Rev: Document #

Symphony Limited 00 FO-XX-XX-XX

Rev Date Page #

Vendor Process Audit Check Sheet 00-00-0000 01
Plant Name Marathan Motors, Faridabad Audit Report No:-
Plant Address Audit Date:- 10/12/2019
Divisions audited Symphony Limited Auditor Name:- Rakesh chaudhary
Models @ the plant Auditee Names:- Umesh, Abhishek

Judgment Criteria Tot Score B/W Grade Score count

Not fulfilled Not suitable for production 0 to 192 R 0 - Worst, 1 - Poor

Partially fulfilled Vendor Suited for Production but needs Some urgent improvements 193 - 576 Y 2 - Satisfactory 3 -Good

4 - Excellent,
Fulfilled Vendor Best Suited for Production 577 - 960 G 5 - Outstanding
Avg. Score 2.4
Total Score 456/960
% Score 47.50%
Signature (Name) Judgment Partially fulfilled
& Date

Score criteria for Plant evaluation

0 Facility or process does not exist 3 Good, but there is a scope of improvement
1 Facility / Process Available but Not followed 4 Fulfils symphony requirements
Facility / Process followed but not as required 5 Symphony plus own process controlled

Process check sheets

observation values Actual Score for points

Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Required Actual Yes No 0 1 2 3 4 5

supervisor must have data for coil manufacturing Yes 5 5

number of turns in coil machine is as per specification
sheet? Yes 5 5

Wire gauge as per spec sheet? 28.3 28.3 Yes 3 3

SUpervisor can not varify as SWG
Coil Supervisor has documents to varify wire gaudge? No 0 0 to mm data was NA with him.

coil resistance is as per specs? 15.8 14 0 0 Actual Coil Resitance & weight
Data not as per specification
sheet. Update the specification
sheet WRT Actual weight and
Weight of coil as per specs? 0 0 Resistance.

Number of turns in coils checked with winding sheet, Yes 2 2 Record of measured data in past
every time when motor model changes? missing.
winding coil should be
OP-10 Coil making made as per specificification Do worker is doing its job sincerely? Yes 3 3
sheet
formars have sharp edges? No 4 4

Keep Latest Reports handy during

ST-1 IQC Report of aluminium wire No 0 0 next Audit. (will ask for TC of any
reel in Storage)

Calibration certificates No 0 0

A check point must be added to check coil resistance

and weight for each type of motor for each machine so
that any problem in coil can be detected before No 0 0
insertion.

A proper documented data for coils that are cheked for No 0 0

resistance, Weight and Turns.

Work instruction No 0 0

After making coil, coil must Coil storage height must be up to fixed limits only. Yes 4 4
OP-20 Coil Storage be stored in bins
Coils must be properly adjusted in bins. Yes 4 4
Bins must have marking for coil identifications Yes 4 4
coils needs to be stored
OP-30 Coil Handling properly in bins Bins must be properly handled from one station to
another. Yes 4 4
 Process check sheets

observation values Actual Score for points

Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Required Actual Yes No 0 1 2 3 4 5

Visually check the process. Yes 3 3

Slot paper is inserted in Check length of slot paper wrt to specs No 1 1
Slot paper insertion No spec Available for Paper
ST-2 OP-40 in stator stack stator stack using slot paper dimensins & width.
insertion machines check thickness of slot paper with vernier wrt specs No 1 1
Work instructions No 0 0
 Process check sheets

observation values Actual Score for points

Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Required Actual Yes No 0 1 2 3 4 5

sharp edges of coil insertion tool No 4 4

proper insertion of slot top paper Yes 4 4
Coil insertion in stator
Coil insertion in
ST-03 OP-50 stator stacks using coils insertion check for aluminium wire enamel damage No 3 3
machine
Work instructions No 0 0
Take any slot top paper and check for length and No spec Available for Paper
Yes 1 1
thickness of paper dimensins & width.

check BDV of phase separator paper No 0 0

Phase separator should be
placed between two coils.
ST-04 OP - 60 coil separator Work instructions No 0 0
insertion

It must properly separate Length of thickness of paper must be specified and Yes 1 1 No spec Available for Paper
two coils from each other paper must be as per that spec dimensins & width.

Height of over hang after shaping (mm) Yes 3 3

OD of over hang after shaping (mm) Yes 3 3
ID of over hang after shaping (mm) Yes 3 3
formars, pressing tools are
ST-05 OP - 70 Coil shaping used to give proper shape Visual check - No enamel damage Yes 3 3 A spec must be prepaed for
winding over hang dimensions.
to over hang coils
Work Instruction No 0 0
Visual check - No slot paper damage Yes 4 4
Overall process Satisfactory..? Yes 3 3
Give stress on lugs, lugs should not loose contact No 4 4
Lug crimping with coil wire work instructions No 0 0
ST-06 OP-80 Lug crimping using lug crimping tool
Overall process Satisfactory..? Yes 4 4

Glass Tape (insulation tape) Check BDV of glass tape Dry & wet condition No 0 0
must be at least 3 layers on
joint/lugs. Work instructions No 0 0
Lead wire fitment
ST-07 OP-90 and insulation on
joints open any processed joint and verify number of layers of 3 3-4 Yes 5 5
No portion of lugs should be glass tape
left uncovered. make a fixture kinf of arrangement
Verify length of lead wires Yes 3 3 to 100% check lead wire
arrangement
Lacing should cover whole
over hang of winding with check for sharp edge of needle No 4 4
lacing thread
lacing strength made by machine YEs 4 4
Lacing should not be mush
ST-08 OP-100 Lacing
tight or much loose.
Work instruction No 0 0

Appearance of lacing should Finished product satisfactory..? Yes 4 4

look proper.
Insulation paper should cover complete overhang Yes 3 3
Overhang Insulation sticking of insulation paper
ST-09 OP-110 on over hang and over hang Manually shaping should be done with tool and trained
and shaping shaping Yes 3 3
man power must be deployed.
check for list of test performed during testing Yes 3 3 DOcumented List of test NA
HV test voltage is as per requirements Yes 3 3
Calibration certificates No 0 0
Testing of finished winding
ST-10 OP-120 Winding testing on automatic winding Skilled man power YEs 3 3
testing
Work Instruction No 0 0
A recoed muist be maintained for
Quarantine material scrap / rework plan No 1 1 amount of motors found faulty
Contingency plan if winding fails in test No 1 1 and reqork / rejection plan for
those motors
Transport to Varnish Tested OK windings to be Check for process.. Satisfactory..? Yes 4 4
ST-10 OP-130 Transferred to varnishing
& baking area and backing area any chance of winding damage during transport..? No 3 3
Check viscosity of varnish.. Yes 4 4
check temperature of oven Yes 4 4
Varnishing and backing of
Varnishing and winging in Oven at duration of complete baking cycle Yes 3 3
ST-11 OP-140 baking controlled temperature and
for define time Work Instruction No 0 0
 Process check sheets
Varnishing and backing of
Varnishing and winging in Oven at observation values Actual Score for points
Station
ST-11 opeartion
OP-140
Number No Operation
bakingName operation
controlled Descriptionand check points / specifications
temperature R-Y-G Status Observation / Remark
for define time Required Actual Yes No 0 1 2 3 4 5
hardness of winding overhang after baking (over hang Yes 4 4
should be solid)
check IQC of turned rotor Yes 3 3
Rotor OD as per spec Yes 2 2 Spec NA
Rotor Surface finish satisfactory..?? Yes 3 3

Rotor Turning / Rotor OD turning as per

ST-12 OP-150 machining requirement to maintain air
gap
 Process check sheets

observation values Actual Score for points

Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Required Actual Yes No 0 1 2 3 4 5

Rotor Turning / Rotor OD turning as per Rotor testing sampling plan No 0 0

ST-12 OP-150 requirement to maintain air
machining gap Work instruction for ROtor testing No 0 0
Documentation of Rotor testing record No 0 0
Rotor Testing Facilities Yes 2 2
Rotor Slot visible Yes 3 3

check density of lacquering - ask for specifications Yes 2 2 Specs NA

lacquering should cover lacquering is covering complete surface of rotor Yes 3 3

ST-13 OP-160 Lacquering on rotor completer surface of rotor. Work instructions No 0 0
layer of lacquer should be smooth and should not make
any spots on rotor surface. Yes 3 3

Rotor Pressing on shaft with Check Rotor Pressing Process Yes 3 3

hand press.
100% inspection for rotor knurling is done..?? Yes 4 4
ST-14 OP-170 Rotor Pressing in Fixtures used to maintain Rotor Pressing Distance..
shaft Rotor should pressed No 2 2
completely up to rotor Calibrated..?
resting point on surface. Work instructions No 0 0
Check fixture height as per spec.. Yes 3 3 Spec Na.
Bearing Pressing on shaft
using hand press Bearing TC / IQC report No 1 1 pl keep bearing TC ,IQC ready.

Measure Bearing B2B distance after bearing pressing No 1 1

ST-15 OP-180 Bearing pressing
Must maintain B2B distance Work instructions No 0 0

Bearing Noise & bearing jam is checked manually? 100% Yes 4 4

Rotor must be stored in defined trolley Yes 4 4

Storage of ready Ready Rotor Storage after
ST-16 OP-190 rotor bearing pressing Rotor must be in verticle position only Yes 4 4
Check any rotor for run out - on bearing support Yes 4 4
check dimensions of LE & OLE cover Yes 3 3
do paint scratch test on LE & OLE cover Yes 3 3
adhesive test of paint on LE & OLE cover Yes 3 3
Sampling Plan of cover testing No 0 0
Cover Inspection report as per samplin plan No 0 0
Work instruction for Cover check No 0 0
check for lead orientation on LE cover Yes 3 3
Check Grommet Dimensions Yes 3 3
Sampling Plan of Grommet testing No 0 0
Material received Sub assembly material must Hardness / softness of grommet material Yes 3 3
ST-17 OP-200 from Sub assembly be as per defined
Section & Store specifications IQC report as per sampling plan of bush No 0 0
Rust on bush No 0 0
Bush alignment Yes 3 3
Capacitor as per specs Yes 3 3
Case bolt length as per specs Yes 3 3
TC of case bolt material. No 0 0

IQC of case bolt. No 0 0 No any doc. available for IQC of

case bolts.

Proper identification on stator stack Yes 2 2

Mixing of wound stator with other models No 3 3
Length of case bolt as specified Yes 1 1
Mixing of hardware No 3 3

ST-17 OP-210 Hardware insertion Hardware needs to be as Rust nuts, bolts and washer No 3 3
per specifications
 Process check sheets

observation values Actual Score for points

Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Hardware needs to be as Required Actual Yes No 0 1 2 3 4 5
ST-17 OP-210 Hardware insertion per specifications
Work instructions No 0 0

Hardware material TC No 0 0 keep TC of Hardare Material (case

bolts) ready.
 Process check sheets

observation values Actual Score for points

Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Required Actual Yes No 0 1 2 3 4 5
joint of LE cover and stator should not be loose or Yes 3 3
extreme tight
LE cover over size or under size No 3 3
Insert LE cover in LE cover should be inserted Lead orientation as required Yes 3 3
ST-18 OP-220 stator lead properly in stator leads
Work instructions No 0 0
Grommet should be fixed properly with lead wire Yes 3 3
Grommet should not come out when stressed Yes 3 3
Soldering pot must be properly heated Yes 4 4
Capacitor leads must be properly soldered Yes 3 3

soldering capacitor leads No loose soldering Yes 3 3

ST-19 OP-230 Insert capacitor cap
& terminal soldering with capacitor lead wire and No burning lead shield burning mark Yes 3 3
capacitor cap fitting
Work instructions No 0 0
Capacitor cap must be fitted with mallet and should not
open easily Yes 3 3

Rotor - Bearing bearing should not be too loose or too tight when
OP-240 insertion in LE cover Insert Rotor in LE cover inserted in bearing housing Yes 4 4

ST-20 Stack of Rotor and stator must be on same level. Yes 4 4

Check Rotor
OP-250 Matching Check Rotor Matching Work instructions No 0 0
height of rotor and stator stack must match. Yes 4 4
OLE cover should not fit too loose or tight. Yes 4 4

Fit OLE cover on Stack using It should sit properly on Stack surface Yes 4 4
ST-21 OP-260 OLE cover fitment.
mallet Work instructions No 0 0
Fit with malleting. Do not hammer Yes 4 4
Length of case bolt as per spec 0
Tighting of bolts Yes 2 2 spec NA
OP-270 Case bolt insertion Case bolt should be fitted Motor should not jam after case bolt fitting Yes 3 3
and tightened.
Work instructions No 0 0
Overall process Satisfactory..? Yes 3 3

OP-280 Nut insertion Nut needs to be fitted with Use torque wrench to measure nut opening torque No 0 0 Torque wrentch with meter needs
proper tighting torque to be procured.
ST-22

OP-290 Nut Tightening Nut Tightening tighting torque must be higher then specified value Yes 2 4 6

Motor should rotate free with hand Yes 4 4

No vibration should present Yes 4 4
After completing motor
OP-300 Motor Free run assembly rotate motor with No Noise should present Yes 4 4
hand
Work instructions No 0 0
No feel of touching should present Yes 4 4

List of routine test with allowable Limits must be present No 0 0

Calibration certificates of instruments No 0 0

Actions after motor failed in test Yes 4 4
Proper document for data storage of test results No 0 0
available?
Skilled workers..? Yes 3 3
Checking for no load power Yes 4 4
Checking for no load current Yes 4 4
Checking for no load LVS Yes 4 4
ST-23 OP-310 1st stage inspection Motor must be thoroughly
inspected Checking for no load run for all speeds Yes 4 4
Checking for Locked Rotor test Yes 4 4
Check for Noise Yes 4 4
 Motor must be thoroughly Process check sheets
ST-23 OP-310 1st stage inspection inspected
observation values Actual Score for points
Station opeartion
Number No Operation Name operation Description check points / specifications R-Y-G Status Observation / Remark
Required Actual Yes No 0 1 2 3 4 5

Check for Vibration Yes 4 4

Check for Rotor touching Noise Yes 4 4
Check for humming Noise Yes 4 4
check for direction of rotation Yes 4 4
Lead location position change Yes 4 4
Motor High voltage fail Yes 4 4
No air hole present in tape after sticking on joints No 2 2
Apply water Apply water resistance tap Work instructions
resistance tap on No 0 0
ST-24 OP-320 joints of stamping on joints of stamping and
cover Tape should completely cover joints between covers Yes 3 3
and cover and stamping
No hardware should be missing Yes 3 3
ST-25 OP-330 hardware insertion hardware insertion
List of hardware that needs to be fitted for motor No 0 0
Soldering length less or more Yes 2 2
ST-26 OP-340 Lead end soldering Lead end soldering Work instructions No 0 0
solder pot not properly heated Yes 3 3
Sticker must stick properly on cover surface Yes 4 4
Name plates and Data mismatch on stickers No 3 3
sticker Name plates and sticker
ST-27 OP-350 pasting
pasting Interchange of stickers No 3 3
Earthing sticker missing No 3 3
Rotation of motor with hand Yes 4 4
Motor touching noise Yes 4 4
Motor humming noise Yes 4 4
Motor bush noise Yes 4 4
Final inspection of
ST-28 OP-360 Final Inspection completely OK motor Bar code sticker and name plate sticker not match Yes 4 4
properly
Colour code rating sticker Yes 4 4
Name plate and other sticker not as per model Yes 4 4
Wrong Motor Serial Number Yes 4 4
Apply Rust Preventive Oil on
ST-29 OP-370 Rust Preventive Oil Rust Prevention oil should cover complete shaft surface Yes 3 3
motor shaft
Oil should not spill out of shaft surface and should not
go in bearing Yes 3 3

Packing Design as per approval Yes 3 3

ST-30 OP-380 Packing Finished Motor packing
Work instructions No 0 0
Dedicated motor storage area given? Yes 4 4
ST-31 OP-390 Storage Storage of packaged motor storage area is free from humidity Yes 4 4
Work instructions No 0 0
Use of stracker/trolley for loading of motors Yes 3 3

Transport motor to Handling is done by skilled manpower Yes 3 3

ST-32 OP-400 Transport container / loading &
unloading of motors Chances of motor damaged during transport No 0 0
Rework / reject plan if motor gets damaged during Yes 3 3 pl. make documented
transport
456
 Symphony Limited
Vendor Process Audit Check Sheet
Plant Name Marathan Motors, Faridabad
Plant Address
Divisions audited Symphony Limited
Models @ the plant

Judgment Criteria
Not fulfilled Not suitable for production
Partially fulfilled Vendor Suited for Production but needs Some urgent improvements
Fulfilled Vendor Best Suited for Production

Signature (Name)
& Date

Score criteria for Plant evaluation

0 Facility or process does not exist
1 Facility / Process Available but Not followed
Facility / Process followed but not as required

Process check sheets

observation values Actual

Station opeartion Operation Name operation Description check points / specifications
Number No
Required Actual Yes No

supervisor must have data for coil manufacturing Yes

number of turns in coil machine is as per specification Yes
sheet?
Wire gauge as per spec sheet? 28.3 28.3 Yes

Coil Supervisor has documents to varify wire gaudge? No

coil resistance is as per specs? 15.8 14

Weight of coil as per specs? No

 winding coil should be Number of turns in coils checked with winding sheet,
OP-10 Coil making made as per specificification every time when motor model changes? Yes
sheet
Do worker is doing its job sincerely? Yes
formars have sharp edges? No
ST-1
IQC Report of aluminium wire yes

Calibration certificates No
A check point must be added to check coil resistance
and weight for each type of motor for each machine so No
that any problem in coil can be detected before
insertion.

A proper documented data for coils that are cheked for No

resistance, Weight and Turns.
Work instruction No

After making coil, coil must Coil storage height must be up to fixed limits only. Yes
OP-20 Coil Storage be stored in bins
Coils must be properly adjusted in bins. Yes
Bins must have marking for coil identifications Yes
coils needs to be stored
OP-30 Coil Handling Bins must be properly handled from one station to
properly in bins Yes
another.

Visually check the process. Yes

Slot paper is inserted in
Slot paper insertion stator
ST-2 OP-40 stack using slot paper Check length of slot paper wrt to specs No
in stator stack insertion machines
check thickness of slot paper with vernier wrt specs No

Work instructions No

sharp edges of coil insertion tool No

Coil insertion in stator proper insertion of slot top paper Yes

Coil insertion in
ST-03 OP-50 stacks using coils insertion check for aluminium wire enamel damage No
stator machine Work instructions No
Take any slot top paper and check for length and Yes
thickness of paper

Phase separator should be check BDV of phase separator paper No

placed between two coils.
coil separator Work instructions No
ST-04 OP - 60 insertion
 coil separator
ST-04 OP - 60 insertion
It must properly separate Length of thickness of paper must be specified and Yes
two coils from each other paper must be as per that spec

Height of over hang after shaping (mm) Yes

OD of over hang after shaping (mm) Yes
formars, pressing tools are ID of over hang after shaping (mm) Yes
ST-05 OP - 70 Coil shaping used to give proper shape Visual check - No enamel damage Yes
to over hang coils Work Instruction No
Visual check - No slot paper damage Yes
Overall process Satisfactory..? Yes
Give stress on lugs, lugs should not loose contact No
Lug crimping with coil wire
ST-06 OP-80 Lug crimping work instructions No
using lug crimping tool
Overall process Satisfactory..? Yes
Glass Tape (insulation tape) Check BDV of glass tape Dry & wet condition No
must be at least 3 layers on
joint/lugs. Work instructions No
Lead wire fitment open any processed joint and verify number of layers of 3 3-4 Yes
ST-07 OP-90 and insulation on glass tape
joints No portion of lugs should be
left uncovered.
Verify length of lead wires Yes

Lacing should cover whole

over hang of winding with check for sharp edge of needle No
lacing thread
ST-08 OP-100 Lacing
Lacing should not be mush lacing strength made by machine YEs
tight or much loose. Work instruction No
Appearance of lacing should Finished product satisfactory..? Yes
look proper.
sticking of insulation paper Insulation paper should cover complete overhang Yes
Overhang Insulation on
ST-09 OP-110 over hang and over hang Manually shaping should be done with tool and trained
and shaping Yes
shaping man power must be deployed.
check for list of test performed during testing Yes
HV test voltage is as per requirements Yes
Testing of finished winding Calibration certificates No
ST-10 OP-120 Winding testing on automatic winding Skilled man power YEs
testing Work Instruction No
Quarantine material scrap / rework plan No
Contingency plan if winding fails in test No
Tested OK windings to be
Transport to Varnish Transferred to varnishing Check for process.. Satisfactory..? Yes
ST-10 OP-130 & baking area any chance of winding damage during transport..? No
and backing area
 Check viscosity of varnish.. Yes
check temperature of oven Yes
Varnishing and backing of
Varnishing and winging in Oven at duration of complete baking cycle Yes
ST-11 OP-140 baking controlled temperature and Work Instruction No
for define time
hardness of winding overhang after baking (over hang Yes
should be solid)
check IQC of turned rotor Yes
Rotor OD as per spec Yes
Rotor Surface finish satisfactory..?? Yes
Rotor OD turning as per Rotor testing sampling plan No
Rotor Turning /
ST-12 OP-150 requirement to maintain air
machining Work instruction for ROtor testing No
gap
Documentation of Rotor testing record No
Rotor Testing Facilities Yes
Rotor Slot visible Yes

check density of lacquering - ask for specifications Yes

lacquering should cover lacquering is covering complete surface of rotor Yes

ST-13 OP-160 Lacquering on rotor completer surface of rotor. Work instructions No
layer of lacquer should be smooth and should not make Yes
any spots on rotor surface.
Rotor Pressing on shaft with Check Rotor Pressing Process Yes
hand press.
100% inspection for rotor knurling is done..?? Yes
Rotor Pressing in
ST-14 OP-170 Rotor should pressed Fixtures used to maintain Rotor Pressing Distance..
shaft No
completely up to rotor Calibrated..?
resting point on surface. Work instructions No
Check fixture height as per spec.. Yes
Bearing Pressing on shaft Bearing TC / IQC report No
using hand press

Measure Bearing B2B distance after bearing pressing No

ST-15 OP-180 Bearing pressing
Must maintain B2B distance Work instructions No
Bearing Noise & bearing jam is checked manually? Yes
100%
Rotor must be stored in defined trolley Yes
Storage of ready Ready Rotor Storage after Rotor must be in verticle position only
ST-16 OP-190 Yes
rotor bearing pressing
Check any rotor for run out - on bearing support Yes
check dimensions of LE & OLE cover Yes
do paint scratch test on LE & OLE cover Yes
adhesive test of paint on LE & OLE cover Yes
 Sampling Plan of cover testing No
Cover Inspection report as per samplin plan No
Work instruction for Cover check No
check for lead orientation on LE cover Yes
Check Grommet Dimensions Yes
Sampling Plan of Grommet testing No
Material received Sub assembly material must Hardness / softness of grommet material Yes
ST-17 OP-200 from Sub assembly be as per defined
Section & Store specifications IQC report as per sampling plan of bush No
Rust on bush No
Bush alignment Yes
Capacitor as per specs Yes
Case bolt length as per specs Yes
TC of case bolt material. No

IQC of case bolt. No

Proper identification on stator stack Yes

Mixing of wound stator with other models No
Length of case bolt as specified Yes
Mixing of hardware No
Hardware needs to be as Rust nuts, bolts and washer No
ST-17 OP-210 Hardware insertion per specifications Work instructions No

Hardware material TC No

joint of LE cover and stator should not be loose or Yes

extreme tight
LE cover over size or under size No
Insert LE cover in LE cover should be inserted Lead orientation as required
ST-18 OP-220 Yes
stator lead properly in stator leads
Work instructions No
Grommet should be fixed properly with lead wire Yes
Grommet should not come out when stressed Yes
Soldering pot must be properly heated Yes
Capacitor leads must be properly soldered Yes
soldering capacitor leads No loose soldering Yes
Insert capacitor cap with
ST-19 OP-230 capacitor lead wire and No burning lead shield burning mark Yes
& terminal soldering capacitor cap fitting Work instructions No
Capacitor cap must be fitted with mallet and should not Yes
open easily

Rotor - Bearing bearing should not be too loose or too tight when
OP-240 Insert Rotor in LE cover Yes
insertion in LE cover inserted in bearing housing
ST-20
ST-20
Stack of Rotor and stator must be on same level. Yes
Check Rotor
OP-250 Check Rotor Matching Work instructions No
Matching
height of rotor and stator stack must match. Yes
OLE cover should not fit too loose or tight. Yes
on Stack using It should sit properly on Stack surface Yes
ST-21 OP-260 OLE cover fitment. Fit OLE cover
mallet Work instructions No
Fit with malleting. Do not hammer Yes
Length of case bolt as per spec
Tighting of bolts Yes
Case bolt insertion Case bolt should be fitted Motor should not jam after case bolt fitting
OP-270 Yes
and tightened.
Work instructions No
Overall process Satisfactory..? Yes

Nut needs to be fitted with Use torque wrench to measure nut opening torque
OP-280 Nut insertion No
proper tighting torque
ST-22

OP-290 Nut Tightening Nut Tightening tighting torque must be higher then specified value Yes

Motor should rotate free with hand Yes

After completing motor No vibration should present Yes
OP-300 Motor Free run assembly rotate motor with No Noise should present Yes
hand Work instructions No
No feel of touching should present Yes
List of routine test with allowable Limits must be No
present
Calibration certificates of instruments No
Actions after motor failed in test Yes
Proper document for data storage of test results No
available?
Skilled workers..? Yes
Checking for no load power Yes
Checking for no load current Yes
Motor must be thoroughly
ST-23 OP-310 1st stage inspection Checking for no load LVS Yes
inspected
Checking for no load run for all speeds Yes
Checking for Locked Rotor test Yes
Check for Noise Yes
Check for Vibration Yes
Check for Rotor touching Noise Yes
Check for humming Noise Yes
check for direction of rotation Yes
Lead location position change Yes
 Motor High voltage fail Yes
No air hole present in tape after sticking on joints No
Apply water Apply water resistance tap Work instructions No
resistance tap on
ST-24 OP-320 on joints of stamping and
joints of stamping Tape should completely cover joints between covers
cover Yes
and cover and stamping
No hardware should be missing Yes
ST-25 OP-330 hardware insertion hardware insertion
List of hardware that needs to be fitted for motor No
Soldering length less or more Yes
ST-26 OP-340 Lead end soldering Lead end soldering Work instructions No
solder pot not properly heated Yes
Sticker must stick properly on cover surface Yes
Name plates and Data mismatch on stickers No
Name plates and sticker
ST-27 OP-350 sticker pasting Interchange of stickers No
pasting
Earthing sticker missing No
Rotation of motor with hand Yes
Motor touching noise Yes
Motor humming noise Yes
Motor bush noise Yes
Final inspection of
ST-28 OP-360 Final Inspection Bar code sticker and name plate sticker not match
completely OK motor Yes
properly
Colour code rating sticker Yes
Name plate and other sticker not as per model Yes
Wrong Motor Serial Number Yes

Rust Preventive Oil Apply Rust Preventive Oil on Rust Prevention oil should cover complete shaft surface
ST-29 OP-370 Yes
motor shaft
Oil should not spill out of shaft surface and should not Yes
go in bearing
Packing Design as per approval Yes
ST-30 OP-380 Packing Finished Motor packing
Work instructions No
Dedicated motor storage area given? Yes
ST-31 OP-390 Storage Storage of packaged motor storage area is free from humidity Yes
Work instructions No
Use of stracker/trolley for loading of motors Yes
Transport motor to Handling is done by skilled manpower Yes
ST-32 OP-400 Transport container / loading & Chances of motor damaged during transport No
unloading of motors
Rework / reject plan if motor gets damaged during Yes
transport
 Rev: Document #
00 FO-XX-XX-XX
Rev Date Page #
00-00-0000 01
Audit Report No:-
Audit Date:- 24/12/2020
Auditor Name:- H.s.varma
Auditee Names:- Umesh, Abhishek

Tot Score B/W Grade Score count

0 to 192 R 0 - Worst, 1 - Poor
193 - 576 Y 2 - Satisfactory 3 -Good
4 - Excellent,
577 - 960 G
5 - Outstanding
Avg. Score 2.4
Total Score 464/960 464 / 960
% Score 48.33%
Judgment Partially fulfilled

3 Good, but there is a scope of improvement

4 Fulfils symphony requirements
5 Symphony plus own process controlled

Score for points

R-Y-G
Status Observation / Remark
0 1 2 3 4 5

5 5 1

5 5 2

5 5 3
SUpervisor can not varify as SWG
0 0 to mm data was NA with him. 4

0 2 2 Actual Coil Resitance not mach 5

operator not traned & weight ok
but No any racord. Training
0 0 requried. 6
 Record of measured data in past
2 2 7
missing.
3 3 Operator not awer 8
4 4 9
Keep Latest Reports handy during
0 4 4 next Audit. (will ask for TC of any 10
reel in Storage)
0 0 11

0 0 12

0 0 13

0 0 14

4 4 15

4 4 16
4 4 17

4 4 18

3 3 19

1 1 20
No spec Available for Paper
1 1 dimensins & width. Data sheet not 21

0 0 22

4 4 23

4 4 24
3 3 25
0 0 26
No spec Available for Paper
1 1 27
dimensins & width.

0 0 28

0 0 29
 No spec Available for Paper
1 1 30
dimensins & width.

3 3 31
3 3 32
3 3 33
A spec must be prepaed for
3 3 34
winding over hang dimensions.
0 0 35
4 4 36
3 3 37
4 4 38
0 0 39
4 4 40
0 0 41
0 0 42

5 5 43

make a fixture kinf of arrangement

3 3 to 100% check lead wire 44
arrangement

4 4 45

4 4 46
0 0 47

4 4 48

3 3 49

3 3 50

3 3 DOcumented List of test NA 51

3 3 52
0 0 53
3 3 54
0 0 55
A recoed muist be maintained for
1 1 amount of motors found faulty 56
1 1 and reqork / rejection plan for 57
those motors
4 4 58
3 3 59
 4 4 60
4 4 61
3 3 62
0 0 63

4 4 64

3 3 65
2 2 Spec NA 66
3 3 67
0 0 68
0 0 69
0 0 70
2 2 71
3 3 72

2 2 Specs NA 73

3 3 74
0 0 75

3 3 76

3 3 77

4 4 78

2 2 79

0 0 80
3 3 Spec Na. 81

1 1 pl keep bearing TC ,IQC ready. 82

1 1 83

0 0 84

4 4 85

4 4 86
4 4 87
4 4 88
3 3 89
3 3 90
3 3 91
0 0 92
0 0 93
0 0 94
3 3 95
3 3 96
0 0 97
3 3 98
0 0 99
0 0 100
3 3 101
3 3 102
3 3 103
0 0 104
No any doc. available for IQC of
0 0 105
case bolts.
2 2 106
3 3 107
1 1 108
3 3 109
3 3 110
0 0 111
keep TC of Hardare Material (case
0 0 112
bolts) ready.

3 3 113

3 3 114
3 3 115
0 0 116
3 3 117
3 3 118
4 4 119
3 3 120
3 3 121
3 3 122
0 0 123

3 3 124

4 4 125
 4 4 126
0 0 127
4 4 128
4 4 129
4 4 130
0 0 131
4 4 132
0 133
2 2 spec NA 134
3 3 135
0 0 136
3 3 137

Torque wrentch with meter needs

0 0 138
to be procured.

2 4 6 139

4 4 140
4 4 141
4 4 142
0 0 143
4 4 144

0 0 145

0 0 146
4 4 147

0 0 148

3 3 149
4 4 150
4 4 151
4 4 152
4 4 153
4 4 154
4 4 155
4 4 156
4 4 157
4 4 158
4 4 159
4 4 160
 4 4 161
2 2 162
0 0 163

3 3 164

3 3 165
0 0 166
2 2 167
0 0 168
3 3 169
4 4 170
3 3 171
3 3 172
3 3 173
4 4 174
4 4 175
4 4 176
4 4 177

4 4 178

4 4 179
4 4 180
4 4 181

3 3 182

3 3 183

3 3 184
0 0 185
4 4 186
4 4 187
0 0 188
3 3 189
3 3 190
0 0 191

3 3 pl. make documented 192

464 960
960

0 192
193 576
577 960