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PRODUCT DEVELOPMENT PROCESS


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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Responsibility

Ref. No. 1.0 1.1 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

1.2

On receipt of Technical Sales Note from Marketing the design classification based on the guidelines E,R&D WI 01, is done as AED-TSN or Standard Prototype and it is taken up for design and development in the 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

1.3 1.4 1.5

NPD Flow Chart Std. Prototype Flow Chart Technical Sales Note / MOM with Customer Marketing

1.6 Based on the Technical Sales Note issued by marketing or discussion had with OE customer the development activities for new product is started. Page No: 1 / 20 Revision No: 3 Date : NOV 07

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


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Ref. No. 1.7

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

1.8

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

2.0 2.1 2.2

-Do-

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Design Input Adequacy Check List Project Note Responsibility ENGG

Ref. No. 2.3

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 the plan 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 to customer through Marketing. Product Design Inputs: During the Development phase the following inputs as appropriate are obtained from customers and internal functions:

2.3.1 2.3.2 2.4 2.5 2.5.1 2.5.2

ENGG Head of ENGG

CFT Team Project Timing Plan

Head of ENGG. CFT / Head of ENGG

Head of ENGG / Marketing

2.6 2.6.1

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Responsibility ENGG / MKT

Ref. No. 2.6.2 -

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 Things Gone 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 TGR / TGW Reports

2.6.3

ENGG ENGG

ENGG/QA/ME D

2.6.4

- 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 time at 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. QFD ENGG GM Product Guidelines Concept Report ENGG

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP 02


Record Responsibility ENGG ENGG

Ref. No.

- 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 SGP product 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. 2.6.5 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. 2.7 2.7.1 Product Concept: The product concept report is finalized incorporating all the technical details and is reviewed by Head of ENGG. Product Concept QFD Matrix Target Cost Report

ENGG / MMD

ENGG / MKT/ CFT

ENGG

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record DR-I Check List Minutes of Meeting Responsibility CFT / Head of ENGG

Ref. No. 2.8.1 2.8.2

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 targeted levels. 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.

3.0 3.1.1 3.1.2 3.1.3 3.1.4

DFM / DFA Report DR-II Check List Minutes of Meeting

Respective Depts (ENGG / MED / MMD) Leader / Head of ENGG/MFG/ MMD

3.1.5 3.1.6

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record DR-III Check List Responsibility ENGG ENGG

Ref. No. 3.2.1 3.3.1

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 is reviewed 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 as record. 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 using RML symbol. The Design Guidelines are referred while preparing the detailed drawings.

Technical Proposal

3.3.2 3.4 3.4.1 3.4.2 3.4.3 3.4.4

ENGG

Design Guide lines

ENGG

ENGG 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. ENGG FMEA Manual DFMEA Record ENGG

3.4.5

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP 02


Record Responsibility ENGG

Ref. No. 3.4.6

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 design personnel are made aware of the requirements. DFMEA aims at reducing the Occurrence & Improving Detection levels for critical parts.

3.5.0

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 Things Gone 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 Process Design Input Data MED / MFG

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Responsibility MED / MFG

Ref. No.

- 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 whole process. - 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 3.5.1 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 Adequacy Checklist

MED / QA MED / QA MED / QA

QA MED / MFG MED MED

3.5.2 3.5.3 3.5.4

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


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Ref. No.

input requirement is reviewed with Head of MED to avoid ambiguity. 3.6.0 Manufacturing Process Design Outputs: The manufacturing process design outputs are expressed as per the following documents: 3.6.1 3.6.2 3.6.3 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 Process Procedure. 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 Significant Characteristics in Control Plans and Standard Operating Procedures. The designation of process significant characteristics is as per RML symbol. Floor Plan Layout Process Flow Charts FMEA Manual Manufactu ring Process Procedure SOP MED 3.6.6 MED MED PFEMA Record MED

3.6.4

QA /MFG / MED

3.6.5

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Responsibility QA/MKT/ MMD MED/ QA / MFG QA/ MED /MFG QA/MED/MFG/ CFT Infrastruct ure Provisioni ng Procedure

Ref. No. 3.6.7 3.6.8 3.6.9 3.7.1 3.7.2

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 manufacturing process. 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 to subcontractors 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 designed by MED and subcontracted outside.

Packaging Specificati on

DR Check List IV

4.0 4.1

New Tooling Inspection Report MED New Gauge Insp. Report

4.1.1

QA Page No: 11 / 20 Revision No: 3 Issue No : 3 Date : NOV 07 Date : NOV 07


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Ref. No. 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. The number 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 technical inputs 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.

Prototype Plan

MED

MED

Sample Insp. Report

QA

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Ref. No. 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 Design Verification:

The Design Verification & Validation Plan is prepared. The test are derived from Customer Test / Engineering Specification 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 captured by 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

ENGG

Test Report Reliability Test and MTTR Repors Design Validation Reports

ENGG ENGG

ENGG ENGG

4.4.2

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Validation Reports Customer Responsibility

Ref. No.

to provide vehicle for fitment & field Testing. Such Tests can be carried out by customer or jointly by RML before launching the product. 4.4.4 If the validation is carried out at customers end ENGG will co-ordinate with customer and all validation test reports 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 reviewed using 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.

ENGG CFT / Leader

4.4.5 4.4.6 4.5 4.5.1 4.5.2

DR Check List V

ENGG. Samples to Customer for Fitment and Approval: QA 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 and copy of reports are forwarded to customer along with samples. INITIAL PRODUCTION PHASE: . 5.1 5.1.1 Review of Process Control Documents: The Process Flow Charts, Control Plans, Standard Operating Procedures and Packaging Specification are Dimensional Reports

5.0

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Responsibility Respective Depts Data on Mfg. Process Outputs

Ref. No.

reviewed for any updation based on the feedback / results of activities carried out in previous phases. 5.2 5.2.1 Validation of Manufacturing Process outputs: During the initial / pilot production, data are captured and evaluated for the following parameters. 5.2.2 5.2.3 5.2.4 5.2.5 Measurement System analysis Process Capability Indices (Cp and Cpk for Special Characteristics) Productivity Levels Rejection / Rework levels and Manufacturing Cost Uptime of Critical Machines / Equipments Tool Life of Critical Tools

QA/MED/MFG

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 parameter deviates from targets, necessary corrective and preventive actions will 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.

Corrective Action Report

MED / QA / MFG QA / ENGG QA

Part Submission Warrant

QA

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Ref. No. 5.2.6 5.2.7 5.3.1 5.3.2 6.0 6.1

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 samples are 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 of MMD/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. NewProcess Performance Report Mat. Cost Record DR Check List VII Process Sign-off CFT / Head of ENGG / MED / MFG / MMD / MKT MFG / MED / CFT MMD MMD DR Check List VI CFT Leader / MFG

6.1.1 6.1.2 6.2 6.3

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Ref. No 7.0 7.1 7.1.1 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

PPAP Reference Manual

7.1.2 7.1.3

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: Sl. No. 1 2 3 4 Requirements Part Submission Warrant Sample Product Master Product Design Records QA QA ENGG ENGG Responsibility Submission Requirement Submitted Retained Yes Yes No Yes Yes No Yes Yes

Executive MKTG

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QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


Record Responsibility

Ref. No Sl. No. 5 6 7 8 9 10 11 12 13 14 15

Requirements Change Records Design FMEA Process FMEA Process Flow Charts Control Plan Dimensional Report Test Results (Material, Performance & Durability Test Reports) Preliminary Process Capability Studies Measurement System Analysis Study Checking Aids Laboratory Scope

Responsibility ENGG ENGG / CFT MED MED QA QA QA / ENGG QA QA QA QA

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PRODUCT DEVELOPMENT PROCESS


ACTIVITY Document

QUALITY SYSTEM PROCEDURE MANUAL Ref: QSP - 02


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 and approved. 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 part approval process is effected. During the Submission of the samples, the followings records / documents are received from supplier. Buyer / STA Buyer / STA / Engineer SQA List of PPAP File QA PPAP File QA QA PPAP File PSW QA QA

Engineer SQA Page No: 19 / 20 Revision No: 3 Issue No : 3 Date : NOV 07 Date : NOV 07
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Ref. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 7.2.3

Process Flow Charts Design FMEA (Proprietary Designs) Process FMEA Control Plan Standard Operating Procedures Design Record Engineering Change Documents Dimensional Results Material Test Result Sample Product Process Capability Studies Measurement System Analysis (Optional) Checking Aids Part Submission Warrant and Records of Compliance of RML Specific Requirements Supplier PPAP Records Executive SQA

The above records / documents are reviewed, approved and maintained.

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