POSITIVE PLASTICS (P) LTD.

IATF 16949:2016
AUTOMOTIVE QUALITY SYSTEM PROCESSES

PLANT 1- D-160 A, SECTOR 7, NOIDA, U.P., INDIA

PLANT 2- PLOT NO. 73 & 74 SECTOR 6, IMT MANESAR,
HARYANA, INDIA

E-mail:[email protected]

THIS MANUAL IS PROPERTY OF JAIN INDUSTRIAL PRODUCTS, ROHTAK. NO PART OF THIS MANUAL IN ANY FORM MAY BE PRINTED OR REPRODUCED WITHOUT
PERMISSION FROM DIRECTOR. ALL INQUIRIES REGARDING THIS MANUAL MAY BE DIRECTED AT THE ABOVE ADDRESS TO MANAGEMENT REPRESENTATIVE WHO IS
RESPONSIBLE FOR ITS ADMINISTRATION.

Copy Number: 01
Holder: Director
 POSTIVE PLASTICS PVT. LTD
Process Name: Product Safety Document No.: PPPL/DP/01
Process Leader: MR Revision No.: 00
Management of product safety PRODUCT SAFETY
Process Objectives: related to manufacturing Eff. Date: 01/04/18
processes
WHAT/RESOURCES WHO/COMPETENCE
1. Computer & Required Stationary 1. Trained Personnel (Product Safety)
2. E-mail/Telephone 2. Responsibility of Personnel
3. Tools & Jigs/Fixtures 3. Training Record as per defined TNI
4. Poka-Yoke/error proofing system

ACTIVITIES

INPUTS 1. Identify the issues related to product's parameters - OUTPUTS

1. Customer notifications >Dimensional issue 1. PFMEA
2. Statutory & regulatory Reqts. >Fit/functional issue 2. Control Plans/Reaction Plans
3. Output of PFMEA >Performance issue 3. Product traceability of manufacturing
4. Identification of SC for product Safety >Testing issue product
5. Lessons learnt from new process 2. Analysis the issues 4. Documents related product safety
development 3. Take actions 5. Work Instructions
4. Implement actions
5. Check Effectiveness
6. Review related documents, e.g.- Control plan, PFMEA & WI

HOW/METHODS MEASUREMENTS
1.By implementation of Poka- Yoke/error proofing techniques 1. Nos of customer complaints related to product safety
2. By implementation of Escalation Process
3. By defined responsibilities for product safety
4. By Taking corrective actions
Reference Documented information’s:-

1- Maintained documented information to support the operation of its processes

2- Retained documented information to have confidence that processes are being carried out as planned.
3.Customer Complaint Record –QF-QA-07.

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 POSTIVE PLASTICS PVT. LTD
Process Name: Preventive Action Document No.: PPPL/DP/02
Process Leader: Maintenance Incharge Revision No.: 00
Implement actions to eliminate the PREVENTIVE ACTION
Process Objectives: cause of potential NCs & prevent Eff. Date: 01/04/2018
their occurrence
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1.Trained Personnel
2. Required Stationary 2. Responsibility of Personnel
3. E-mail/Telephone 3. Training Record as per defined TNI

ACTIVITIES

INPUTS a) determining potential nonconformities and their causes OUTPUTS

1. Output of escalation process b) evaluating the need for action to prevent occurrence of 1. Documented information of action
2. Lesson learnt from previous incidents nonconformities taken
3. Output of risk assessment & opportunity c) determining and implementing action needed 2. Output of review result and
4. Any prediction of CFT
d) documented information of action taken effectiveness of the preventive action
5. Output of horizontal deployment process
reviewing the effectiveness of the preventive action taken taken
of CA
utilizing lessons learned to prevent recurrence in similar
processes

HOW/METHODS MEASUREMENTS
1. By taking action as per results of management review 1. No’s of utilizing lessons learned to prevent recurrence in similar
2. By Risk analysis Processes
3. By implementing the KAIZEN & suggestion process 2. No repeated concern
4. By taking feedback from customers 3. No. of Kaizen Per year
5.By Analyzing of results of collected data

Reference Documented Information:-

1. Daily Production Report:-QF-PD-18 and Today Rejection Sheet:-QF-PD-09.
2-CAPA/8 D Report/ customer specified format – QF-QA-12

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 POSTIVE PLASTICS PVT. LTD
Process Name: Calibration/Verification Records Document No.: PPPL/DP/03
Process Leader: QA In charge CALIBRATION / VERIFICATION RECORDS Revision No.: 00
Process Objectives: To verify the conformity of products Eff. Date: 01/04/2018

WHAT/RESOURCES WHO/COMPETENCE
1. Computer /E-mail/Telephone 1.Trained Personnel
2. Required Stationary
3. Primary instruments for calibration
4. Excel based in-house made calibration module
5. List of Approved NABL External Laboratory

ACTIVITIES

1. If new instrument, identify as per identification method

INPUTS 2. Check whether instrument calibrate in internal / OUTPUTS
1. List of monitoring & measuring external laboratory 1. Calibrated instruments determine
equipments 3. Send the instruments for calibration to external their status
2. Physical instruments for calibration laboratory 2. Safe-Guarded from adjustments,
4. Verify the calibration report and verify the results if applicable
5. Initiate the appropriate action based on assessment 3. Calibration result record /
6. If instrument calibrate in internal laboratory:
Certificate
7. Clean the instrument
8. Put the instrument in standard room at 22±2 oC Temp.
For at least 2 hours for soaking
9. Verify the validity of primary instrument before calibration
10. Do the calibration as per work instructions
11. Maintain the record of calibration

HOW/METHODS MEASUREMENTS
1. 1. External Calibration Agency must be ISO 17025 1. No. of measuring and monitoring equipments are not qualified to
2. In-house made calibration work instructions, when Measuring standards / calibration work instructions.
no such standards exist 2. No Miss out of instrument for calibration
3. Laboratory Scope 3. Calibration Plan vs Actual

Reference Documented Information’s:-

1- Master List of Measuring equipment :-QF-QA-08

2- Calibration Schedule of measuring instrument :-QF-QA-09
3- 3. Gauge Validation Report (internal) –QF-QA-45

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 POSTIVE PLASTICS PVT. LTD
Process Name: Competence Document No.: PPPL/DP/04
Process Leader: MR COMPETENCE Revision No.: 00
Process Objectives: To upgrade the skill Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Competent Faculty
2. Required Stationary
3. E-mail/Telephone
4. Infrastructure for Training

ACTIVITIES

1. Identify the training needs with the help of

INPUTS Process Leaders OUTPUTS
1. List of Employees 2. Prepare skill matrix based on training needs 1. Training need identification & skill
2. Incompetent Manpower 3. Prepare annual training planner Matrix
3. Competence Gap 4. Make arrangement for faculty 2. Training Planner
5. Prepare training material / module 3. Training Circular
6. Make arrangement for training 4. Training attendance / effectiveness
7. Infrom to participant about the training topic, date, time record
and venue by circular 5. On-the-job-training record
8. Get it signed by participants on training attendance sheet
7. Evaluate the effectiveness & take necessary actions
8. Update the training records
9. Provide on-the-job-training, whenever is required

HOW/METHODS MEASUREMENTS
1. Refer Training Material / Module
2. External Expert Hiring 1. Training /Quarter
3. Outside Trainings/Seminars 2. Absentism
3. No. of Accidents
Refrence Documented informations:-
1- ORGANIZATION CHART :-QF-MR-19
2- Training need identification –QF-HR-04
3-Skill matrix –QF-HR-06
4- Attendence Sheet –QF-HR-02.
5- Employee Training Cum evaluation record-QF-HR-01

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 POSTIVE PLASTICS PVT. LTD
Process Name: Internal Auditor Competency Document No.: PPPL/DP/05
Process Leader: MR INTERNAL AUDITOR COMPETENCY Revision No.: 0
Process Objectives: To Ensure System Effectiveness Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Understanding of the automotive process approach.
2. Required Stationary 2. Understanding the applicable customer-specific requirements.
3. E-mail/Telephone 3. Understanding of applicable ISO 9001 & IATF 16949 requirements.
4. Understanding the applicable core tool
5. Understanding how to plan, conduct, report, and close out audit findings

ACTIVITIES

1. Identify the personal training

INPUTS 2. Arrange the training OUTPUTS
1. Quality Management System 3. Make the audit plan 1. Qualified Internal Auditors
Auditors 4. Conduct the audits
2. Manufacturing Process Auditors 5. Make the report
3. Product Auditors 6. Review the report
4. CSRs 7. Ensure the effectiveness of audit
8. Re-trained the personal, if required
5. ISO 9001-2015

HOW/METHODS MEASUREMENTS
1. By Internal/External Training 1. No. of Internal Auditors qualified
2. By Experience 2. Minimum no. of Audit Man days/Year
3. By Maintain knowledge of relevant requirements based on 3. Reduction in No. of Non conformities in External audits
internal changes and external changes
4. By executing a minimum one no. of audit per year
Reference Documented information’s:-

1- List of Internal Auditors- QF-HR-08

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 POSTIVE PLASTICS PVT. LTD
Process Name: Employee Motivation Document No.: PPPL/DP/06
Process Leader: MR EMPLOYEE MOTIVATION AND EMPOWERMENT Revision No.: 00
Process Objectives: To Motivate the Employees Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Experienced Personnel (Top Management)
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Top Management is directly communicate to

INPUTS employees OUTPUTS
1. Employee 2. Employee can meet with top management directly 1. Motivated & Empowered
2.Outs source 3. If any dispute, resolved by top management Employees
2. 2
Agency 4. Create friendly work environment
5. Create an environment that promote innovation
6. Top Management promote of quality and technological
awareness throughout the whole organization

HOW/METHODS MEASUREMENTS
1. Punctuality in Salary / Wages. 2) Friendly Work Environment 1. Man-Power Turn-Over Ratio
3. No retracement Policy 2. Less Than 10% Absentism
4. Help to Employees to build their capital infrastructure 3. Zero Accident
5. Help given promptly, in case of emergency
6. Emotional Attachment with Employees
7. Empowerment given to employees for their working turnery

Refrence Documented informations:-

1- KAIZEN record- QF-MR-12
2-Suggestion Form cum record-QF-HR-08
2- Criteria for best employee of the month-WI-82.
3- WI for Selection Committee :-WI-83

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 POSTIVE PLASTICS PVT. LTD
Process Name: Engineering Specifications Document No.: PPPL/DP/07
Process Leader: Leader-Process Engineering ENGINEERING SPECIFICATIONS Revision No.: 00
Process Objectives: Timely review of changes Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Trained Personnel
2. Required Stationary
3. E-mail/Telephone
4. Auto CAD Software

ACTIVITIES
1. Reviewed the changes in customer engineering
INPUTS standards / specifications and related revisions OUTPUTS
1. Change in customer engineering 2. Ensure that there is no adverse impact on conformity 1. Updated Process Engineerings
standards/ specifications and related to requirements documents
revisions 3. If adverse impact on conformity to requirements, take
action to prevent adverse impacts
4. Discuss the changes amongst CFT
5. If required, update the respective process-engg. Documents
6. Review should be completed within 10 working days of
receipt of notification of engineering standards/specifications
changes
7. Distribute the update process engineering documents
to respective persons for implementation
8. Each changes shold be implemented in the
production, if applicable

HOW/METHODS MEASUREMENTS
1. Review the changes in customer engineering standards / 1. Timely submission of changed PPAP documents, if required
Specifications 2. Review of impact of ECN in 10 working days
2. Procedure for APQP for new part development 3. Implementation of ECN within one month/customer
3.Document Control Procedure requirement, whichever is earlier

Refrence Documented informations:-

1- Engineering change Note-QF-DV-08
2- Engineering change implementation record –QF-DV-29

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 POSTIVE PLASTICS PVT. LTD
Process Name: Design and Development D & D OF MFG PROCESSES AND Document No.: PPPL/DP/08
Process Leader: Leader-Process Engineering IDENTIFICATION OF SPECIAL Revision No.: 00
Process Objectives: To Ensure timely development CHARACTERISTICS Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Trained Personnel (Process Engineering Team)
2. Required Stationary
3. E-mail/Telephone
4. Auto CAD Software & Tools

ACTIVITIES
1. Do feasibility study, if feasible
2. Prepare quotation; keep in mind targets for productivity,
INPUTS process capability, timing, and cost OUTPUTS
1. Customer Part Drawing including 3. Send quotation to customer through marketing person 1. Part Drawings
Special Characteristics 4. Prepare APQP & submit to Customer 2. List of special characteristics
2. Cutomer-Specific Requirements, 5. Prepare Part/Blank/Forging Drawing 3. PFMEA
6. Prepare List of special characteristics/ PFMEA / control plan/packaging standard/PSW 4. Control Plans
if any
7. Arrange machine tool / cutting tool/measuring tool, if required 5. Packaging Standard
3. Customer-Standards, if any 6. Part submission warrant
8. Parts Developed as per Control Plan
4. Product sample, if any 7. Identified special characteristics
9. Part samples send to customer for approval
10. If any change noticed, then in-corporate
11. Then Finalized the control Plan & Other related Documents, if required
8. Prepare a pilot lot
9. Send pilot lot along with PPAP documents to customer
10. Get it PSW signed approved by customer

HOW/METHODS MEASUREMENTS
1. Refer experience from previous development 1. On time submission of initial samples
2. Use multi-discplinery approach 2. First time approval of product from customer
3. Target productivity & cost
4. Customer specific requirements

Refrence Documented informations:-

1- Manufacturing process development plan:-QF-DV-04 5- PFD-QF-DV-05.
2- Control plan-QF-DV-07.
3- List of special characteristics QF-DV-12.
4- PFMEA-QF-DV-06

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 POSTIVE PLASTICS PVT. LTD
Process Name: Supplier Selection SUPPLIER SELECTION Document No.: PPPL/DP/09
Process Leader: Leader-Purchase & Stores AND STATUTORY & REGULATORY Revision No.: 00
Process Objectives: Ensure Products meet the requirement REQUIREMENTS Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Get supplier information.

INPUTS 2. Get it filled assessment form by supplier O
1. Supplier Assessment Form 3. Ensure that purchased products, processes, and U
1. Supplier assessment
services conform to the current applicable statutory and form T
2. Applicable current statutory and 2. Approved supplier
P list
regulatory requirements regulatory requirements in the country of receipt, the country of U
shipment, and the customer-identified country of T
3. Customer approved sources, if any destination, if applicable S
4. Select the supplier bases of criteria in Procedure(PPPL-QP- 16)
5. Add the supplier in approved supplier list

HOW/METHODS MEASUREMENTS
1. Work Instructions from Supplier Selection 1. No. of suppliers added/deleted from approved supplier list
2. Applicable statutory & regulatory requirements 2. Compliance of applicable statutory & regulatory requirements
3. CSRs 3. Selection of Supplier within 15 days of Requirements

Reference Documented informations:-

1-Supplier Selection form-QF-PU-07.
2-Approved supplier list- QF-PU-04

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 POSTIVE PLASTICS PVT. LTD
Process Name: Control of outsourced processes Document No.: PPPL/DP/10
Process Leader: Leader-Purchase & Stores CONTROL OF OUTSOURCED PROCESSES Revision No.: 00
Process Objectives: Ensure Products meet the requirement Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Identify the processes

INPUTS 2. Check whether all required processes can be done OUTPUTS
1. List of Machines in-house 1. Selected Suppliers
2. Customer Supplied Part Drawings / 3. If yes, do the in-house 2. O/S process control methods
Specifications 4. If no, search for suppliers, who have facilities of that kind of
processes
5. Select the supplier basis on processes
6. Verify conformity of externaly provided products, processes,
and services to internal and external customer requirements
7. Prepare criteria and actions to reduce the type and extent
of controls
8. Assessment of the supplier performance

HOW/METHODS MEASUREMENTS
1. By Previous Experience 1. No. of Processes outsourced
2. Study of Process Flow Diagram 2. External provider audit score
3. CSRs 3. Ext. provider performance monitoring
4. Compliance of CSRs related to process
4. Process Parameters/Specifications
5. Documented work instructions/Procedures
Refrence Documented informations:-
1- Supplier audit Sheet:-QF-PU-10
2- Incoming Inspection Register –QF-QA-02
3- Supplier QMS development Plan-QF-PU-12.

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 POSTIVE PLASTICS PVT. LTD
Process Name: Supplier Monitoring Document No.: PPPL/DP/11
Process Leader: Leader-Purchase & Stores SUPPLIER MONITORING Revision No.: 00
Process Objectives: To Ensure Supplier Performance Eff. Date: 01/04/2018

WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES
1. Collect the data in respective format
INPUTS 2. Feed in the system OUTPUTS
1. Supplier Performance Form 3. Calculate the performance rating 1. Supplier Performance Report
4. Inform to supplier, if needed
5. Ask customer actions from suppliers, if needed
6. Ensure effectiveness of corrective actions

HOW/METHODS MEASUREMENTS
1. Work Instructions for Supplier Performance Monitoring 1. Improvement of Supplier performance rating
2. Supplier audit check sheets 2. Improvement in supplier audit score
3. Competent auditors 3. Adherence of Supplier QMS development Plan

Reference Documented informations:-

4. Supplier Rating Sheet –QF-PU-02.

5. Supplier Audit Sheet-QF-PU-10

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 POSTIVE PLASTICS PVT. LTD
Process Name: Productive Maintenance Document No.: PPPL/DP/12
Process Leader: Leader-Maintenance TOTAL PRODUCTIVE MAINTENANCE Revision No.: 00
Process Objectives: To Availability of Equipments Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Trained Personnel (Maintenance Team)
2. Required Stationary
3. E-mail/Telephone
4. Required Tools and Techniques

ACTIVITIES

1. Identify key equipments

INPUTS 2. Ensure availability of replacement parts OUTPUTS
1. List of machines 3. Do the preventive maintenance as per plan, so 1. Preventive maintenance compliance
2. List of Critical spares applicable customer-specific requirements can be met matrix
3. Preventive maintenance plan 4. Fill the preventive maintenance check sheet
4. CSRs 5. Regular review of maintenance plan and objectives
6. Take corrective actions where objectives are not achieved
7. Maintain the documentation of above these activities
8. Do the periodic overhaul, if required

HOW/METHODS MEASUREMENTS
1. Preventive maintenance check sheet 1. To improve OEE (Overall Equipment Effectiveness)
2. Predictive maintenance method, as applicable 2. To increase MTBF ( Mean Time Between Failure)
3. TPM concepts 3. To reduce MTTR (Mean Time to Repair)
4.Procedure for Maintenance 4. Adherence of prev. maint. schedule

Reference Documented informations:-

1- PM plan –QF-MT-07.
2- PM Check Sheet –QF-MT-08
3- List of Critical spare parts:- QF-MT-03
4- Machine Break down Register-QF-MT-05

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 POSTIVE PLASTICS PVT. LTD
Process Name: Identification & Traceability Document No.: PPPL/DP/13
Process Leader: MR Revision No.: 00
To support identification of clear
stat and stop points for product IDENTIFICATION AND TRACEABILITY
Process Objectives: received by the customer or in the Eff. Date: 01/04/2018
field that may contain quality and /
or safety-related NCs
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1.Trained Personnel (QA & production Team)
2. Required Stationary
3. E-mail/Telephone
4. Required Tags and Markers

ACTIVITIES

a) to identify nonconforming/suspected product;

INPUTS b) to segregate nonconforming/suspected product; OUTPUTS
1. Analysis of customers traceability c) to meet the customer/regulatory response time 1. Identifcation methods
2. Any regulatory requirements requirements; 2. Traceability records
3. Risk assessment output d) identification of individual products, if specified by the
4. CSRs customer or regulatory standard;
5.Similar part identification
e) identification and traceability requirements are extended
to externally provided products with safely / regulatory
characteristics.

HOW/METHODS MEASUREMENTS
1. WI and by Tags 1. To ensure the identification & traceability at required stage
2. Zero customer complaint w.r.t. identification & traceability

Refrence Documented informations:-

1- WI for Flow Card – WI-28
2- Product Identification tag :-QF-PD-10;

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 POSTIVE PLASTICS PVT. LTD
Process Name: Control of Changes Document No.: PPPL/DP/14
Process Leader: MR CONTROL OF CHANGES Revision No.: 00
To Ensure Continuing Conformity
Process Objectives: with Requirements
Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1.Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Define verification and validation activities to

INPUTS ensure compliance with customer requirements OUTPUTS
1. Changes caused by organization, the 2. Validate changes before implementation 1. Record of verification and validation
customer, or any supplier 3. Retain records of verification and validation
4. Notify the customer of any planned product realization
changes, when required by the customer
5. Obtain the documented approval, prior to implementation
of the change, if necessary
6. Complete verification by production trial run and new
product validation, if necessary

HOW/METHODS MEASUREMENTS
1. By verification and validation of changes 1. FTR Product
2. Zero concern related to change

Reference Documented informations:-

1- Product Validation/Re-validation Record-QF-DV-22.
2- 4 M TAG:-QF-4M-01
3- Change Request Form :-QF-4M-02
4- 4M Tracking Sheet:-QF-4M-04
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 POSTIVE PLASTICS PVT. LTD
Process Name: Control of Rew./Rep. Product Document No.: PPPL/DP/15
Process Leader: MR CONTROL OF REWORKED/REPAIRED PRODUCT Revision No.: 00
Process Objectives: To ensure nonconforming Product not shipped to customer Eff. Date: 01/04/2018

WHAT/RESOURCES WHO/COMPETENCE
1.Required Machine Tool 1. Trained Personnel
2. Required Cutting Tool
3. Required Measuring Tool

ACTIVITIES

1. Identify the parts by yellow tag / yellow paints

INPUTS 2. Do the rework /repair OUTPUTS
1. Reworkable / Repairable Parts 3. Again re-inspect 1. Reworked / Repaired Parts
3. Customer requirements 4. If OK, then move to next operation
4. 100% check rework parts,only 5. If not OK, then move to rejection bin
reworkable dimension without
effecting other dimension.
6. Move to scrap yard through rejection disposition report and
retain the report as record
7. Obtain approval from the customer before rework / repair,
if necessary

HOW/METHODS MEASUREMENTS
1. Control Plan 1. Reduction in External PPM
2. Work Instructions 2. Reduction in cost of poor Quality
3. Segregation/Sorting 3. Reduction in Internal PPM
4. No of Lot Rejected In PDQA
5. Rework PPM

Refrence Documented informations:-

1- Rework and Re-Inspection Report ,:-QF-QA-25.

2- WI for Segregation and Rework – WI-34

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 POSITIVE PLASTICS PVT. LTD
Process Name: Nonconforming Product Disposition Document No.: PPPL/DP/16
Process Leader: MR NONCONFORMING PRODUCT DISPOSITION Revision No.: 00
To ensure nonconforming Product not
Process Objectives: shipped to customer
Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1.Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Rework / repair / reject / suspect / obsolete

INPUTS parts identified as nonconforming parts by red tag or OUTPUTS
1. Nonconforming Parts red paint 1. Rejection Disposition Report
2. Move to rejection bin
3. Prepare a rejection disposition report and move to scrap
yard
4. Prepare a rejection dispostion report on monthly basis
and move to scrap yard
5. PPPL has verified that the parts to be scrapped is
rendered
unusable prior to disposal
6. PPPL is not divert nonconforming product to service or
other use without prior customer approval

HOW/METHODS MEASUREMENTS
1. Disposition or scrap WI 1. Reduction in In-House PPM
2. Reduction in customer PPM
3. Reduction in Cost of Poor quality
Refrence Documented informations:-

1. Material Job Card-QF-PD-12.

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 POSTIVE PLASTICS PVT. LTD
Process Name: Internal Audit Programme Document No.: PPPL/DP/17
Process Leader: MR INTERNAL AUDIT PROGRAMME Revision No.: 00
Process Objectives: To Ensure System Effectiveness Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1. Qualified Internal Auditors
2. Required Stationary
3. E-mail/Telephone
4. ISO 9001:2015 Standard
5. IATF 16949:2016 Standard

ACTIVITIES

1. Prepare internal audit schedule, keep in

INPUTS mind impartiality, supplier and customer OUTPUTS
1. List of Qualified Internl Auditors relationship and an auditor can not audit their 1. Internal Audit findings
2. Annual Internal Audit Plan own process. 3. Internal Audit non-
2. Internal Audit schedule handover to all auditees conformance reports
3. Internal audit schedule along with respective internal
4. Audit closers with evidences
check
audit sheet format handover to respective auditor.
4. Note down the internal audit findings by auditors
and handover to Quality Systems Leader.
5. Prepare a non-conformance report by Quality Systems Leader
6. Reporting the results of audit and status
in Management Review meeting

HOW/METHODS MEASUREMENTS
1. Refer Internal Audit findings check sheet 1. No. of NCs/Opportunities for improvement per audit
2. Guidance with requirements of ISO 9001:2015 & IATF 16949:2016 2. Increase in Internal Audit effectiveness
standards 3. Adherence of Internal Audit programmed
4. 5 S Audit Score
3. Guidance of ISO 19011:2011
4. Internal Audit procedure
Reference Documented information:-

1- Internal audit plan (QMS process, Mfg process & product) QF-MR-06,QF-QA-32,QF-QA-23.
2- Internal audit schedule (QMS process, Mfg process & product) QF-MR-07
3- Internal audit Check Sheet (QMS process, Mfg process & product)QF-MR-17,QF-QA-14A,QF-QA-14B.

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 POSTIVE PLASTICS PVT. LTD
Process Name: Problem Solving Document No.: PPPL/DP/18
PROBLEM SOLVING / ERROR-PROOFING /
Process Leader: MR Revision No.: 00
CONTINUAL IMPROVEMENT
Process Objectives: To Ensure Improvement is implemented Eff. Date: 01/04/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1.Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Take containment, interim actions, and related

INPUTS activities to control of nonconforming outputs, wherever OUTPUTS
1. Customer Complaints including Field is necessary 1. Red Bin analysis report with effective
data
Failures 2. Find out the root cause using methodology after analysis
2. In-House Rejection 3. Implement of systematic corrective actions, consider
3. Current Manufacturing Issues error-proofing devices for failure or simulated failure
4. Audit Findings 4. Verify the effectiveness of implemented corrective actions
5. New Product Developments 5. Review and update the documents, wherever necessary
6. Risk assessment results 6. Error-proofing device identified, controlled, verified, and
calibrated, where feasible
7. Record the above improvement in continual improvement format
8. Apart from above manufacturing process improvement action
plan to reduction of process variation and waste can be taken
as a continual improvement project

HOW/METHODS MEASUREMENTS
1. By using problem solving techniques 1. No. of continual improvement done
2. Work Instruction for Poka Yoke 2. No repeated concern
3. Kaizen 3. Timely submission of CAPA to customer

Reference Documented informations:-

1- Corrective & Preventive Action Record- QF-QA-12 .
2- Daily Production Report :-QF-PD-18
3- Today Rejection Sheet :-QF-PD-09

Prepared By (MR): Approved By (MANAGING DIRECTOR): Page: 01 of 01

 POSTIVE PLASTICS PVT. LTD
Process Name: Temporary process Change control Document No.: PPPL/DP/19
TEMPORARY PROCESS CHANGE
Process Leader: MR Revision No.: 00
CONTROL RECORD
Process Objectives: To Ensure Improvement is implemented Eff. Date: 05/01/2018
WHAT/RESOURCES WHO/COMPETENCE
1. Computer 1.Trained Personnel
2. Required Stationary
3. E-mail/Telephone

ACTIVITIES

1. Take containment, interim actions, and related

INPUTS activities to control of nonconforming outputs, wherever OUTPUTS
1. Customer Complaints including Field is necessary 1. Continual improvement report
Failures 2. Find out the root cause using methodology after analysis
2. In-House Rejection 3. Implement of systematic corrective actions, consider
3. Current Manufacturing Issues error-proofing devices for failure or simulated failure
4. Audit Findings 4. Verify the effectiveness of implemented corrective actions
5. New Product Developments 5. Review and update the documents, wherever necessary
4. Risk assessment results 6. Error-proofing device identified, controlled, verified, and
calibrated, where feasible
7. Record the above improvement in continual improvement format
8. Apart from above manufacturing process improvement action
plan to reduction of process variation and waste can be taken
as a continual improvement project

HOW/METHODS MEASUREMENTS
4. By using problem solving techniques 5. FTR product
5. Work Instruction for Temporary Change 6. No related concern
6. CAPA
7. Contingency Plan

Reference Documented information:-

1- Contingency Plan:-QF-MR-14.

Prepared By (MR): Approved By (MANAGING DIRECTOR): Page: 01 of 01