RML Product Development Manual- 031108

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    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

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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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    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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    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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    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

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    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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    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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    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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    Issue No : 3 Date : NOV 07 Approved By : Management Representative

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    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

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    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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    document.

    Issue No : 3 Date : NOV 07 Approved By : Management Representative