connect.forcemotors.com · Web viewQUALITY POLICY. We at “FORCE MOTORS” are committed to...

QUALITY POLICY

We at “FORCE MOTORS” are committed to manufacture and supply products of superior technology at competitive price, which will satisfy the customers in totality for performance and reliability.

We will achieve this by effective implementation of a comprehensive quality management system and by continual improvement.

R&D PROCEDURE MANUAL

(ISO9001:2015/ IATF 16949:2016)

01

RESEARCH AND DEVELOPMENT

Procedure Manual

[ ISO 9001:2015 / IATF: 16949 ]

Doc No : R&D/II/D/01

REV NO: - 00

ISSUE NO/DT: 00/27.11.2017

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MANUAL IDENTIFICATION, OWNERSHIP, AND AUTHORISATION

1. COPYRIGHT

RESEARCH & DEVELOPMENT DEPT. of FORCE MOTORS LTD. has the copyright of this R&D Procedure Manual. No part of this QUALITY MANUAL will be reproduced in any form without the written permission of the RESEARCH & DEVELOPMENT DEPT of FORCE MOTORS LTD.

2. STATUS

THIS IS A CONTROLLED COPY SIGNIFIED BY A RUBBER STAMP (IN GREEN) AS INDICATED BELOW, WITHOUT WHICH THIS DOCUMENT IS VOID AND INVALID. THIS STAMP HAS TO BE PRESENT ON EACH AND EVERY PAGE OF THIS MANUAL

3. STAMP

4. APPROVED BY:

SIGNATURE: ……………………………………………………

H O D

DATE: - 27.11.2017

Place: Pune 411 035, INDIA

5. CONTROLLED COPY NO.: - 01

6. ISSUED TO: - AMR

7. ISSUE NO: - 00

8. ISSUE DT: - 27.11.2017

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CONTENTS LIST

DOC No

DESCRIPTION

ISO 9001:2015 / IATF:16949 CL No.

REV No

Page

R&D/II/D/01

Manual identification, ownership & authorization

--

0

02

R&D/II/D/02

Contents List

--

0

03

R&D/II/D/03

Issue and Revision Sheet

--

0

04

R&D/II/D/04

Introduction

--

0

06

R&D/II/D/05

Scope

--

0

07

R&D/II/D/06

Controlled copy holder’s list

--

0

08

R&D/II/D/07

Abbreviations & Terminology

--

0

10

R&D/II/D/08

Document Numbering System

0

11

R&D/II/D/09

Organization Chart of Research & Development Department

--

0

12

R&D/II/D/10

External and Internal issue List

4.1

0

13

R&D/II/D/11

List of Needs and Expectation of Interested Parties

4.2

0

14

R&D/II/D/12

Responsibility & Authority

5.3

0

15

R&D/II/D/13

Actions to address Risks and Opportunities

6

0

27

R&D/II/D/14

Organizational Knowledge

7.1.6

0

29

R&D/II/D/15

Communication

7.4

0

30

R&D/II/D/16

Guidelines for DCR

8.3.6

0

31

R&D/II/P/01

Procedure for Product Safety

4.4.1.2

0

33

R&D/II/P/02

Procedure for Product Design & Development

8.3

0

37

R&D/II/P/03

Procedure for Proto Manufacturing

8.3.4

0

46

R&D/II/P/04

Product Testing (LAB testing / Vehicle testing / Engine Testing)

8.3.4

0

50

R&D/II/P/05

Procedure for Design & Development Review

8.3.4

0

54

R&D/II/P/06

Procedure for CAE Analysis

8.3.4

0

58

R&D/II/P/07

Procedure for Design & Development Output

8.3.5

0

62

R&D/II/P/08

Procedure for Design & Development Changes

8.3.6

0

69

R&D/II/D/17

Document information on development of product with embedded software

8.3.2.3.

0

73

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ISSUE AND REVISION SHEET

Sr.No. DCN No. Date Changed Doc. Ref.

1

DCN/R&D/0217/05/2000R&D/III/D/04 Issue No. 1 released through electronic media

2

DCN/R&D/0418/11/2000R&D/III/D/04 Issue No 2 completed revised.

3

DCN/R&D/0518/03/2001R&D/III/D/04, 05 revised & R&D/00/46 form is added in F&F list.

4

DCN/R&D/0618/03/2001R&D/02/03 form revised

5

DCN/R&D/1301/10/2001R&D/III/D/04 Issue No. 3 released through electronic media.

6

DCN/R&D/2503/04/2003R&D/IlI/D/04 Issue No. 3 released through electronic media.

7


8


9


10


11


12

DCN/R&D/3110/07/2005R&D/00/28 & R&D/00/29 deleted, Manual revised for ISO/TS requirements

13

DCN/R&D/3212/09/2005FORCE MOTORS LTD logo incorporated Fitment performance Report

R&D/00//01 in place of R&D/00/111 ,R&D/00/131 & R&D/00/132 forms added

14

DCN/R&D/3306/09/2006Forms controlled by lED are deleted from the List of Forms & Formats

15

DCN/R&D/3425/09/2007R&D Procedures 04 & 06, Documents 02,03, 09 are revised

16

DCN/R&D/3505/11/2007R&D Procedures 05, Documents 02,03 are revised

17

DCN/R&D/3619/01/2008General guide line for DCR Clearance is revised, (Doc No. –R&D/II/D/11)

18

DCN/R&D/3707/06/2008Cad analysis request cum report(R&D/01/24) is modified & released through

electronic media

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ISSUE AND REVISION SHEET

Sr.No. DCN No. Date Changed Doc. Ref.

19

DCN/R&D/3827/12/2008Design and Development Activity Plan (R&D/00/136) introduced.

20

DCN/R&D/3924/10/2009Procedure manual (R&D) revised and updated for new issue no 7

21

DCN/R&D/4006/08/2010Procedure manual revised for changes to existing procedures & introduction of

new formats.

22

DCN/R&D/4115/09/2010R&D/III/D/04 Issue No. 1 released through electronic media

23

DCN/R&D/4215/09/2010Procedure for keeping the Status of Non Conformity Reports identified

properly now as hard and soft format in MLQR of AMR

24

DCN/R&D/4315/09/2010Column containing the Issue No & Revision No updated in MLQSD of AMR

25

DCN/R&D/4415/09/2010Column containing the Issue No & Revision No updated in MLQSD of HOD

26

DCN/R&D/4521/01/2011List of Forms and Formats updated

27

DCN/R&D/4621/01/2011Issue and Revision Sheet updated

29

DCN/R&D/4821/01/2011Team Feasibility Commitment fine tuned in R&D/II/P/01, page 5 of 9.

30

DCN/R&D/4921/01/2011Various Changes in the Procedure Manual.

31

DCN/R&D/5020/09/2012Control Copy Holder List modified (Doc No. –R&D/II/D/06)

32

DCN/R&D/5125/09/2015Entire manual is reviewed and reissued.

33

DCN/R&D/5227/11/2017Entire manual is reviewed and reissued.

34 DCN/R&D/5303/04/2019 DFMEA Guideline is updated as per FMEA fourth revision AIAG standard

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INTRODUCTION

RESEARCH & DEVELOPMENT DEPARTMENT OF FORCE MOTORS LTD, Pune.

1.0 Introduction

1.1 FORCE MOTORS LTD, Research & Development (R&D) department is responsible to design new products based on the inputs given by the management.

1.2 It is also responsible to carry out design changes in the existing products to cater for product life improvement & performance, safety, environment protection, new legislative requirements, value engineering, customer satisfaction etc.

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SCOPE

This manual covers the requirements of International Standard ISO9001:2015 / IATF 16949: 2016

for Design activity as applicable to RESEARCH & DEVELOPMENT DEPARTMENT of FORCE MOTORS LTD, Pune.

The Objectives of the various sections within the Research & Development department is in the form of Critical & Conformance KPI’s which is reviewed monthly in order to cater to the Company

Level Objectives.

List of Customer Specific requirements (CSR)

Sr No

Customer

Requirements

Monitoring & Review mechanism

1

Marketing Dept

Product design as per marketing dept. with applicable regulatory and statutory requirement as notified.

Project Review meeting, FAMC, SLA

Monitoring

3

PE Dept.

Release of new design as per time plan for Tool design and tool manufacturing

Project Review meeting, FAMC,

SLA Monitoring

Timely release of Design modification note

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CONTROLLED COPY HOLDER LIST:

Copy No 1 – Hard copy of manual with the AMR (R&D)

Copy No 2 – Soft copy available on the Tempest

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ABBREVATION

WORD

ADD

Ancillary ` Dept.

AP

Activity Plan

Appd

Approved

Asst

Assistant

BIS

Bureau of Indian Standards

BoM

Bill of Material

BOM

Board of Management

BTS

Bajaj Tempo Standards

CAD

Computer Aided Designing

CAM

Computer Aided Manufacturing

CAE

Computer Aided Engineering

MD

Managing Director

Cl.

Clause

Comm

Commercial

CMVR

Central Motor Vehicle Rule

CT

Component Testing

CRRN

Change in Regulatory Requirement Note

CV

Commercial Vehicle

Cyl

Cylinder

D&D

Design & Development

DCR

Design Change Request

DCN

Document Change Note

DDD

Design Description Document

DEPT

Department

DGM

Deputy General Manager

Div

Division

DH

Divisional Head

DMN

Design Modification Note

DOC/Doc

Document

Drgs

Drawings

DT

Date

Dy

Deputy

DVdP

Design Validation Plan

DVdSR

Design Validation Summary Report

DVP&R

Design Verification Plan and Report

DVS

Design Verification Summary Sheet

DWN

Design Withdrawal Note

EIC

Engineer / Executive In charge

ELL

Engineering Legislation and Liaison

E

Engine

EDDT

Engine Design, Development & Testing

Engg

Engineering

Elec

Electrical

FAMC

Functional Activity Management Committee

FML

FORCE MOTORS LTD

FMS

Force Motors Standards

GDN

Goods Dispatch Note

YC Potential Critical Characteristics

YS Potential Significant Characteristics

GP

General Procedure

GM

General Manager

HCV

Heavy Commercial Vehicle

HOD

Head of Department

Inst

Instrumentation

KPI

Key Performance Indicator

LCV

Light Commercial Vehicle

MR

Management Representative

MIN

Material Inward Note

Min.

Minimum

MOM

Minutes of Meeting

MRF

Material Request Form

Mfg

Manufacturing

Mgmt

Management

MRV

Material Requisition Voucher

No.

Number

PG

Page

PDED

Product Drawing and Engineering Documentation

PM

Proto Manufacturing

PPC

Prototype Planning Cell

PRL

Project Review List

PRN

Product Release Note

PRR

Product Release Request

PR

Proto Request

Pr/P

Procedure

Proto

Prototype

RCIA

Receipt cum Inspection Advice

Ref.

Reference

R&D

Research & Development

SUV

Sport Utility vehicle

REV/Rev

Revision

SCV

Small Commercial Vehicle

Sd

Signed

Sr/S.

Serial

SIAM

Society of Indian Automobile Manufacturers

SIC

Section In charge

SIR

Sample Inspection Requisition

TRR

Test Request Requisition

TCR

Technical Change Request

UV

Utility Vehicle

Veh

Vehicle

VED

Vehicle Evaluation Division

3WH

3 wheeler

3 wh

3 wheeled vehicle

TGR

Thing gone right

TGW

Thing gone wrong


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DOC NUMBERING SYSTEM

DOC Numbering System identified in GP is followed for Department manual. For The sub level manuals in R&D Department (Division manuals) the following document numbering system is followed.

Sub Level IIIDocument

Dept - Div /Level /Document/Sr. No.

(Div.)

Example

R&D - CT/III/D/01

Work InstructionDept - Div/Level/Work Inst./Sr. No.

Example

R&D - CT/III/WI/01

Sub. Level IVForm/Format

Dept/Revision No./Sr. No.

(Div.)

Example

R&D/00/01

Departmental Registers to be numbered as follows

Register

Dept/Div/Reg. Name/Sr. No.

Example

R&D/ELL/SIAM doc./001

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Organization Chart:

1. Organization Chart of each section is available with the concerned DH/SIC

2. Copy of this is sent to HOD by the DH’s & to the SIC’s by the DH’s

3. The charts are updated depending on the changes

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UNDERSTANDING THE EXTERNAL AND INTERNAL ISSUES

R&D Department has determined external and internal issues that are relevant to the purpose and its strategic direction, and which can affect its ability to achieve the intended results of its quality management system. This information is monitored and reviewed in FAMC meet.

The external and internal issues are identified and are continuously being monitored and reviewed by management.

External Issues:

Political Factors (P)

1. Government rules, regulation and policies for vehicle requirement as notified.

Technology Factors (T)

1 Unique selling product points.

2 Competitive products..

Dealer /Customer (D/C)

1. Regular new product launch

Internal Issues:

Strength: 1 Top Management Involvement.

2 Good Product development team.

3. Good infrastructure in terms of hardware & software

Opportunities: 1.Timely Product launches.

2 Product Fit & Finish in line with competitors..

Threat: 1 New product from Competitors.

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UNDERSTANDING THE NEEDS AND EXPECTATION OF INTERESTED PARTIES

R&D has determined requirements of the interested parties, that are relevant to Quality management system, and which can affect its ability to consistently provide products and services to meet customer and statutory & regulatory requirements.

The information and relevant requirements of these interested parties are monitored and reviewed in FAMC

Interested parties

Requirements

Monitoring & Review mechanism

External providers

1. Technical support

Defined in PO, Documents of terms and conditions, Procedures & Reviewed in departmental FAMC

Customer

1. Customer specific requirement

Defined in Procedures & Reviewed in departmental FAMC

Statutory &

Regulatory Body

1.Complying with the statutory and

regulatory requirements as

defined from time to time.

Defined in Procedures & Reviewed in departmental FAMC & BOM

Employees

1.Skill enhancement by arranging training program,

2. Sharing of organizational knowledge


Dealers

1. New Product launch


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RESPONSIBILITY AND AUTHORITY OF HOD has mentioned in Apex manual.

Responsibility and Authority of Design Team

DH – Responsibilities

Sr No.

1

Project Planning along with SIC

2

Project review in macro level & Monitoring

3

Conduct brain-storm sessions with key stakeholders to resolve critical issues

4

Mentoring

5

Priortize projects as per corporate level guidelines

6

Performance Managerment evaluation (Appraisals)

7

Resource Management .

8

Resources allocation & Management approval for additional resources

9

Establishing new test facility for testing as per project plan & time line

10

Review & upgrage internal processes/technology as per market trend

11

Strategic directions for effective utilisation of resources & Technology

DH – Authorities

Sr No.

1

ApproveTest requests

2

Resource Allocation

3

Recruitment

4

Training recommendation as part of skill enhancement to the team

5

Gate pass & Leave approvals

6

PRODUCT specifications Sign-off

7

Approval to get required existing parts from Pithampur

8

Approvals for all releases for Powertrain components

9

Priorities change based on requirement

10

Contingency solution approval to implement for field failures

SIC – Responsibilities

Sr. No.

1

Plan daily work and discuss with team

2

Review 2D/3D drawings & layouts

3

Review design calculations

4

Initiate / give prototpye request / Test request

5

Discuss & approve DCR

6

Interaction for DMN / PRN

7

Analyze Field failures and then countermeasures

8

Design review / discussions with R&D Team

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Responsibility and Authority of Design Team


9

Design review / discussions with Production Team

10

Interaction with Vendor

11

ISO / TS related work

12

Interaction with Pithampur QC for production issues

13

Homologation Activities

14

Review work status with Department Head

15

Review Project status with PE/ADD/Purchase

16

Review Marketing requirement

17

Review SIR status

18

Review Proto assly / Mfg status

19

Review with PDED

20

FAMC review

21

IQA results interaction with R&D Team

22

Project planning

23

Project Execution and monitoring

24

DVVP preparation

SIC – Authorities

Sr No.

1

DCR /SIR/ vendor drg approval

2

Technical discussion with candidates @ Recruitment

3

PRN release

4

DMN approval

5

Data transfer initial approval

EIC – Responsibilities

Sr No.

1

2D/ 3D drg release

2

Engine packaging feasibility study.

3

Proto part request initiation

4

Proto part follow up/ Casting tooling request

5

Data transfer intitiation.

6

DAR booking

7

DCR raising/ DMN followup

8

Data information input sharing with supplier

9

On job training

10

House keeping

EIC – Authorities

Sr No.

1

Catia Tool license allocation to end users

2

First level design & drawing review and approval to next level

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Responsibility and Authority of Proto Manufacturing Team


Sr No.

1

Management approvals for proto type vehicle/components manufacturing.

2

Proto type manufacturing as per project plan & time line.

3

Review of Proto Type project activities.

4

Inter action with HOD, Design DH for proto type manufacturing.

5

Attend CFT meeting.

6


7

Review meetings for Safety awareness.

8

Technology & infrastructure up-gradation.

9

Resources allocation & Management approval.

10

Proto type manufacturing philosophy.

DH – Authorities

Sr No.

1

Material movement to outside factory for Processing on returnable basis .

2

Raw material procurement on cash purchase basis ( As per Management approval).

3

Raw material / Bought out Material availability for proto part manufacturing ( 901 Movement )

4

Leave / Official gatepass / Personal gatepass sanctioning.

5

Cash purchase voucher sectioning.

6

TA / DA bill sanctioning

7

Cash withdrawal voucher signing.

8

Trainee & Probationer employee monthly report evaluation.

9

Employee appraisal evaluation.

10

Inter departmental support for proto part manufacturing ( Processing).

11

Rejected & Material not in use ( Scrap note ) signing.

12

R & D entry gatepass signing for visitors.


Sr No.

1

Ensuring availability of Raw material for proto part manufacturing.

2

Interdepartmental interaction for priorities.

3

Morning meeting & Work allocation.

4

Training for Safety awareness.

5

To attend Projects CFT meetings.

6

Ensuring availability of proto parts for assembly.

7

Other department interaction for process support

8

Vendor interaction & visit for proto part manufacturing.

9

Interaction with Design departments.

10

To maintain shop discipline.

11

Resource utilization.

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Responsibility and Authority of Proto Manufacturing Team

SIC – Authorities

Sr No.

1

Selection of temporary workmen.

2

To raise Raw material indent.

3

Selection of new employee.

4

Training recommendation for skill enhancement.

5

Internal goods movement ( Gatepass) signing.

LIC – Responsibilities

Sr No.

1

Shift scheduling.

2


3

Housekeeping ( Maintain 5's).

4

To ensure Work discipline.

5

Parts manufacturing as per drawings.

6

Record for proto parts.

7

Ensuring preventive maintenance schedule & Break down record.

8

Daily attendance ( Muster record ).

9

Calibration compliance.

10

Proto parts confirmation as per specification ( Quality check).

11

Inter departmental interaction for proto part manufacturing.

12

On job training to workmen.

LIC – Authorities

Sr No.

1

Break down intimation.

2

Fraud punching intimation to time office.

3

Workmen (Internal Gatepass) signing.

Responsibility and Authority of Engine Testing LAB


Sr. No.

1

Management & execution of power train projects

2


3

Resources allocation & Management approval.

4

Establishing new test facility for engine testing as per project plan & time line

5

Review to upgrade existing technology & test facility

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Responsibility and Authority of Engine Testing LAB

DH – Authorities

Sr No.

1

To sign the Test requests for carrying out the tests

2


3


4



Sr No.

1

To plan & execute the tests as per request.

2

To Maintain the test facility

3

Release the test results

4


5


6


7

To attend Projects meetings.

8

Ensuring availability of spare & consumable parts for test equipments.

9

Other department interaction for maintenance support

10

Vendor interaction & visit for AMC.

SIC – Authorities

Sr No.

1

To raise indent.


Sr No.

1

To conduct emission tests as per procedure

2

Maintenance of Test equipments / instruments

3

calibration of test equipments / instruments to be carried out Inhouse or with the help of external agency

4

Shift scheduling.

5


6


7

Inter departmental interaction for maintenance.

LIC – Authorities

Sr No.

1

Break down intimation.

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Responsibility and Authority of Homologation and Regulation


Sr No.

1

Management & execution of Homologation and Regulations Activities

2


3

Product certification and Regulatory requirements monitoring

4

Addressing Interdepartmental and departmental meetings to create Regulatory requirements awareness

5

Periodical reviews of Homologation and certification activities

6

Interaction with external agencies SIAM /TMA/ARAI / VRDE / CFMT&TI/ TUV / CIRT and CMVR TSC / AISC / SCOE

DH – Authorities

Sr No.

1

Giving Approvals to process Homologation activities and certification documents

2


3


4



Sr No.

1

To plan & execute the Certification activities based on Product certification request.

2

To Maintain the CMVR certification records

3

Interdepartmental interaction for CMVR testing

4


5


6

To attend Projects meetings.

7

Ensuring availability of stationary for certification activities

8

Other department interaction for Certification support

9

Interaction with Domestic Marketing and International sales and Marketing for country specific Homologation requirements.

10

Study and comments on Government Notified Regulatory requirements

11

Study and comments on Indian and Automotive Standards

12

Recommendations to meet the Regulatory requirements

13

Study of National / International standards

14

Uploading, Obtaining Approvals for certified models on Vahan Portal for vehicle registration

15

R&D Recognition compliance

16

Test and Certification charges bills processing

17

Attending outside meetings for SIAM/TMA/CMVR-TSC/AISC/SCOE

18

Liasoning visit to ARAI/VRDE/ TUV/CFMT&TI/ICAT and CIRT

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Responsibility and Authority of Homologation and Regulation

SIC – Authorities

Sr No.

1

To raise indent.

2

Liasoning with Test Agency


Sr No.

1

To prepare Certification Change Matrix based on Product change Matrix

2

To Identify Statutory test requirements

3

Preparation of Technical documents

4

Processing of domestic and export certification applications

5

Maintenance of Test reports and certification records

6

Liasoning with Test Agency

7

Co-ordination between Test Agency and Testing team

8


9

MIS preparation

10

Inter departmental interaction for certification activities

11

Preparation of export homologation documents

12

Self certification activities

LIC – Authorities

Sr No.

1

Statutory testing schedule intimation.

Responsibility and Authority of PDED ( Product Drawing and Engineering Documentations)


Sr No.

1

Control on drawings preparation & release activity

2

Control on PRN/DMN/UDMN/UPRN/DMMN preparation & release activity

3

Control on suppliers & subcontractors drawings activity

4

Control on translation standards & documents of foreign origin.

5

Control on DCR/PRR/DPR activity

6

Control on Archives activity (record of drgs/std, printinig of drgs. against prints requisition etc)

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DH – Authorities

Sr No.

1

Approval of drawings.

2

Check the PRN/DMN/UDMN/UPRN/DMMN

3

Approval of suppliers or subcontractors drg

4

Approval of translation standards & documents of foreign origin.

5

Approval of prints requisition


Sr No.

1

Checking of PRN/DMN/UDMN/UPRN/DMMN

2

Checking the BoM before release

3

Issue of the drawings / standards to user Dept.

4

Vendor drawing received & serial no allocation in R&D

5

To maintain records & documents

6

Verification of drawings w.r.t existing configuration

7

DCR/PRR/DPR serial no allocation & forward to concern.

SIC – Authorities

Sr No.

1

To check of Sub assly & assly BoM in SAP.

2

To check of DMN/PRN/UDMN/UPRN/DMMN

3

To check BOM in SAP

4

To verify suppliers or subcontractors drg

EIC – Responsibilities

Sr No.

1

Preparation of Drawings as per guideline & check list.

2

Updation in drawings based on feedback & discussion.

3

Release of Drawings as per guideline & check list.

4

Preparation of DMN/PRN/UDMN/UPRN/DMMN as per guideline & check list.

5

Updation in DMN/PRN/UDMN/UPRN/DMMN based on feedback & discussion.

6

Release of DMN/PRN/UDMN/UPRN/DMMN as per guideline & check list.

7

Record of drawings/Standards.

8

Removal/Retension of obsolete drawings.

9

Updation of drawings revision status in electronic media.

10

Preparation/Updation of BoM.

EIC – Authorities

Sr No.

1

NIL

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Responsibility and Authority : R & D Vehicle Testing / Component Testing


Sr No.

1

New proto type building & validation execution activities

2

Project reviews ( Existing & New ) with design team & management

3

Preparing approval notes for vehicle proto building & validation activities, new Rigs / Equipments and purchase of raw material etc.

4

Technology & infrastructure upgradation in vehicle & component testing

5

Project Review of Vehicle testing / Component testing activities.

6

Resource Management & required approvals from management

7

Execution of all critical issues in vehicle & component testing

8

Interaction with HOD, Design DH for testing related feedback & critical issues

9

Executions of vehicle display of new concept / proto as per management guidelines

10

Proto vehicles test drive for critical observations & feedbacks

11

Review meetings for Safety awareness.

12

Review of FAMC for concerned groups & Attending FAMC meeting

13

Weekly MIS report review with concerned group leader & weekly meeting with Head R&D.

14

Daily interactions & addressing project critical issues with SIC & EIC of vehicle & component testing

15

Shop floor activities related to work safety & healthy environment

DH – Authorities

Sr No.

1

Material movement to outside factory for Processing on returnable basis .

2

Raw material procurement on cash purchase basis ( As per Management approval).

3

Raw material / Bought out Material availability for proto vehicle testing / related components required for testing ( 901 Movement )

4

Leave / Official gatepass / Personal gatepass sanctioning.

5

Cash purchase voucher sanctioning.

6

TA / DA bill sanctioning

7

Cash withdrawal voucher signing.

8

Trainee & Probationer employee monthly report evaluation.

9

Employee appraisal evaluation.

10

Inter departmental support for proto part manufacturing ( Processing).

11

Rejected & Material not in use ( Scrap note ) signing.

12

R & D entry gatepass signing for visitors.

13

VRDE entry gatepass note

14

Dar booking approval for the non bargainable employees

15

Final report approval for the vehicle testing & component testing

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SIC – Responsibilities ( Vehicle & Component Testing)

Sr No.

1

Ensuring availability of components, Man power availability for proto vehicle building & Component testing

2


3


4


5

To attend Projects CFT meetings.

6

Ensuring availability of vehicle components for assembly.

7

Other department interaction for process support

8

Vendor interaction & visit for vendor test witness etc

9

Interaction with Design departments.

10

To maintain shop discipline.

11

Resource utilisation.

12

Preparing & attending FAMC for management review meeting.

13

CFR closing report discussion with concerned for design group & EIC for closing the same.

SIC – Authorities

Sr No.

1

Selection of temporary workmen.

2

To raise Raw material / component requirement indent for Vehicle & component testing

3

conducting interview for selection of new employee.( Technician,engineer grade)

4


5

Internal goods movement ( Gatepass) signing.

6

Approval of personal & official gatepass for Engineers and Workmen

7

Signing Test reports of Vehicle & Component Testing

8

Vehicle Gatepass / Diesel Slips Approval

EIC – Responsibilities ( Vehicle testing )

Sr No.

1

Shift scheduling.

2


3

Housekeeping ( Maintain 5's) & improving the score

4


5

Assy of vehicles as per design lay out provided by design group

6

Keeping Records for std ,development, exclusive part list .

7

preparing build data of proto vehicles & highlighting deviations against specifications to concerned design group.

8

Ensuring preventive maintenance schedule & Break down record of all vehicles

9


10


11

Proto parts confirmation as per specification ( Quality check).

12

Inter departmental interaction for proto part manufacturing.

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13


14

Preparing CFR report for the failed components on vehicle

15

Review meeting with the design groups for the closing CFR

16

Maintaining the record for the closed CFR report after getting the closing report

17

Preparation of the daily running record for the endurance test vehicles

18

Preparation of the MIS for the review meeting with DH

19

Data collection for preparing FAMC for the management review meeting

20

preparation for the test reports for the test vehicles ( assembly report , performance report , endurance test report , pave test report )

21

Maintaining the tools & gadgets for the vehicle assembly & keeping in proper condition .

22

keeping the minimum inventory stock of components & vehicles

23

keeping the record for the consumable parts on vehicle.

EIC – Authorities ( Vehicle testing)

Sr No.

1

Attending vehicle Break down & rectifying the same

2


3


4

Preparation document for removed oil from test vehicle for analysis

5

Xerox requisition

6

Test report sign before proceeding to SIC & EIC

EIC – Responsibilities ( Component testing )

Sr No.

1

Shift scheduling.

2


3

Housekeeping ( Maintain 5's) & improving the score

4


5

Preparing test plan, test setup, conducting tests & monitoring test during shift duty and preparing test reports.

6

Making new test fixtures and set up as and when required

7

Ensuring preventive maintenance schedule & Break down record of test rigs & fixtures.

8


9


10

Inter departmental interaction for testing

11


12

Updating daily test status & obsrvation sheet.

13

Preparation of MIS for the review meeting with DH

14

Data collection for preparing FAMC for the management review meeting

15

Communication to concerned group regarding audit component failure status.

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EIC – Authorities ( Component testing)

Sr No.

1

Interviewing and selection of temporary workmen

2


3


4

Xerox requisition

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Actions to address Risks and Opportunities

External Issues:

Requirements

Risks

Actions to mitigate risk

Opportunities

Political Factors (P)

1. Government rules, regulation and policies for vehicle requirement as notified.

1.Ensure implementation of rules , regulations and policies.

1. Can stop business.

1. Timely implementation of regulation

1. Continous business

Technology Factors (T)

1 Unique selling product points.

2 Competitive products.

1. Customer attraction

2. Benchmarking.

1. Can reduce business. 2. Can reduce market share.

1. Build USP's like comforts, better mileage , Higher goods carrying capacity, Long service intervals, long life of aggregates etc. compared to benchmarking data

1. Increase in market share .

Employee

1Training, Competency & Skill Development.

2 Working Conditions

1.Skill enhancement

2.Empowerment 3.Involvement in new development

Inadequate competency.

Low morale.

Training, Multi skilling.

Delegation of authorities and responsibilities.

1) Increased employee morale.

2) Reduce cost to company

Customer (D/C)

1. Regular new product launch

1. Reduction in business.

1.0 To design and develop new product on market research

1) Increase in market share, Brand value

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Interested parties

Requirements

Risks

Actions to mitigate risk

Opportunities

External providers

1. Technical support to supplier

1. Component / system not conforming to specification

2. Delay in development.

1, Clarifying technical requirement to the supplier

2. Extending support in components /systems development

3. Defining design validation plan and ensuring compliance

1. Timely development of component/systems as per schedule.

Customer

1. Customer specific requirements

1) Affect market reputation and will delay supply of product

2) Unsatisfied customer may lose business and damage organization reputation.

3. Customer dis-satisfaction

1. Ensure Fit to use product of good Quality with proper and clear communication ensuring customer specific requirements are met and spares available

2. Upgrade product based on customer feedback.

1) Increase in market share, Brand value.

Statutory &

Regulatory Body

1.Complying with the statutory and regulatory requirements as

Notified

Business may stop.

Comply to statutory and regulatory requirements well in advance is ensured by R&D as per procedures.

1) Uninterrupted sale.

Employees

1.Skill enhancement

2.Empowerment 3.Involvement in new development

Inadequate competency.

Low morale.

Training, Multi skilling.

Delegation of authorities and responsibilities.

1) Increased employee morale.

2) Reduce cost to company

Dealers /Stockists

1. New product launch

1. Reduction in business , Customer satisfaction , reduction in sales

1. Ensure on time supply of products, spares,

1. Increase in market value of investors

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ORGANISATIONAL KNOWLEDGE

R&D Department have set mechanism to share technical knowledge among all employee working in department.

· Technical presentations received from vendors, Suppliers and CD/DVDs of conference stored at below server location -

\\rndstorage\user F\ others.

Provided access to new technologies to concern design engineers.

· Aggregate-wise technical information of Projects is available at below sever location.

\\rndstorage\Non_Cad_Data

· All standards are available for design and testing engineers at below server location

\\rndstorage\ARD\Standards

· To enhance designer skill / knowledge, training of CATIA V5 Software, Analysis softwares is organized as and when required.

· Organized demonstrations / Presentations on new software update at R&D. Sometimes skypee is used for the same.

· Internet facility has been provided in R&D CAD Centre on e-mail desktops to refer latest information.

· Data related to CAE Knowledge base (Crash, CFD, NVH, e-Books, Load data of all vehicle, Seminars, SAE Presentations ) is made available at below server location -

\\rndstorage \ User F\ Others \ CAE Knowledge Base

· Test reports ( Vehicle Testing / Engine Testing / Components Testing ) are saved at below path

\\rndstorage\ARD\RELEASE\Scanned Test Report's.

These reports can be referred while designing new similar parts / Modification in existing part etc.

· Provided access to lesson learnt documents to existing as well as new comers.

· Dedicated location has been provided to all sections on R&D Server to save organizational knowledge which is specific to the organization. It is generally gained by experience.

\\rndstorage\UserF\OTHERS\Organizational knowledge

Separate documents is maintained at section level to demonstrate organizational knowledge clause.

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COMMUNICATION

The internal and external communications relevant to the QMS is determined including what, when, with whom, how and who will communicate.

What

When

With whom

How

Who

Internal Communication

Quality Policy

Always

All R&D employees

Display

AMR

Importance of effective QMS

During Induction

New Joining

Presentation

AMR

Quality objectives

Yearly

Divisional Head

Division KPI

HOD

Customer complaints / feedback

After receipt of complaint

Dept Head / Divisional Head

Monthly Warranty review

Service Dept.

What

When

With whom

How

Who

External Communication

Technical support to supplier

During Development

Supplier

Through ADD

Development Engineer

Supplier issue

Receiving information

Through ADD

Telephone/Email


Customer feedback

New product launch

Customer

Through Sales and Marketing


Action taken on customer complaints

After completion of action

Service Dept.

Email / letter / Warranty meeting


Each section in R&D department have maintained Internal and external communications matrix in line with their activity.

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GUIDELINES FOR DCR:

1) DCR’s from R&D to be filled after completing Sketches / Analysis / Proto / Proving by concern DH.

2) Procedure for DCR’s received other than R&D dept

a) Received by PDED and recorded in the DCR Register.

b) Copy of the DCR is forwarded to the concerned DH.

c) Categorization of DCR’s by DH as followsA – Process / Design Improvements

B – Cost Reduction

C – Error Correction

D – CMVR / Govt. Regulator Act

E – Field Complaints / Warranty Claims

F – Safety

d) For category of A,B,D,E and F, DFMEA is must.

e) Pl refer FMEA Ranking which is available on Tempest ( FML Intranet).

f) All DFMEA's should be approved by Homologation person for Product Safety requirements.

3) Ensure that DFMEA is reviewed with DCR.

4) Error correction DMN’s

a) Classify the error as one among the above from A to F.

b) Study the case for error on case to case basis & prepare a report on the cause of error.

c) Identify the more frequent cause of error.

d) Study & propose corrective measures to minimize the same.

5) For DCR implementing, guideline by management (TCR) wide note M/33/5/3998 dated 07.09.2007 is to be followed.

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DCR PROCESSING TABLE:

S.No

ACTIVITY

MAN DAYS

1

DCR Copy Receipt

3

2

DCR Approval

10

3

2D drawing preparation

2 to 15 (depending upon the complexity)

4

Proto Manufacturing

6 to 30 (depending upon the complexity)

5

3D Models

10 to 15 (whenever applicable)

6

Advance DMN preparation

6

7

Advance DMN discussion (ADD/PE/PUR) indicating:

8 to 10

7a

Make and Buy

7 days are given to PE/ADD/PURCHASE/QC for their comments and 1 days for discussion.

7b

Target date of implementation

7c

Tooling involved

7d

Tooling / Equipment cost involved

7e

Cost Impact on Vehicle

7f

Old Stock assumption

8

Updation of DMN after advance DMN discussion

4 (based on availability of concerned)

9

Firm DMN approval

6 to 20 (Based on management availability)

10

Firm DMN release

6

11

Validation of proto of proposed change

2 to 10 (depending on complexity)

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TITLE: PROCEDURE FOR Product safety.

PURPOSE: The purpose of this procedure is to define Product safety in design and development process.

SCOPE: It covers safety in products, designed and developed at R&D Dept.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with HOD & operational responsibility lies with DH, Design and Homologation.

PROCEDURE:

Refer flow chart for process – Product safety

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TITLE: PROCEDURE FOR PRODUCT DESIGN & DEVELOPMENT

PURPOSE: The purpose of this procedure is to define a method for the Design & Development activity.

SCOPE: This covers the requirement of Design & Development Planning in R&D Department of FML,

Pune.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with HOD & operational responsibility lies with concerned DH.

PROCEDURE:

Refer flow chart for process – Product Design & Development.

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TITLE: PROCEDURE FOR PROTO MANUFACTURING

PURPOSE: The purpose of this procedure is to define a method for the manufacture prototype

components for Design & Development Verification.

SCOPE: The procedure covers the manufacturing of prototype components for the Design Verification of the new products under development & also for the existing products undergoing design changes in R&D of FML, Pune.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with DH (Proto Mfg.) & operational responsibility lies with concerned SIC (Proto Mfg.)

PROCEDURE:

Refer flow chart for process – Proto manufacturing.

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TITLE: PROCEDURE FOR LAB TESTING / VEHICLE TESTING/ ENGINE TESTING

PURPOSE: The purpose of this procedure is to define the method for validation of sample(s) / vehicle(s)

by conducting required tests on the components at Component testing / on Vehicle / on Engine at test cells.

SCOPE: This procedure covers the

1) Proto samples developed for first time /second source development /Proto samples made in house/ Proto samples removed from vehicle / SIR / Modified samples / Field Failure / Data generation / Data collection.

2) Random selected samples received from Receipt Inspection (in CT).

3) Proto Vehicle/Engine developed first time.

Of R&D Department, FML, Pune

RESPONSIBILITY: The responsibility of implementation of this procedure lies with DH (Testing Group) & operational responsibility lies with SIC (Testing Group).

PROCEDURE:

Refer flow chart for process – Component testing/Vehicle Testing/Engine Testing.

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TITLE: PROCEDURE FOR DESIGN & DEVELOPMENT REVIEW.

PURPOSE: The purpose of this procedure is to define a method for the Design & Development Review.

SCOPE: The procedure covers the Design & Development Reviews for the new products under

development & the existing products undergoing the Design change in R&D of FML, Pune.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with HOD & operational responsibility lies with concerned DH.

PROCEDURE:

Refer flow chart for process – Design & Development Review.

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TITLE: PROCEDURE FOR CAE ANALYSIS.

PURPOSE: The purpose of this procedure is to define the method for conducting CAE Analysis.

SCOPE: The CAE Analysis covers the verification of concept design, detailed design and after validation design changes in the new products released for production and the products, which are in series production and also covers field failure, Simulation and modifications to avoid field failure for existing Products.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with HOD & operational responsibility lies with DH (CAE).

PROCEDURE:

Refer flow chart for process – CAE Analysis

58

TITLE: PROCEDURE FOR DESIGN & DEVELOPMENT OUTPUT.

PURPOSE: The purpose of this procedure is to define the method for Design & Development output documents.

SCOPE: This covers the Design & Development outputs documented by R&D Department of FML, Pune.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with HOD & operational

responsibility lies with DH Product Drawing & Engineering Documentation (PDED).

PROCEDURE:

Refer flow chart for process – Design & Development output


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TITLE: PROCEDURE FOR DESIGN CHANGES.

PURPOSE: The purpose of this procedure is to define the method for design changes.

SCOPE: It covers the design changes in the new products released for production and the products, which are in series production.

RESPONSIBILITY: The responsibility of implementation of this procedure lies with HOD & operational responsibility lies with DH(PDED).

PROCEDURE:

Refer flow chart for process – Design & Development changes.

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Document information on development of product with embedded software.

A. Calibration ID requested by Engine design to PDED.

B. PDED provides information like Vehicle type, Engine Number , Force number , Calibration ID Number and supplier Number / type by providing drawing number which is released.

C. Engine design will forward Calibration ID to suppliers.

D. Supplier provides different data sets for conductive emission , fuel consumption tests.

E. Based on tests conducted and test reports released by engine testing and vehicle testing , data set is finalised and it is informed to supplier for containerisation.

F. Finalized ECU's ( Electronically Controlled Unit) with containerised data set is introduced in series production.

G. Randomly selected vehicles and Engines from series production for emission test to ensure conformity of production ( COP).

H. Information on embedded software used on various product is available with concern design group in Format named "List of Systems with Embedded software" ( R&D/00/179 ).

73

StampApproved by:

Reviewed by: Revision date: 27.11.2017

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