BOM Level

Bit Finish
BOM Level One

Bit Sub Assembly

BOM Level Two

Carbide Ball & Rollers BOM Spares Consumables

Leg Finish Cone A Finish Cone B Finish Cone C Finish

BOM Level Three

Cone A Cone B Cone C

Leg Process Process
Process Process

Leg Forging Cone Forging Cone Forging Cone Forging

BOM Level Four

 Masters Creation

Product Process

Finish Product Master Operation Master

Sub Assembly Master Quality Plan

Leg Forging Master Machine Master

Cone Forging Master Instrument Master

Drawing Master Fixture Master

Work Instruction Master

Gage Master

Tools Master

Purchase Others
BOM Item Master Employee Master

Supplier / Vendor Master Customer Master

TDC Master Maintenance Spare

Payment term Fixture Spares

Price Master

Unit Master
 Sales Inquiry

Customer Inquiry

Prepare Inquiry
Review

Inquiry Review Customer giving the

By Design additional requirement

IR Communicate to customer
Approved regarding additional
by Design requirements

Provide Price &

Delivery
Change requested
by customer

Prepare Quotation

Changes
Possible
Send quote to
customer
Communicate to
Communicate to
customer with
customer about regret
revised change
Quote
Accepted By
Customer
Amend the Quote

Customer Order
Sent copy of
Amended Quote to
Customer
 Order Acceptance Process

Receipt of
Customer PO

Acknowledge
Customer about PO

Print PO and
Prepare CR

Receive revised PO
from the customer
Submit CR to Design

Communicate to
CR
customer regarding
Complaint
non compliance

Check for Free stock

Free stock
available

Submit CR to PPC for

Allocate Free Stock
delivery confirmation

Prepare OA

Send OA copy to
customer
A
 Order Acceptance Process

OA
Change requested
Accepted By
by customer
Customer

Customer OA Changes
acknowledgement Possible

File all documents Communicate to

Customer PO, OA Communicate to
customer with
Copy. CR copy in file customer about regret
revised change

Amend the OA

Sent copy of
Amended OA to
Customer
 Production Planning Process

Receipt of
Customer OA

Check for Yes Allocate

Free
Free Stock
Stock

No
Update
Pending Order

Create Work Order Create Work Order

For Leg Finish For Cone Finish

Verify Allocate Free

Yes
Free Stock To WO & Give it
Stock to Assembly

No
Update Work Order Update Work Order
For Leg Finish For Cone Finish

Verify
No Raise Forging Indent
Forging
Stock

Yes

Go To
A Purchase Process
 Production Planning Process

Raise MR for Raise MR for

Leg Forging WO Cone Forging WO

Stores Issue of Stores Issue of

Leg Forging WO Cone Forging WO

Prepare RC Batch Qty Prepare RC Batch Qty

For Leg Forging WO For Cone Forging WO

Issue Forging to
Production for Manufacturing
 Out Sourced Process

On Daily Basis PPC to Send forging to vendor with

Plan out sourced process for • RDC
approved vendors • Drawings
• Quality Plan

No Approve
Plan Follow up with vendor for
completion of operations
Yes

Create Job Order / RDC for

Inform production for any
Vendor operations
delay and for NC inform
Design & quality

Approve No
RDC
Vendor to return material
with DC and vendor
Yes inspection report

Print RDC, Drawing,

Quality Plan & Store RC at PPC
Security to Verity Physical Qty,

Security to Verity Physical

count during loading
Any Qty
Yes
Difference
Inform to PPC
No Any Qty PPC will verify
Difference No with vendor

Yes Update in in ward Register

Against RDC with Vendor DC
Upload scanned copy of DC
Update in Out ward Register
Upload scanned copy of RDC

B
 Out Sourced Process

PPC to verify the documents,

Ensure availability of
Vendor DC, Invoice
Vendor Inspection Report,

All No
PPC to inform vendor for
Documents
necessary documents
Available

Yes

PPC to prepare RRDC and

issue to Quality for inward
inspection with RC
 Out Sourced – Inward Inspection Process

Quality to receive material,

RRDC, vendor inspection NC to raised and inform PPC
report from PPC for inward
inspection

PPC will review the NC with

Quality to inspection as per Design
quality plan for each vendor
operation

Design to review the NC and

decide appropriate action
Is Material No
OK

Y Yes Can it be No Can it be Yes

e accepted reworked
s
QC to inform PPC about No
inspection completion and
hand over RRDC

Material to Go to Out
be rejected sourced Process

PPC to move the material for

next operation with properly
filled route card
PPC to update the
WO monitoring
sheet with rejected
qty. If needed to be
replaced

No Is Yes Issue debit note

Inform vendor Rejection
for the vendor
Higher
 Quality- NC Process

NC to raised and inform

Quality to inspect the material Concern person
as per quality plan

NC will review by Concern

Person and discuss with design
Is the
Material No
OK

Yes Design to review the NC and

decide appropriate action

Apply the color code / tag

As required by process

Yes No Yes
Can it be Can it be
accepted reworked
QC to inform concerned
about inspection
No
completeness

Material to
Concern Person
be rejected
will do the R/W

PPC to update the WO

monitoring sheet for
rejected qty Offer to Quality

Dispose the PPC to replace

rejected as per the rejected
procedure material based
on requirement
Yes Is the No
Material
OK
 Purchase Process

Purchase Indent

Approved
Purchase
item
Send Inquiry
Get the Quote
Negotiate Best
Price & delivery
E Payment Terms
Place Trial Order

Issue Control copy of

drawing, TDC, QP along
with PO to Supplier

Get PO Receipt
Confirmation

Track the PO with

supplier to get items
delivered as per
commitment

Receipt of Trail Order

Inward Inspection
GRN Preparation
by Quality
Offer to Quality
Any
Delay

Item OK

Inform PPC / Production

Approve the
supplier and Item
Follow NC
Discuss with supplier for
Process Flow Chart
improved delivery
Stock Update in
Store
 Purchase Process

Verify Purchase Indent for

Item Number
Item Description
Required Qty
Drawing Details
TDC Requirements Receipt of Corrected
Quality Plan Requirements Purchase Indent
Supplier Details if any
Is Receipt Date as per lead time

Is Purchase
Inform to Purchase Indenter
Indent data
for correction
compliant

Issue Control copy of

Prepared & Approve
drawing, TDC, QP along with
Purchase Order
PO to Supplier

Track the PO with supplier to

get items delivered as per Get PO Receipt Confirmation
commitment

Receipt PO Items
Any Inward Inspection
GRN Preparation
Delay by Quality
Offer to Quality

Inform PPC / Production Item OK

Discuss with supplier for

improved delivery Stock Update in
Follow NC Stores
Process Flow Chart
 Purchased – Inward Inspection Process

Quality to receive material, NC to raised and inform

GRN, Supplier inspection Purchase
report from stores for inward
inspection

Purchase will review the NC

Quality to inspection as per with Design
quality plan & TDC for each
Purchase item

Design to review the NC and

decide appropriate action
Is Material No
OK

Y Yes Can it be No Can it be Yes

e accepted reworked
s
QC to inform purchase &
stores about inspection No
completion and hand over
GRN
Material to
be rejected

Stores to update the stock

Purchase to inform
supplier and return
the rejected items

Purchase to inform
Supplier to rework supplier about
and return the rework and return
material the material
 Production Process

Material will be receive from

PPC with Proper Route Card

Verify the material with route Yes

Validation
card and ensure the previous
required
operations completeness

No

Pick the drawing, QP,WI as per Validate the Process then

route card continue the production

Any
Yes Inform PPC for
Document
correction
Issue

No

Operator to perform setup Operator to continue

production as per process production as per process
documents documents and record the SIR

Offer first piece to quality for

FIR
Quality to perform patrolling
inspection during production

FIR Yes
Approved

No
Patrolling Yes
Inspection
Complete the NC Process approved

No
C
 Production Process

Get printout of route card and

Partial Qty Yes update the produced qty on
Produced new route card and attached
xerox copy of existing route
card
No

Update daily production log,

route card in system

Stage
Inspection QC to Perform stage
Required inspection

No

No
Is Item Ok
Move the material for next
operation with properly filled
route card Yes

Apply color code / Tag as

Final process required
Inspection

Follow NC Process
flow chart

Is Item Ok

IDN the accepted WO Leg / Cone Finish Stock

material with to updated store stock
component number
 Production – Heat Treatment

Receive material from

previous work center with
route card

Verify the material with route Process

card and ensure the previous Validation
operations completeness done

Pick the drawing, QP,WI as per Validate the Process then

route card continue the production

Any
Inform PPC for
Document
correction
Issue

Do heat treatment as per Operator to continue

route card drawing production as per process
documents and record the SIR

After heat treatment, do the

specimen inspection
C

Specimen
Approved

Complete the NC process

 Production – Heat Treatment

Get printout of route card and

Partial Qty Yes update the produced qty on
Produced new route card and attached
xerox copy of existing route
card
No

Update daily production log,

route card in system

Stage
Inspection QC to Perform stage
Required inspection

No

No
Is Item Ok
Move the material for next
operation with properly filled
route card Yes

Apply color code / Tag as

process required

Follow NC Process
flow chart
 Assembly Process

Based on daily All Sub

Follow up for material
production plan check Assembly
from PPC / Production /
for Finish Leg & cone spares
Purchase
Stock available

Issue MR and draw the

material from store for
Finished Leg,
Finished Cone,
Assembly Spares

Pick the drawing, Any

Inform PPC for
QP,WI as per route Document
correction
card Issue

Operator to perform setup

production as per process
documents

Process
Offer first piece to Validate the Process then
Validation
quality for FIR continue the production
completed

Operator to continue
Quality to perform
FIR production as per
patrolling inspection
Approved process documents and
during production
record the SIR

Complete the
Patrolling
NC Process
Inspection
approved
D
 Assembly Process

Get printout of route card and

Partial Qty Yes update the produced qty on
Produced new route card and attached
xerox copy of existing route
card
No

Update daily production log,

route card in system

Stage QC to Perform stage

Inspection inspection
Required
No

No
Is Bit Ok
Move the material for next
operation with properly filled
route card Yes

Apply color code / Tag as

Bit Final process required
Inspection

Follow NC Process
flow chart

Is Bit Ok

IDN the accepted OA Update FG Stock with

With Bit Numbers finish bits