AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.

: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 1 of 9

ASWINI GROUP

REVISION CONTROL

The Revision Control format given below is used for updating revisions in the Procedures and issued along with the
document.

DETAILS
REV. REV. ISSUE
TOTAL NO. REVIEW DATE
NO. DATE DESCRIPTION OF REVIEW NO.
OF PAGES PAGE NO.

0.0 04.09.13 6 All New release 1.0 04.09.13

0.0 04.01.17 6 All In line with IATF Requirements 2.0 04.01.17

1.0 07.01.19 8 All Input-process-output introduced 2.0 07.01.19

 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 2 of 9

ASWINI GROUP

EFFECTIVE
NAME SIGNATURE DATE
DATE
PREPARD &
RELEASED 07.01.2019
BY
07.01.2019
APPROVED H.GIRI
07.01.2019
BY (CEO)

1.0 Purpose

To establish, implement and manage a process for standardization of work, production planning, execution and process
monitoring and control online.

2.0 Scope

This Process is applicable to all products manufacturing within ASW, including outsourced processes.

3.0 Reference

IATF 16949:2016 Clause 8.5.1 (8.5.1.1, 8.5.1.2, 8.5.1.3 & 8.5.1.7), 8.5.6 (8.5.6.1, 8.5.6.1.1) and 9.1.1.1

4.0 Definition / Abbreviations

WI - Work instruction, SPC - Statistical process control, SOP – Standard Operating Procedure, RM – Raw Material, FG –
Finished Goods, QA – Quality Assurance, UCL – Upper Control Limit, LCL – Lower Control Limit, CP – Process Capability,
Cpk – Process Capability index, USL – Upper Specification Limit, LSL – Lower Specification Limit, UOM – Unit of
Measurement.

5.0 Responsibility

HOD: Production Head

Team: Production, Quality & Stores

6.0 Input – Process – Output

Input Process (Activity) Output

Process Flow, Control Plan & SOP, Work Instructions &

Operation Standardization
PFMEA Visual Standards
Monthly Production Plan, RM
Production Capacity, Customer
Requirement Plan, Weekly
Schedule, RM Stock and FG Production Planning & Control
Production Plan and Daily
Stock
Machine Loading Plan
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 3 of 9

ASWINI GROUP

Monthly Production Plan, Finished Product, Daily

Weekly Production Plan and
Daily Machine Loading Plan &
Resources
Production Run
Production Report and In-
Production Run
process Inspection Report –
Operator Observation
Defect Prevention and Variation
Statistical Process Control
Reduction

Production Run Temporary Change of Process Controls Process Deviation Report

 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 4 of 9

ASWINI GROUP

6.1 Work Instruction

Identifies the processes needed for the product and prepare Standard Operating Procedure (SOP). The process instructions
for the Standard Operating Procedure should be posted and should include set-up parameters such as machine speeds,
feeds, cycle time, etc., setting procedures, safety instructions, operator responsibilities, part application, process control
methods, in-house and customer complaints. It should be accessible to the operators and supervisors. These instructions
should be developed from the following inputs;

 PFMEAs
 Control plan(s)
 Process flow chart
 Floor plan layout
 Characteristics matrix
 Handling requirements
 Customer inputs
 Past experience
 Engineering drawings, performance specifications, material specifications, visual standards and industry
standards.

6.2 Production Planning & Control

Input Production Planning - Activity Output

Production Capacity, Prepare monthly production plan based on Monthly production

Customer monthly the customer schedule, enquiry and oral order plan & RM
schedule, RM stock received from customer relation requirement plan.
and FG stock

Communicate to purchase/quality and

maintenance departments.

A
Monthly production Prepare Weekly machine loading plan for Weekly machine
plan & RM stock upcoming week. loading plan.

Weekly machine Daily machine loading

Prepare daily machine loading plan &
loading plan. plan
communicate to shop floor.

Communicate to production supervisor,

setters and operators

Monitor and update the actual production in

` the daily production report

Monthly production
plan, Weekly machine Review production plan every day with Changes of production
loading plan & Daily Production Head planning A
machine loading plan

Review production plan every month with

MD
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 5 of 9

ASWINI GROUP

6.3 Production Run

Input Production Execution - Activity Output

Daily machine loading Organize manpower as per daily machine

plan and resources as loading plan and allocate job
necessary (plant layout)

Daily machine loading Job setup / job change / run the machine as
plan / SOP per the daily machine loading plan

SOP Inspect the setup samples and get approval First off Inspection
from line inspector.

No
Is approved by line Adjust / correct setting
inspector? and take new samples

Yes

Monitor production & inspect as per operator

SOP instruction plan mentioned in the SOP and
record the results in the operator observation
page of the in-process inspection report

No Stop Production and

Yes
Is the results are as per adjust / correct setting
specifications? And refer corrective
action procedure

Record the actual shift production in the daily

production report and machine loading plan and file it.

Record all the down times in the daily production

report and file it.
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 6 of 9

ASWINI GROUP

6.4 Statistical Process Control

Input Statistical Process Control - Activity Output

Safety and Significant, Open new X bar R control chart for safety
Characteristics and significant characteristics mentioned in
mentioned in the SOP the SOP by the symbol <SC> and <CC>

Draw the control limits from the previous

control chart

Select 5 consecutive samples measure and

record the values in the X bar R control chart
up to job change. Frequency – 1 Hour.

Calculate average, range and plot the value in

the X bar R control chart
Average = Sum of the subgroup value
divided by 5
Range = Maximum – Minimum value of
the subgroup.

Yes No Stop Production and

Is the plotted points are adjust / correct setting
with in the control and refer corrective
limits? action procedure
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 7 of 9

ASWINI GROUP

Input Statistical Process Control - Activity Output

Yes
Collect and file control chart after job change
and continue with the same chart whenever
the part is running.

Once the chart completed calculate control

limit, Cp and Cpk from the following
formulas.

Constants for sub group No. 5

A2 = 0.577, d2 = 2.326, D3 = 0, D4 = 2.114

X double bar (X dbar) = Average of X bar

R bar = Average of R
X bar Control limits,
UCL = Xbbar + A2*Rbar
LCL = Xbbar – A2*Rbar

R bar Control Limit

UCL = D4*Rbar
LCL = D3*Rbar

Sigma (S) = Rbar / d2

CP = Total Tolerance / (6*S)

Cpk = Min{( USL – Xdbar)/( 3*S), (Xdbar – LSL)/(3*S)

Are the Cp & Cpk value No Take CAPA to

>= 1.67 improve the process

Yes

Draw a new control limit and continue to

monitor the process again.
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 8 of 9

ASWINI GROUP

6.5 Temporary Change of Process Controls

Input Temporary Change Process Control - Activity Output

Temporary change in process Identify change/deviation

controls (operator, machine, against control plan in ongoing
tools, gauge, process control production process controls
parameters, location, etc.)

Stop the production and restore

Process Flow, PFMEA, Control Analyze the the process controls (as per the
Plan, CSR & Customer Risk control plan)
Feedback/Complaints (PFMEA)?

Prepare work instruction,

Alternate process controls
inspection/test, identification
(4Ms), inspection, test, etc.
and traceability requirements
methods/techniques

Prepare process deviation permit

with all necessary supporting
details

QA and/or Stop the production and restore

Customer the process controls (as per the
Approval? control plan)

Run the production process with

deviation permit and as per the
plan and instructions

Conduct inspection, testing,

verification, audit, etc. as per the
plan & instructions

QA and/or Stop the production, and recall

Customer the products in all stages, and
Approval? treat with control of NC product

Identify the lot with suitable Control on process deviation

means for easy identification and traceability at all
and traceability stages/Process Deviation Report
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-13
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 07.01.2019

PRODUCTION CONTROL Page 9 of 9

ASWINI GROUP

7.0 Further Reference

7.1 Documented Information

As per List of Documented Information to be maintained – RD-ASW-01
As per List of Documented Information to be retained – RD-ASW-02