forwarded to customer
along with Pilot / Initial Production Lot.
Data on
Mfg.Process
Outputs
Corrective
ActionReport
PartSubmission
Warrant
Respective
Depts
QA/MED/MFG
MED / QA /MFG
QA / ENGG
QA
QA
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
No.ACTIVITY Document Record Responsibility
5.2.6
5.2.7
5.3.1
5.3.2
6.0
6.1
6.1.1
6.1.2
6.2
6.3
The further production / despatch will be made only after receipt of approved Part Submission Warrant from
Customer or confirmation from customer to proceed the production.
Incase any non-conformance reported by customer, corrective actions will be implemented and again samplesare submitted to customer for approval.
Design Review is carried out on the results of Initial Production using Review VI checklist.
The review is carried out with Manufacturing Unit Head before start of mass production.
MASS PRODUCTION PHASE:
After the approval from customer, the mass production is started. The performance of the Product, Process
and Feed Back from Customer are monitored by CFT for minimum 3 months. If any deviation noticed in the
performance, then the CFT initiated appropriate actions in consultation with Head of ENGG/MFG/MED.
Raw material cost is monitored against the target material cost by MMD for minimum 3 months.
If cost exceeds the target level during that monitoring period, the same will be reviewed with Head ofMMD/ENGG/MKT for necessary corrective actions.
Design Review is carried out on the results of Mass Production using Review VII checklist.
The review is carried out with Manufacturing Unit Head and Process-Sign off is made and the Process is
handed over the manufacturing.
DR CheckList VI
NewProcess
Performance
Report
Mat. Cost
Record
DR CheckList VII
Process
Sign-off
CFT Leader /MFG
MFG / MED /
CFT
MMD
MMD
CFT / Head of
ENGG / MED /
MFG / MMD /MKT
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Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai
PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
NoACTIVITY Document Record Responsibility
7.0
7.1
7.1.1
7.1.2
7.1.3
PART APPROVAL PROCESS:
Production Part Approval for OEM Products:
The production part approval process is triggered, when any one of the following situation occurs:
- Submission of new part / product to customer,
- Correction on previously submitted product and
- Modification in product due an Engineering change
A sample of 5 nos.or as required by Customer is forwarded to customer for evaluation along with the required
records for evaluation by customer.
Requirements for Production Part Approval:
PPAP
ReferenceManual
Executive
MKTG
Sl.
No.Requirements Responsibility
Submission Requirement
Submitted Retained
1 Part Submission Warrant QA Yes Yes
2 Sample Product QA Yes No
3 Master Product ENGG No Yes
4 Design Records ENGG Yes Yes
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Page No: 17 / 20Revision No: 3 Date : NOV 07 Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED document.
Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
NoACTIVITY Document Record Responsibility
Sl.
No.Requirements Responsibility
Submission Requirement
Submitted Retained
5 Change Records ENGG No Yes
6 Design FMEA ENGG / CFT No Yes
7 Process FMEA MED Yes (Assy) Yes
8 Process Flow Charts MED Yes (Assy) Yes
9 Control Plan QA Yes (Assy) Yes
10 Dimensional Report QA Yes (Assy) Yes
11Test Results (Material, Performance
& Durability Test Reports)QA / ENGG Yes Yes
12Preliminary Process Capability
StudiesQA Yes (Assy) Yes
13Measurement System Analysis
StudyQA Yes (Assy) Yes
14 Checking Aids QA Yes (Assy) Yes
15 Laboratory Scope QA No Yes
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Page No: 18 / 20Revision No: 3 Date : NOV 07 Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED document.
Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
NoACTIVITY Document Record Responsibility
7.1.4
7.1.5
7.1.6
7.1.7
7.1.8
7.1.9
7.1.10
7.1.11
7.2
7.2.1
7.2.2
For submission of the above documents / records Level 2 as identified in PPAP manual is followed or
otherwise specified by Customers
The submission required documents / records are submitted to customer for review.
After satisfactory completion of all the above requirements, Part Submission Warrant is reviewed andapproved.
Customer approval on Part Submission Warrant is obtained by Engg / QA.
The copy of documents / records submitted to customer is retained in PPAP file.
Upon request from customer, the identified Non-submission required documents / records will be forwarded.
The PPAP file is updated, if any of the above documents / records get revised.
List of PPAP file is maintained.
Supplier Production Part Approval Requirement:
For new components or existing components from new sources or engineering changes, production partapproval process is effected.
During the Submission of the samples, the followings records / documents are received from supplier.
PPAP File
PSW
PPAP File
List of
PPAP File
QA
QA
QA
QA
QA
Buyer / STA /Engineer -
SQA
Buyer / STA
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Engineer -
SQA
Page No: 19 / 20Revision No: 3 Date : NOV 07 Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED document.
Issue No : 3 Date : NOV 07 Approved By : Management Representative
RANE (MADRAS) LTDChennai PRODUCT DEVELOPMENT PROCESS
QUALITY SYSTEM
PROCEDURE MANUAL
Ref: QSP - 02
Ref.
NoACTIVITY Document Record Responsibility
7.2.3
1. Process Flow Charts
2. Design FMEA (Proprietary Designs)3. Process FMEA
4. Control Plan5. Standard Operating Procedures
6. Design Record7. Engineering Change Documents
8. Dimensional Results9. Material Test Result
10. Sample Product
11. Process Capability Studies
12. Measurement System Analysis (Optional)13. Checking Aids
14. Part Submission Warrant and
15. Records of Compliance of RML Specific Requirements
The above records / documents are reviewed, approved and maintained.
Supplier
PPAP
Records
Executive
SQA
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Soft copy is CONTROLLED document. If printout is taken this become an UNCONTROLLED
document.
Issue No : 3 Date : NOV 07 Approved By : Management Representative