Template Process Optimization Check List

PROCESS OPTIMIZATION - CHECK LIST Shop:

Weld

Group Leader:

Date:

Zone:

H79

Team Leader:

Part No:

Zone:

H79

Associate:

Sl.no

Status

Check Points

OK NG NA

1

 Associate movemen movement/ t/ no.of walk walk step is reasonable reasonable

2

Operation is done within the Strike zone(within reach of hands)

3

 Associate is is not waiting waiting for the part /Mc/ Container  Container 

4

Cycle time of the process matches / within the Engg design cycle time

6

No additional operations/Over Processing found w.r.to Engg process design.  Associate has has no bending; bending; no no stretching; stretching; no weight weight lifting(>15Kg) lifting(>15Kg);; no abnormal posture.

7

 Associate is is involved for doing process optimzatio optimzation n kaizens recently. recently.

8

 Associate is is trained sufficiently sufficiently in the process process

9

No recent defect outflow from the process to Firewall/Customer.

POKA YOKE EVALUATION 10

 All Failure modes are are enlisted specific to the the process. process.

11

 All the Failure Failure modes modes are addresse addressed d by Poka Poka Yoke.

12

 Associate is is aware how how to inspect inspect each Poka Poka yoke to confirm its effectiveness.

13

Each Poka yoke is effective and robust.

STANDARD OPERATION 14

 All Operations Operations in the the weld shop have have 100% 100% SOP

15

 Associate awarene awareness ss about about Standard Standard Operation Operation is better. better.

16

 All SOPs are controlled controlled and displaye displayed d near to to the operators. operators.

17

SOPs have work instructions, work parameters, standards, quality key points, safety keypoints and material flow.

18

 Associate does does tip dressing dressing properly properly as per standard. standard.

19

 Associates wear Safety Safety PPE as as mentioned mentioned in the the SOP.

TPM & 5S

`

20

TPM Standards are arrived specific to the Jig & machine.

21

 Associate is is able to demostrate demostrate the TPM check points points one by by one as per sheet.

22

5S Standards are available & associates got trained.

23

 Associate is is able to demostrate demostrate as per 5S 5S check sheet. sheet.

MATERIAL FLOW 24

Raw Material FG trolleys and Child parts are placed at designated locations.

25

No swarf/ debris on the shop floor.

26

Child Parts/Parts SNP is fixed and been followed

28

The day production is equal to the day plan given by PPC. (Confirm for any over production/ under production) Fixed route for Transportation of Trolleys.

29

Dedicated Quarantine Area to keep the defective parts is in use.

30

Each Associate's skill matrix cum training plan is displayed.

31

Each Line's layout with material IN and OUT flow is displayed.

27

Technical Team:Loganathan - Lean (Leader) Dinesh - PED Xavier - Prodution Kumaresan - QA Mani - Tool room Sakthi - Maintenance

Part Name:

WASTE ELIMINATION

5

V4

REACTION STANDARDS 32

Reaction standard for Defect out flow is available & Practiced

33

Sweep away standards are clear & awareness among Associates and Inspectors are better.

34

Standard for handling Fallen fasteners & fallen parts on the floor.

35

Reaction standard for Power failure is available & Practiced

36

 Associate is is aware about about the recent defect defect outflow outflow & Counter Counter measures.

37

Counter measures are effective to avoid recurrence.

38

Firewall confirms defect outflow and feedback to concerned operator  Total

Observations

Recommendations

Resp.

Target

Support Required