hm auto bench mark gap analysis report 19.09.08
DESCRIPTION
TRANSCRIPT
![Page 1: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/1.jpg)
1. DATE OF AUDIT : 19 SEP 2008
2. AUDITOR :
HMI: SARAVANAKUMAR
3. IMPROVEMENT PLAN SUBMISSION DATE :
4. SIGNATURE
BENCH MARK GAP ANALYSIS - HM AUTO INDUSTRIES (SL Lumax)
BENCH MARK GAP ANALYSIS - HM AUTO INDUSTRIES (SL Lumax)
HM AUTO SL LUMAX HMI
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SL
NOCategory
Plan
Completed Remaining
Monthly Completion
Trend
Initial Added Total 09/08 10/08 11/08 12/08
1 Material
2 Machine
3 Method
4 Man
5 3C / 5S
Total
IMPROVEMENT STATUS
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BENCHMARK COMPANY H. M Auto Industries
Functional Layout, no back and forth movement
Subsequent operations not linked
0101 FUNCTIONAL LAYOUTArea SHOP FLOOR
Resp Vijayakumar / Magesh
Target Date 15/11/08
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BENCHMARK COMPANY H. M Auto Industries
Painted shop floor with effective 3C/5S activities
3C/5S (Press shop standards
not available)
0202 SHOP FLOOR PAINTINGArea SHOP FLOOR
Resp Vijayakumar/ Magesh/ Saleem
Target Date 15/11/08
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BENCHMARK COMPANY H. M Auto Industries
Incoming Inspection area with trends display
Area not identified for Incoming Inspection
0303 SUPPLIER CONTROLArea INCOMING INSP.
Resp Magesh/ Saleem
Target Date 10/11/08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Incoming inspection flow chart displayedIncoming inspection flow chart
not available
0404 RECEIVING INSPECTIONArea INCOMING INSP.
Resp MAGESH
Target Date 20.10.08
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BENCHMARK COMPANY H. M Auto Industries
Incoming Inspection as per Inspection Std
AOI not available with the sub supplier, Regular inspection not carried out
0505INCOMING INSPECTION
– CHILD PARTS
Area INCOMING INSP.
Resp MAGESH
Target Date 15.10.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Raw material, child part master sample with validity
Master samples not available for
sub supplier parts
0606 MASTER SAMPLEArea INCOMING INSP.
Resp SALEEM / MAGESH
Target Date 1.11.08
MASTER SAMPLES
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Packing standardized for incoming partsPacking not standardized for raw
material / sub supplier parts
0707 RECEIVING INSPECTIONArea INCOMING INSP.
Resp MAGESH
Target Date 10.11.08
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BENCHMARK COMPANY H. M Auto Industries
Supplier rejections analyzed and
counter measures verifiedSupplier rejection reporting system and
proper procedure not available
0808 SUPPLIER REJ. ANALYSISArea INCOMING INSP.
Resp Magesh / Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Storage area with FIFO racks for child parts
Storage area identified, FIFO not in practice
0909 CHILD PART STORAGEArea R/M STORES
Resp Vijayakumar / Magesh/ Saleem
Target Date 10.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
R/m stock status with FIFO system FIFO Board displayed with alerts
1010INCOMING MATERIAL
STOCK WITH FIFO
Area R/M STORES
Resp Vijayakumar
Target Date 10.07.08
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BENCHMARK COMPANY H. M Auto Industries
Coils stored properly with identification Keeping coils on to the floor
1111 R/M STORAGEArea R/M STORES
Resp Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Chowel photo
Storage racks available for steel strips, location identified, stock monitored
Raw Material storage and FIFO system not in proper
1212 R/M STORAGEArea R/M STORES
Resp Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Material identification well definedIdentification tag available for some raw materials, basic information not covered in tags
1313 R/M STORAGEArea R/M STORES
Resp Magesh / Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Wooden support to eliminate damage Chances of scratch is more
1515 COIL STORAGEArea R/M STORES
Resp Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Fork lift operator can move around easily
1717 MIRROR FOR SAFETYArea R/M GANG WAY
Resp Saleem
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
Welding line organized with functional layout & visual controls
Welding line not organized properly
1818 WELDING LINE SET UPArea WELDING LINE
Resp Vijayakumar / Magesh/ Saleem
Target Date 25.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Enough lighting, proper ventilation to avoid operator fatigue
Additional lighting & ventilation, proper ventilation to avoid operator
fatigue
1919 SAFETY MEASURESArea WELDING LINE
Resp Vijayakumar / Saleem
Target Date 25.11.08
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BENCHMARK COMPANY H. M Auto Industries
My Machine Concept will be introduced
2020 MY MACHINE CONCEPTArea Incoming Storage
Resp Vijayakumar
Target Date 20.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Detailed machine preventive maintenance check sheet
Preventive maintenance check sheet not available
2121 MACHINE MAINTENANCEArea M/C TABLE
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Machine check points highlighted on the machine
2222 CHECK POINTS ON M/CArea MACHINE
Resp Vijayakumar/ MAGESH
Target Date 5.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Critical spares list prepared and maintained
2323 M/C CRITICAL SPARESArea MACHINE
Resp Vijayakumar
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
2424PROCESS PARAMETER MONITORING
Area Machine
Resp Magesh
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
2525PROCESS PARAMETER MONITORING
Area Machine
Resp Magesh
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
Work instruction and process parameters not displayed
2626PROCESS PARAMETER MONITORING
Area Machine
Resp Magesh
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Recommend to replace a single tank to parallel connection
2727PROCESS PARAMETER MONITORING
Area Incoming Storage
Resp Saleem
Target Date 30.11.08
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BENCHMARK COMPANY H. M Auto Industries
Electrode coil not protected from atmosphere
2828PROCESS PARAMETER MONITORING
Area Machine
Resp Vijayakumar
Target Date 20.10.08
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BENCHMARK COMPANY H. M Auto Industries
Unit description different
litre / min flow rate
2929PROCESS PARAMETER MONITORING
Area Incoming Storage
Resp Magesh
Target Date 7.10.08
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BENCHMARK COMPANY H. M Auto Industries
3030MACHINE STATUS – VISUAL DISPLAY
Area Machine
Resp Vijayakumar
Target Date 10.11.08
MACHINE STATUS DISPLAY
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BENCHMARK COMPANY H. M Auto Industries
Welder certificate not available
3131 WELDER CERTIFICATIONArea Welding
Resp Vijayakumar / Saleem
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Welding parameter specification not available, refer to STD
3232 WELDER CERTIFICATIONArea Welding
Resp Magesh
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
3333 GRAVITY CHUTEArea Welding
Resp Vijayakumar / Saleem
Target Date 25.11.08
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BENCHMARK COMPANY H. M Auto Industries
Recommended to install a gravity chute
3434 PRODUCTION LINE UPArea Welding
Resp Vijayakumar / Saleem
Target Date 25.11.08
CHUTE
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BENCHMARK COMPANY H. M Auto Industries
All types of safety wearing provided Poor man safety
3535 PERSONAL SAFETYArea Welding
Resp Saleem / Vijayakumar
Target Date 20.11.08
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BENCHMARK COMPANY H. M Auto Industries
3636 HANDLING OF WIP PARTArea Welding
Resp Vijayakumar
Target Date 25.11.08
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BENCHMARK COMPANY H. M Auto Industries
Rubber sleeve provided at goose neck area
3737 WELDING – JOB REPORTArea Welding
Resp Vijayakumar
Target Date 30.10.08
RUBBER SLEEVE
![Page 38: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/38.jpg)
BENCHMARK COMPANY H. M Auto Industries
3838 NOZZLE CLEANINGArea Welding
Resp Vijayakumar
Target Date 30.10.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Periodic jig maintenance, Inspection
(Plan Vs Actual)
3939 JIG MAINTENANCEArea MACHINE
Resp Vijayakumar/ MAGESH
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
4040 WIRE FEEDER GUIDEArea Welding
Resp Vijayakumar
Target Date 15.10.08
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BENCHMARK COMPANY H. M Auto Industries
Poorly routed cable
4141 EARTH CABLE ROUTINGArea Welding
Resp Vijayakumar
Target Date 30.10.08
POOR EARTHING
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BENCHMARK COMPANY H. M Auto Industries
4242PROCESS MONITORING –
GAS FLOW METER
Area Welding
Resp Magesh
Target Date 30.10.08
GAS FLOW METER
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BENCHMARK COMPANY H. M Auto Industries
4343 WELDING – JOB REPORTArea Welding
Resp Magesh
Target Date 30.10.08
PARTITION
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
4444CHIP REMOVAL
PROCEDURE
Area Welding
Resp MAGESH
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
Master samples and defective samples not displayed
4545MASTER, DEFECTIVE, F/M/L SAMPLES DISPLAY
Area Incoming Storage
Resp Magesh/ Saleem
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
4646 WELDING – JOB REPORTArea Welding
Resp Magesh
Target Date 30.10.08
JOB REPORT
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BENCHMARK COMPANY H. M Auto Industries
4747REJECTION TREND DISPLAY – CELL WISE
Area Quality
Resp Magesh
Target Date 10.11.08
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BENCHMARK COMPANY H. M Auto Industries
1818 NC PART CONTROLArea Quality
Resp Magesh
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Poor 3C & 5S of rejected part bin
4949 REJECTION STORAGEArea Rejection
Resp Maesh
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
5050 NC PART HANDLINGArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
5151 Q ALERT DISPLAY ON M/C Area Incoming Storage
Resp Magesh
Target Date 30.10.08
Q ALERTDISPLAY
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BENCHMARK COMPANY H. M Auto Industries
5252INSPECTION TABLE FOR ALL MACHINES
Area Incoming Storage
Resp Magesh / Saleem
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Clamping screw length oversize
5353INSPECTION TABLE FOR ALL MACHINES
Area Incoming Storage
Resp Vijauakumar
Target Date 30.9.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Break down status monitored
5454 BREAK DOWN STATUSArea PRODUCTION
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Idle time monitored for all machines
5555MACHINE IDLE TIME
MONITORING
Area PRODUCTION
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Direction of flow marking with colour coding
5656FLOW MEDIUM / DIRECTION MARKING
Area WATER LINE
Resp Vijayakumar / SALEEM
Target Date 30.10.08
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BENCHMARK COMPANY H. M Auto Industries
Material over stacking (WIP)
5757 IN-PROCESS STORAGEArea WIP
Resp Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Material over stacking (WIP)
5858 IN-PROCESS STORAGEArea WIP
Resp Vijayakumar
Target Date 15.11.08
![Page 59: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/59.jpg)
BENCHMARK COMPANY H. M Auto Industries
Big sized wooden bins used for
in-process
5959 WIP STORAGE & HANDLINGArea WIP
Resp Vijayakumar
Target Date 15.11.08
![Page 60: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/60.jpg)
BENCHMARK COMPANY H. M Auto Industries
Over stacking, more chances of component damage
6060 WIP STORAGE & HANDLINGArea WIP
Resp Vijayakumar
Target Date 15.11.08
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BENCHMARK COMPANY H. M Auto Industries
Rust on the component (awaiting for inspection)
6161DUST COVER FOR PLATED PARTS
Area WIP
Resp Vijayakumar
Target Date 15.11.08
Transparent LDPE Lid to avoid Dust
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
TROLLIES WITH CASTERS FOR EASY HANDLING - WIP
6262TROLLIES FOR EASY
HANDLING
Area SHOP FLOOR
Resp SALEEM / MAGESH
Target Date 10.07.08
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BENCHMARK COMPANY H.M AUTO INDUSTRIES
Fork lift for material handling to avoid fatigue
6363FORK LIFT FOR LOADING /
UNLOADING
Area SHOP FLOOR
Resp SALEEM / MAGESH
Target Date 10.07.08
![Page 64: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/64.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
RED LINE PROVIDED IN TROLLIES FOR MAX. STACK HEIGHT
6464STACKING LEVEL IN
TROLLIES
Area SHOP FLOOR
Resp Vijayakumar
Target Date 25.10.08
![Page 65: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/65.jpg)
BENCHMARK COMPANY H. M Auto Industries
Traceability not available from raw material incoming stage to F/G dispatch
6565 LOT TRACEABILITYArea Incoming Storage
Resp Magesh
Target Date 25.11.08
![Page 66: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/66.jpg)
BENCHMARK COMPANY H. M Auto Industries
6666 ASSY SHOP SET UPArea Incoming Storage
Resp Saleem / Vijayakumar / Magesh
Target Date 25.22.08
![Page 67: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/67.jpg)
BENCHMARK COMPANY H. M Auto Industries
6767 FINAL INSP. STANDARDArea Incoming Storage
Resp Magesh
Target Date 20.10.08
FINAL INSP STD
![Page 68: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/68.jpg)
BENCHMARK COMPANY H. M Auto Industries
Inspection area needs more light
7070 FINAL INSP. AREA LIGHTINGArea Incoming Storage
Resp Saleem / Vijayakumar
Target Date 10.11.08
![Page 69: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/69.jpg)
BENCHMARK COMPANY H. M Auto Industries
Master samples to be prepared with master list / due date /
location
6868 MASTER SAMPLESArea Incoming Storage
Resp Magesh / Saleem
Target Date 1.11.08
MASTER SAMPLES
![Page 70: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/70.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
FINISHED GOODS STOCK STATUS WITH VISUAL CONTROLS
6969 F/G STOCK STATUSArea F/G STORAGE
Resp SALEEM / MAGESH
Target Date 10.07.08
![Page 71: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/71.jpg)
BENCHMARK COMPANY H. M Auto Industries
Inspection area needs more light
7171 FINAL INSP. AREA LIGHTINGArea Incoming Storage
Resp Vijayakumar / Saleem
Target Date 10.11.08
![Page 72: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/72.jpg)
BENCHMARK COMPANY H. M Auto Industries
Rack of Weld bead width
7272 FINAL INSP. AREA LIGHTINGArea Welding
Resp Vijayakumar
Target Date 20.10.08
![Page 73: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/73.jpg)
BENCHMARK COMPANY H. M Auto Industries
NG parts out going without any proper check
7373 FINAL INSP. AREA LIGHTINGArea Incoming Storage
Resp Magesh
Target Date 20.10.08
![Page 74: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/74.jpg)
BENCHMARK COMPANY H. M Auto Industries
7474 REJECTION TREND DISPLAYArea Incoming Storage
Resp Magesh
Target Date 25.10.08
![Page 75: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/75.jpg)
BENCHMARK COMPANY H. M Auto Industries
7575INSPECTION TABLE FOR DESTRUCTIVE TEST
Area Welding
Resp Vijayakumar / Saleem
Target Date 20.11.08
![Page 76: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/76.jpg)
BENCHMARK COMPANY H. M Auto Industries
7676 SAMPLES RETAININGArea Incoming Storage
Resp Magesh
Target Date 20.11.08
![Page 77: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/77.jpg)
BENCHMARK COMPANY H. M Auto Industries
7777 TRANING ROOMArea Incoming Storage
Resp Magesh / Saleem
Target Date 25.11.08
![Page 78: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/78.jpg)
BENCHMARK COMPANY H. M Auto Industries
7878 CALIBRATION STICKERArea Incoming Storage
Resp Magesh
Target Date 30.10.08
![Page 79: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/79.jpg)
BENCHMARK COMPANY H. M Auto Industries
7979 CHECKER, JIG STORAGEArea Incoming Storage
Resp Magesh / Vijayakumar
Target Date 15.11.08
![Page 80: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/80.jpg)
BENCHMARK COMPANY H. M Auto Industries
Testing facilities not sufficient (Hardness testing, welding penetration
testing & roughness testing not available)
8080 INSPECTION & TESTINGArea Incoming Storage
Resp Magesh / Saleem
Target Date 30.11.08
![Page 81: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/81.jpg)
BENCHMARK COMPANY H. M Auto Industries
8181 TOOL STORAGEArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 10.11.08
![Page 82: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/82.jpg)
BENCHMARK COMPANY H. M Auto Industries
Tooling rack to be modified to minimize the area of contact bet. the tool and the rack
8282 TOOL STORAGEArea Incoming Storage
Resp
Target Date 7.10.08
![Page 83: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/83.jpg)
BENCHMARK COMPANY H. M Auto Industries
There is no place / identification for tools
8383 TOOL STORAGEArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 10.11.08
![Page 84: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/84.jpg)
BENCHMARK COMPANY H. M Auto Industries
Finished goods storage area not organized
8484 FINISHED GOODS STORAGEArea Incoming Storage
Resp Vijayakumar / Magesh
Target Date 10.11.08
![Page 85: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/85.jpg)
BENCHMARK COMPANY H. M Auto Industries
No QC identification tag on the pallet
8585 FINISHED GOODS STORAGEArea Incoming Storage
Resp Magesh
Target Date 30.10.08
![Page 86: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/86.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Improper bin leads more people to handle, Needs to improve size and type of bins
8686 RECEIVING INSPECTIONArea INCOMING INSP.
Resp MAGESH
Target Date 30.10.08
![Page 87: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/87.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Sensors provided between ram & bed
to avoid accidentSensors Provided
8787 SAFETY MEASURESArea WATER LINE
Resp SALEEM / MAGESH
Target Date 25.06.08
![Page 88: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/88.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
First, middle, last samples - top
Master, defective samples –second
Checker – bottom
8888 SAMPLES DISPLAYArea INSP. TABLE
Resp SALEEM / MAGESH
Target Date 15.11.08
![Page 89: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/89.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool daily preventive maintenance
check sheet
8989 TOOL CHECK SHEETArea M/C TABLE
Resp Vijayakumar/ MAGESH
Target Date 25.10.08
![Page 90: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/90.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
OPERATORS PROPERLY TRAINED AND CERTIFIED
9090 WELDER CERTIFICATIONArea MACHINE
Resp SALEEM / MAGESH
Target Date 15.11.08
![Page 91: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/91.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Cover provided for welding coil to isolate it from surrounding
9191COVER FOR WELDING COIL
(MIG WELDING)
Area MACHINE
Resp Vijayakumar/ MAGESH
Target Date 30.09.08
![Page 92: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/92.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool maintenance schedule displayed & followed
9292TOOL MAINTENANCE
SCHEDULE
Area MOULD STORAGE
Resp Vijayakumar/ MAGESH
Target Date 25.10.08
![Page 93: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/93.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool layout display for traceability
9393 TOOL LAYOUTArea MOULD STORAGE
Resp Vijayakumar/ MAGESH
Target Date 25.10.08
![Page 94: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/94.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Tool name plate provided on all tools
9494 TOOL IDENTIFICATIONArea MOULD STORAGE
Resp Vijayakumar/ MAGESH
Target Date 10.11.08
![Page 95: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/95.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
9595TOOLING TABLE WITH
RUBBER MAT
Area MOULD STORAGE
Resp SALEEM / Vijayakumar
Target Date 30.10.08
![Page 96: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/96.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
9696TOOL PAINTING – MODEL
WISE COLOUR
Area MOULD STORAGE
Resp SALEEM / Vijayakumar
Target Date 30.10.08
![Page 97: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/97.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Critical spares list prepared and maintained
9797 TOOLING CRITICAL SPARESArea MACHINE
Resp Vijayakumar
Target Date 10.11.08
![Page 98: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/98.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Detailed mould history card
9898 TOOL HISTORY CARDArea MOULD STORAGE
Resp MAGESH
Target Date 30.10.08
![Page 99: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/99.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
All components revalidated periodically to monitor the process / tooling consistency
9999COMPONENT
REVALIDATION
Area SHOP FLOOR
Resp MAGESH
Target Date 25.10.08
![Page 100: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/100.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
CHOWEL PHOTO
Weld penetration tested samples displayed
100100 FMEA SAMPLES DISPLAYArea SHOP FLOOR
Resp MAGESH
Target Date 20.11.08
![Page 101: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/101.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Inspection plan based on quality issues
101101SAMPLING INSPECTION PLAN
Area FINAL INSP.
Resp MAGESH
Target Date 25.10.08
![Page 102: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/102.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Inspection standard prepared with all quality check points
102102FINAL INSPECTION
STANDARD
Area FINAL INSP.
Resp MAGESH
Target Date 30.10.08
![Page 103: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/103.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Control plan & work instruction in line with AOI
103103 INSPECTION AGREEMENTArea SHOP FLOOR
Resp MAGESH
Target Date 30.10.08
![Page 104: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/104.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Quality check points for all parts
104104 PDI STANDARDArea PDI
Resp MAGESH
Target Date 30.10.08
![Page 105: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/105.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Customer approved packing standard displayed in PDI area
Packing standards not available
105105 PACKING STANDARD AT PDIArea PDI
Resp MAGESH
Target Date 30.10.08
![Page 106: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/106.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Trend charts displayed in shop floor
106106 PERFORMANCE DISPLAYSArea SHOP FLOOR
Resp MAGESH
Target Date 10.11.08
![Page 107: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/107.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Customer complaint free days monitored
107107CUSTOMER COMPLAINT
MONITORING
Area SHOP FLOOR
Resp MAGESH
Target Date 30.10.08
![Page 108: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/108.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Finished parts stored & identified properly
Proper location (layout) not yet identified for F/G storage
108108FINISHED PART FIFO/
IDENTIFICATION
Area F/G STORAGE
Resp Vijayakumar/ MAGESH
Target Date 15.11.08
![Page 109: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/109.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
NC parts located on the customer complaint review area
Customer complaints not reviewed properly through daily meeting
109109CUSTOMER COMPLAINT
REVIEW
Area SHOP FLOOR
Resp SALEEM / MAGESH
Target Date 30.9.08
![Page 110: Hm Auto Bench Mark Gap Analysis Report 19.09.08](https://reader033.vdocuments.site/reader033/viewer/2022050808/546819e8af7959a2358b49ba/html5/thumbnails/110.jpg)
BENCHMARK COMPANY H.M AUTO INDUSTRIES
Plant safety status displayed Safety visual control not displayed
Area SHOP FLOOR
Resp Vijayakumar/ Saleem
Target Date 20.11.08110110
PLANT SAFETY STATUS DISPLAY