MANAGEMENT REVIEW MEETING MINUTES
Glasstech Industries (India) Pvt Ltd. S.No
MRM No.: 1
Topics
ISO Num :F / MR/ MRMMOM VER :1.0
Date : 20th Nov 09
Action Plan
Responsibility
Target Date
Remarks Status as on 20th Nov 09
1
Pending points of previous MRM meeting.
2
Review of Objectives
a
Customer complaints
b
Production Volumes
c
Inprocess rejections
d
Ontime delivery
3
Internal Quality Audit
This is the 1st MRM meeting as per ISO 9001:2008 standards , however last MRM's points were discussed & reviwed , These points also will be taken into consideration in the next MRM agenda meeting .
MR
The objectives set in Aug 09 were reviewed & were found in line with the targets set ( Refer annexure for the results of 4 objectives set)
COO
Discussed
From Aug 09 to Oct 09
Closed
In the Internal Quality Audit conducted on 7th & 9th Nov 09 - Total 14 NC & 2 obs were found ( Refer the Annexure of Audt summary ) Marketing 2 NC & 1 obs
1 NC & 1 OBS closed & 1 NC Pending
Management Responsibility - Nil
Nil
MR - Nil
NIL
Human Resource - Nil
NIl
PPC - 1 NC Production Drilling - 1NC
1 NC closed 1 NC pending
Production Tempering - 2NC
2 NC closed
Production Lami - 1 NC
1 NC closed
Production DGU - 1 Nc , 1 Obs
1 NC closed & 1 obs pending
Dispatch - 1 NC
1 NC Pending
Quality Assurance - 1 NC
1 NC Closed
Maintenance - 1 NC
1 NC closed
Stores - 2 NC Purchase - 1 NC
1 NC closed & 1 NC pending 1 NC Closed
Note : Final review by MR is pending for all the NCs & will be completed by 28th Nov 09 , Targets dates for completion are given in NCR reports
4
Process performance
Temepred /HS Glass - 107 test done - 106 pass , 1 fial (approx 30 glasses were retempered job num 905 )
QC Manger
Upto Oct 09
Closed
Roller wave test : 76 Test done - 76 test pass - Max value of Avg dept found to be 0.19 mm in Job num 812 & 900 against the Target of 0.2 mm .
QC Manger
Upto Oct 09
Closed
DGU Potlife Test - Total 64 Test done - 63 test pass - 1 fail due to more fast curing time ( resetting done & made ok) .
QC Manger
Upto Oct 09
Closed
DGU Butter fly - Total 60 Test done , 58 test pass - 2 fail ( resetting done )
QC Manger
Upto Oct 09
Closed
DGU Dessicant Test - Total 56 test done - 56 test pass
QC Manger
Upto Oct 09
Closed
DGU shore A Hardnesss - Total 58 Test done - 58 Test pass
QC Manger
Upto Oct 09
Closed
Lamination : Boil Test 15 Test done & 15 test pass
QC Manger
Upto Oct 09
Closed
Room Conditions - Daily basis 2 times reading taken , All found Below 30 Deg c
QC Manger
Upto Oct 09
Closed
5
Product confirmity
Based on the inprocess & Random Test inspection reports Dimensions : From last 3 months the data recorded for sizes found with max +/- 1 mm
QC Manger
Upto Oct 09
Closed
6
CA PA customer complaints
From last 3 moths for the complaints accepted by Glasstech 6 Corrective action have been taken & are closed ,Most of the colours for Master colour samples are ready ,few samples are pending as till date order has been not placed for them
Marketing Head & QC Manger
Up to Oct 09
Closed
7
CA PA Inprocess rejections
From the past 3 months data , in 3 areas corrective action were QC Manager & taken ,Viz Grinding machine, Tempering Machine , Handling Breakage CFT Team in all deptts & have been started implenting .
Oct-09
Closed
8
Training
It was decided to meet the Planned the trainning session & individual deptts head to speed up & regularise tranning progamms.
Plant Manger/HR Admin
By Next review meeting
Closed
a
Regular training
For 1st Quarter Sessions planned - 12 , Sessions Actual- 8
Concerned Deptt Heads
Till Oct 09
Closed
b
Safety training
Session Plan - 1 , Session Actual- 1
HR Admin
Till Oct 09
Closed
c
Fire fighting training
Session Plan - 1 , Session Actual- 0
HR Admin
Till Oct 09
Closed
d
First Aid training
Session Plan - 1 , Session Actual- 1
HR Admin
Till Oct 09
Closed
9
Production Head / QC manger
2] Control plan in details to be made for controlling the process at micro level. Detailed training to be provided to the workers for same .
Production Head / QC manger
3] Exsisting machine check list are not detailed one , hence there are chances of missing the checks before start up of machine . Detailed machine checklist to be made & introduced.
Production Head / QC manger
By Next review meeting
4] The ideas coming from the suggestions schemes to be implemented & results to be monitored for the benefits getting to the company.
Production Head / QC manger
By Next review meeting
5] Pls for re-training of all the operators & incharges for Tempering, DGU & Lamination line by machine supplier.
Production Head / QC manger
By Next review meeting
6] Introduction of format for recording , control & traceability of Incoming farmas & Out going farmas
Production Head / QC manger
By Next review meeting
7] Enlarged area for stores planned in the new shade .
Production Head / QC manger
By Next review meeting
8] Exsisting ceramic printing supplier to be discontinued , once the New ceramic printing line is installed & commissioned .
Production Head / QC manger
By Next review meeting
Plant Manager
Oct-09
Closed
Mr Anoop ( Marketing)
Oct-09
Discussed
Oct-09
Closed
Plant Manager
By Nov09 end
Inprocess
Plant Manager
By Jan 09 end
Inprocess
10
Devaitions /Consession From Aug 09 to Till date , 5 Devaitions have been recorded for minor issues related to asthetics looks & till date no complaints forms & details received for those deviations sent.
11
Customer Feed Back
12
Changes in SOP & QSM No Issues
13
This being the first By Next review MRM , improvements are planned & meeting completion, implementation will be reviewed in next By Next review meeting. meeting
Summary of Continuous 1] To Set Min Max Consumables list by each process / Deptt Improvements Planned ( Benefit : Inventory cost will reduce , Stock problems will decrease & achieved ( BY Plant as minimium stock will be mainted by Stores & Purchase ) Manager & QA )
Prior to Aug 09 ,Total 12 feedbacks received & 1 form had negative feecback form for delivery concern, From Aug 09 to Oct 09 Total 5 feedback forms received ,& no negative feed back received .
MR
Resource needs to any It is planned to have a Manual grinding team on contract Basis for
grinding work of edge polishing & minor repair works like scratches 3 nos fresh Diploma electronics enggs needed in all 3shifts for machine manitenance team to handle the sophesticated CNC Based machines
Prepared by
Checked By
Approved by
MR
COO
Glasstech Industries India Pvt Ltd ( Obj Sr. No.
Area
1st Unit of Last Year Avg Target Measure data 08for this ment 09 year 09-10 April.09
Inprocess rejections 1 ( Excluding RM & Dispatch ,Transport Breakage
%
NA
2%
4.46
Average
4.8
Total Rejections ( Customer complaints + 2 Dispatch & Transit breakage+RM defects +Inprocess rejections)
%
NA
3%
6
Average 3
Quarter
6.4
Customer complaints Registered
Nos
Customer complaints Accepted
Nos
No of orders
Nos %
% Accpeted complaints on Order basis
NA
NA
4
3nos /month
4
NA
NA
88
NA
2%
4.55
Average
4.4
4 Production Volumes Tempered Production DGU Production Laminated Production Total Production Volumes
FG FG FG FG
SQM SQM SQM SQM
NA NA NA NA
25000 9000 1833 35833
15988 7223 0 23211
Average
Tempered Rejection DGU Rejection Laminated Rejection % Rejection Tempered
21312 SQM SQM SQM %
NA NA NA NA
NA NA NA 0.50%
406.1 398.2 0.0 2.5
Average % Rejection DGU
3.6 %
NA
0.20%
5.5
Average % Rejection Laminated
4.7 %
NA
1%
0.0
Average
0.0
5 Ontime Delivery Total orders Total Delivery on time
% On time Delivery
Average
Nos Nos %
NA NA Na
NA NA 80%
,,,-
,-
t Ltd ( Objectives ) Year 09-10 1st Quarter
2nd Quarter
3rd Quarter
May.09 June.09 July.09 Aug.09 Sept.09 Oct.09
2.46
7.54
2.78
4.8 2.9
2.95
2.11
10.4
3.2
4
3.2
4
7
5
2
4
9
4
6
4
1
2
2
106
126
195
154
216
173
3.77
4.76
2.05
0.65
0.93
1.16
21312
1.3
#DIV/0!
2.9
#DIV/0!
2.9
3.5
1.2
17849 10346 14434 13401 8180 4349 4274 4581 0 0 0 1246 26029 14695 18708 19228
Dec.09 Jan.10
1.33
2.6
6.4
4.4
Nov.09
4th Quarter
###
###
###
#DIV/0! 16003 4058 1963 22024
19194 5686 1854 26734
19987
445.5 588.3 196.7 136.0 141.6 122.1 31.6 362.6 79.2 36.1 32.5 43.0 0.0 0.0 0.0 27.8 62.4 26.2 2.5 5.7 1.4 1.0 0.9 0.6
0
#DIV/0!
0
0
8911
###
0
###
###
3.6 0.4
1.1 8.3
1.9
4.7 0.0
,-
0.8
0.8
1.1 0.0
0.0
0.0 ,,,-
0.8
#DIV/0!
2.2
0 0 0
154 118 77
53
###
#DIV/0! 3.2
1.4
1.8 ,,,-
###
#DIV/0!
###
#DIV/0! ###
#DIV/0! 216 179 83
173 141 82
###
#DIV/0!
### ###
#DIV/0!
###
###
#DIV/0!
4th Quarter
Actual Avg 09-10 March. Feb.10 10
3.4
#DIV/0!
### 4.7
#DIV/0!
###
3.3 ### ###
#DIV/0!
### 15316.4 5478.7 723.3
0
0
0
### ###
12552.4
Remarks
#DIV/0!
2.3
### ###
#DIV/0!
2.9
### ###
#DIV/0!
0.9
### ###
#DIV/0!
53.2
Customer complaints analysis Break up Month
Total no of complaints registered
Total no of complaints accepted
% Accepted
April.09
4
4
100
0
May.09
4
4
100
June.09
7
6
July.09
5
Aug.09
Production error
extra short
0
4
0
0
0
4
0
86
1
0
5
1
4
80
1
0
4
0
2
1
50
1
0
1
0
Sept.09
4
2
50
2
0
2
0
Oct.09
9
2
22
7
0
2
0
0 12
0
22
1
#DIV/ 0 0 0!
0
0
0
Nov.09
#DIV/0!
Dec.09
#DIV/0!
Jan.10
#DIV/0!
Feb.10
#DIV/0!
March.10
#DIV/0!
Total
35
23
66
April .10
#DIV/0!
May.10
#DIV/0!
June.10
#DIV/0!
July.10
#DIV/0!
Aug.10
#DIV/0!
Sept.10
#DIV/0!
Oct.10
#DIV/0!
Nov.10
#DIV/0!
Dec.10
#DIV/0!
Jan.11
#DIV/0!
Feb.11
#DIV/0!
March.11
#DIV/0!
Total
0
Quater1 Aug 09 ~oct 09 Aug-09 Sep-09
0
Target 3nos /month
Actual
Customer Not an error complaint
Avg
1 2
2
Nov 09 Corrective actions :
No Actions taken as res
Nov 09 Corrective actions :
Oct-09
Quater2 Nov 09 ~ Jan10
3nos /month
Target 3nos /month
Target
3 nos /month
Jul-10
5
4
No corrective actions were planned as in some cases but verbal strict instructions were given to respective pr
Actual
Avg
May 10 Corrective actions : Due to heavy production load & year ending completion During heavy load exsisting people make mistakes in ba COO informed all the take necessary actions against th of money for each replacement & discussed about abou Admin to call for Biodatas . Also discussed to put final inspection team at dispatch COO planned to meet individual process owners to dis Discussed to start an internal mistake register for all dep be made & necessary action will be taken on respective
17
9
8
Target
May-10
Jun-10
Feb 10 Corrective actions : Dec-09 , complaint number 48 was later on found as cus know to us , but sent with the intention that it will go ins
3
Apr-10
Quater4 May10~July 10
Avg
3
Feb-10
Mar-10
Actual 5
Jan-10
Quater3 Feb 0 ~ April 10
2 3
Nov-09 Dec-09
No Actions taken as res
Actual
Avg
12 2 nos /month
9
6
9
Aug 09 Corrective actions : In july 2010 , Final inspection team deputed in Dispatch In july 2010 fresh Diploma engineers were appointed & Mistake register started from 22nd of July 2010 Rejection from may 10 was decreasing as all process we To make aware to all incharges about loss in comany in Hence no corrective action were taken for this quater , o planned.
ysis
up
ons :
Break up Production error
Head office error
Labelling issue
Visual Size Drilling Coating defect error error damage error
0
0
4
1
0
0
4
4
0
0
5
0
0
4
0
0
1
0
0
2
0
0
2
2
wrong coating side
DGU error
Temp Ceram ering i crror error
3 2 3
1
1
1
3
0
5
5
3
0
0
0
0
0
0
0
0
0
0
0 0 0
0
0
22 0 0 0 0 0 0 0 0 0 0 0 0
0
0
0
No Actions taken as results are with the targets
ons : ber 48 was later on found as customer error as he didn’t give the orientation pattern & complaint 50 was with the intention that it will go inside the fitting.
ere planned as in some cases only cleaning & chipping issue was observed ions were given to respective process owners for avoiding such issues in future.
ions : n load & year ending completion work , errors increased to an Avg 9 , against an target of 3 . ting people make mistakes in basic things. ake necessary actions against the respective operators , make them aware about loss to company interms cement & discussed about about putting new fresh diploma holders in each process & informed HR as . inal inspection team at dispatch stage after 1~2 months to control rejections if rejection rate continues. individual process owners to discuss about the inprocess rejections as well. ernal mistake register for all deptts with 1 ~2 months , same to submit to Quality deptt , final summary will ction will be taken on respective process owners.
ions : ection team deputed in Dispatch stage , effective from 9th july 2010 ma engineers were appointed & training started. from 22nd of July 2010 was decreasing as all process were being monitored for control of rejections for basic reasons. charges about loss in comany in terms of money ion were taken for this quater , only monitoting of the data & discussion with respective process owers is
Break up DGU Chiiping, Fragments Wrong Delami Automatic Wavine packing/ condensat spots / not as per order / nation glass bkg ss loading ion scratch std PI
1 1 1 1
1
0
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
Replacement Analysis Year 09~10 ( Only Process Reject Cutting
Process
Grinding
Drilling
Edge Deletion
QTY
SQM
QTY
SQM
QTY
SQM
QTY
April.09
0
0
34
75.65
8
12.61
11
May.09
1
1.13
27
60.42
2
2.54
3
June.09
8
11.04
17
42.58
4
6.36
10
July.09
55
67.6
12
22.4
8
16.68
4
Aug.09
29
49.51
58
115.87
10
17.63
9
Sept.09 14
26.26
75
122.98
21
41.87
1
Oct.09
34.26
48
109.4
6
15.2
2
Nov.09 Dec.09 Jan.10 Feb.10 March.10
16
Total
123
189.8
271
549.3
59
112.89
40
Process Rejection Exculding Dispatch & RM Defects ) Edge Deletion
Ceramic
Tempering
Insulating
Lamination
SQM
QTY
SQM
QTY
SQM
QTY
SQM
QTY
24.26
54
118.28
184
406.08
223
398.2
0
10.23
29
50.23
223
445.54
14
31.56
0
12.6
8
17.25
374
588.28
209
362.56
0
14.54
26
44.55
85
196.68
32
79.2
17
22.71
70
140.48
67
136.04
30
36.12
17
3.29
4
8.9
78
141.59
16
32.45
23
3.19
0
0
63
122.12
21
42.96
11
90.82
191 379.69 1074
###
545 983.05
68
fects ) Lamination
Others (HO ,Site ,washing)
Sub Total
Production In SQM
SQM
QTY
SQM
QTY
SQM
Tem+DGU+Lam
0
0
0
514
1035.08
23211
0
20
37.61
319
639.26
26029
0
33
67.06
663
1107.73
14695
47.57
19
31.77
258
520.99
18708
27.78
10
21.61
300
567.75
19228
62.38
9
24.79
241
464.51
22024
26.15
2
3.48
169
356.76
26734
0
0
0
0
0
0
0
0
0
0
163.88
93
186.32 2464
###
% Rejection
4.46 2.46 7.54 2.78 2.95 2.11 1.33 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Devaitions / concession Month Aug-09 Sep-09 Oct-09
Deviation 0 5 0
Avg 2
Nov-09 Dec-09 Jan-10
###
Feb-10 Mar-10 Apr-10
###
May-10 Jun-10 Jul-10
###
Aug-10 Sep-10 Oct-10
###
Customer complaints against deviations 0 0 0 0 0 0
NIL Hard copy pasted in files
Feed back forms Month Feedback forms Aug-09 Sep-09 5 Oct-09
Avg 5
Nov-09 Dec-09 Jan-10
#DIV/0!
Feb-10 Mar-10 Apr-10
#DIV/0!
May-10 Jun-10 Jul-10
#DIV/0!
Aug-10 Sep-10 Oct-10
#DIV/0!
