Ref.

No:

ABP/P2/05 1 of 4 0 02.05.2003

Company ABC

CORRECTIVE ACTION

Page No.: Rev.No.: Rev.Date:

1 PURPOSE To define the process of corrective action and establish, implement and continually improve the effectiveness. 2 SCOPE This process covers for taking corrective action for all potential non-conformance of Incoming materials rejections In-house rejections, Customer complaints, Internal Audits at TVS Autolec Limited - Plant 2 3 WORK INSTRUCTIONS Nil 4 DOCUMENTS GENERATED Document Name. Ref . No: Thing Gone Wrong (TGW) -------5 RECORDS Record Name Quality Problem & counter measure Report (QPCR) Corrective Action Report

Format No. Record Indexing Storage No. Method Location TAF/P2/5.1 R5.1 Date Wise Met.Lab

Maintained by Retention Period. Head-QA 12 Months

Disposition Method Destroyed

TAF/P2/16.2 R5.2

Date Wise Met.Lab

Head-QA

12 Months

Destroyed

PREPARED BY:

APPROVED BY:

Ref. No:

ABP/P2/05 2 of 4 0 02.05.2003

Company ABC

CORRECTIVE ACTION

Page No.: Rev.No.: Rev.Date:

6 BMS Control plan Quantifier Aggregation Level Source of Data Collection Bad work scrap note Compilation Frequency Monthly Responsibility Process Review Team Process Review Team Process Review Team Control Method Trend chart Trend / Paynter/ Pareto chart Paynter chart

In-House Rejection trend Overall Customer Rejection trend Customer Wise Corrective action Initiated Overall with in stipulated time No of repetitive complaints / Inhouse rejections 7 Interelated process Control of documents - ABP/P2/01 Internal Audit - ABP/P2/03 Customer complaint analysis - ABP/P2/16

From the customer reports Monthly

corrective action Report Monthly

Overall

Bad work scrap note, customer reports

Monthly

Trend / Paynter Process Review chart/ Pareto chart Team

PREPARED BY:

APPROVED BY:

ABP/P2/05 1 of 4 0 02.05.2003

otential non-conformance of Incoming materials rejections In-house rejections,

ABP/P2/05 2 of 4 0 02.05.2003

Trend chart Trend / Paynter/ Pareto chart Paynter chart Trend / Paynter chart/ Pareto chart

Company ABC Limited ISO/TS 16949 Inputs / Trigger

Internal Rejection, Customer complaints, Rejected products,

Corrective Action
Doc. No : Job Position Start BP/05 Activity Est.Date : 02.05.2003

Rev No. Rev Date Page Document Generated

0 3 of 4 Reference/ Instruction

Control/ Criteria

Incoming rejection Incoming Inspection Report

In House rejection

Customer

Internal audit

Process Performance

Head QA

Identify potential non-conformance

Raise QPCR and sent to supplier

(P4) Inspection Incharge Receipt Inspection

Refer Analysis of Customer Complaints

B
Refer Internal Audit

QPCR

Head QA

Verify the corrective action initiated by

Not accepted

Call supplier for discussion

Accepted

Head QA

Supplier audit to be

Obtain modified
Review the related documents

Head QA

No Change

Change
Refer control of documents ABP/P2/01
End

Prepared by:

Approved by:
A

Material Minimum Monthly *Yearly Supplier PM Delivery Stock Plan

Stores Equipment Purchase *Yearly Abnormality Raw Preventive *1st Bin Purchase Power Delivery MRIR Inter Card Visual Material office Building Note.

Stores Equipment Purchase *Yearly Abnormality Raw Preventive *1st Bin Purchase Power Delivery MRIR Inter Card Visual Material office Building Note.

Stores Equipment Purchase *Yearly Abnormality Raw Preventive *1st Bin Purchase Power Delivery MRIR Inter Card Visual Material office Building Note. observation &

Company ABC Limited ISO/TS 16949 Inputs / Trigger

Material Minimum Monthly *Yearly Supplier PM Delivery Stock PlanABC Company

Corrective Action
Doc. No : Job Position BP/05 Activity
A

Est.Date :

02.05.2003

Limited ISO/TS 16949 Inputs / Trigger

Corrective Action
Doc. No : Job Position BP/05 Activity Est.Date : 02.05.2003

Rev No. Rev Date Page Document Generated Stores Purchase Equipment *Yearly Abnormality Raw Preventive *1st Bin Purchase Power Delivery MRIR Inter Card Visual Material office Building Note. Rev No. Rev Date Page Document Generated

0 3 of 4 Reference/ Instruction Stores Equipment Purchase *Yearly Abnormality Raw Preventive *1st Bin Purchase Power Delivery MRIR Inter Card Visual Material office Building 0 Note. 4of 4 Reference/ Instruction

Control/ Criteria
Stores Equipment Purchase *Yearly Abnormality Raw Preventive *1st Bin Purchase Power Delivery MRIR Inter Card Visual Material office Building Note. observation &

Control/ Criteria

Internal Rejection reports, Concessional Approval Note Product Audit Report, Process Audit Report, Layout Inspection & Functional Testing Reports

Review the required documents

CFT
Identify the potential Nonconformance & Look in to the PFMEA for Failure Mode or Effects

CFT
Identify the cause for the problem in FMEA

Fault tree analysis

Use DOE to ensure wether all causes are captured

PFD, PFMEA, DFMEA, Product Structure Tree

CFT

If cause already there, analyze, why the Nonconformance happen

Cause is not there Find the cause for the problem.

Corrective Action Report

1. Team should have process and product experts 2. Use DOE and capture exact cause(s) 3. Do reverse calculation and fix target date for each step for corrective action plan 4. Assign clear responsibility for implementing action and ensure responsibilities are understood.

CFT Cause is there Concerned

Review the corrective action
Initiate the corrective action Review the Changerelated documents 8D report

No Change

Process Flow Diagram, PFMEA,

Corrective Action Report

Head - QA
Monitor the effectiveness of Ok

Change
Refer control of documents ABP/P2/01

8D report Corrective Action Report

Not ok

E N D

No repeat complaints within 3 months of taking actions

8D report

CFT
P5

OK

Prepared by:

Approved by:

Company ABC Limited

Corrective Action

Rev No.

Company ABC Limited ISO/TS 16949 Inputs / Trigger Company ABC Limited ISO/TS 16949 Inputs / Trigger

Corrective Action
Doc. No : Job Position Doc. No : Job Position
P4

BP/05 Activity

Est.Date :

02.05.2003

Corrective Action
BP/05 Activity Est.Date : 02.05.2003

Rev No. Rev Date Page Document Generated Rev Date Page Document Generated

0 3 of 4 Reference/ Instruction

Control/ Criteria 5of 5

Reference/ Instruction

Control/ Criteria

PFD, PFMEA, DFMEA, Product Structure Tree

Is Horizantal Deployment Possible?

NO

Similar Part families, Similar components / Assys, Similar processes and similar nature of problems to be considered for horizontal deployment

YES
Implement the corrective aciton horizontally and see the effectiveness 8D report

Update TGW Database

Things gone wrong report (TGW) PFMEA, PFD, DFMEA, Control Plan, WI's, Process Sheets Updated

END

B Business processes performance trends and targets from monthly reviews

Management Representative Representative Process Champions

Identify processes where target not achieved

Identify root cause for not achieving process performance targets P6

D From P6

Company ABC Limited ISO/TS 16949 Inputs / Trigger

Corrective Action
Doc. No : Job Position BP/05 Activity Est.Date : 02.05.2003

Rev No. Rev Date Page Document Generated

0 6of 6 Reference/ Instruction Control/ Criteria

Company ABC Limited ISO/TS 16949 Inputs / Trigger

Corrective Action
Doc. No : Job Position BP/05 Activity Est.Date : 02.05.2003

Rev No. Rev Date Page Document Generated

0 3 of 4 Reference/ Instruction

Control/ Criteria

P6

Process Champions

Process Champions

Plan and initiate action on the activity that affects achievement of process performance targets

Action Plan with target date for each step Monitor with in 3 months of implementaion

Process Performance Management trend charts after Representative implementation with target

Management Representative

Monitor the effecive of action taken

Effective / Ineffective?

Not effective
D (P5)

Performance target achieved / exceeded

Effective

Update business process documents and distribute as per the document control procedure

Abnormality observation &

Abnormality observation &

Use DOE to ensure wether all

1. Team should have process and product experts 2. Use DOE and capture exact cause(s) 3. Do reverse calculation and fix target date for each

4. Assign clear responsibility for implementing action and ensure responsibilities are understood.

Similar Part families, Similar components / Assys, Similar processes and similar nature

Monitor with in 3 months