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1.0 Process Approach of Production process



2.0 Turtle Diagram of Production process

3.0 COMMUNICATION MATRIX
Company Name | ||||||
DEPT; | AS ON DATE: | |||||
S.NO. | DESCRIPTION OF COMMUNIQUE | MODE OF COMMUNICATION | RESPONSIBILITY | FREQUENCY | COMMUNICATION RECD. FROM | COMMUNICATED TO |
4.0 Cost of Poor Quality
Details of Costs for calculating Cost of Poor Quality | ||||||
Cost of Raw Materials | Cost of Press Strokes / Machining / Welding | Cost of BOP Parts | ||||
Sl. # | Description | Price | Description | Cost per Stroke | Description | Price |
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Note: The above indicated costs are for Cost of Poor Quality Calculation purposes only. These are not actual costs. | ||||||
Approved By: |
DAILY DATA COLLECTION SHEET FOR COST OF POOR QULAITY
DATE :- | |||||||||||
Rejection Cost | Rework Cost | ||||||||||
S. NO. | PART NAME | Failure Process NAME | Raw Material Cost Rs./Nos. | Process Cost (Rs.) | Total Cost (Rs.) | Reject Qty ( No.) | Rejection | Rework | Rework Qty ( No.) | Rework | Remarks |
Cost Of Poor Quality (Rs) | Process Cost (Rs) | Cost Of Poor Quality (Rs) | |||||||||
5.0 Engineering Change Request
Part Name : | Date: | |||
Part Number/Drg Number : | Deptt: Name ;- | |||
Request to Dept.Name | ||||
S.No. | Existing Dimensions/Part | Changes Required | Reasons of changes | Remark If any |
REQUESTED BY | APPROVED BY |
6.0 Daily Production Report
Date | Shift (A/B) | Machine No | Operator | Part No | Operation | Production | Time Losses | Remarks | |||||||||||||
Plan Qty | Ok Qty | Rework | Rejection | Man | Machine | Material | Method | Measurement | |||||||||||||
Short | Absent | leave | B/Down | Setting | Internal | External | Total Trails | Fixture B/D | Samples | Decision | |||||||||||
Prepared By : Approved By: |
7.0 Disposal Note cum Rework Data
Deptt.:- | Period :- | ||||||||||||
S.No. | Part Name | Prod | Rej Pcs. | PPM (Rej.) | Nature of Rej. | Root cause | Action Plan | Rework Pcs. | PPM (Rew.) | Nature of Rework. | Root cause | Action Plan | Remarks |
Prepared By | Verify By | Approved by (DGM) | Approved by ( Director ) |
8.0 Competence Matrix
DEPTT: | ||
DOC.REF. | DEPTT/COMPETENCE MATRIX | DATE: |
REVISION: | 00: | Page : 1 of 1 |
Sr. No. | Level of Personnel | Educational Qualification | Experience Required | Skill Required (If any) | Remarks |
9.0 Identification and Monitoring of Work Environment
PROCESS NAME :
NAME OF DEPT :
HEAD OF DEPT:
AS ON DATE: REVISION NO.: Monitoring Details | ||
Name | Date | Sign |
S. No. | Environmental Parameters | Controlling Means (If any) | Resp. | Qty. | Goods Conditions | Remarks | ||
Reqd. | Avail. | OK | Not OK | |||||
A. | TEMPERATURE | |||||||
B. | LIGHTING | |||||||
C. | NOISE | |||||||
D. | HUMIDITY | |||||||
E. | PERSONAL PROTECTIVE EQUIPMENTS | |||||||
1. | MASK | |||||||
2. | HELMATE | |||||||
3. | APREN | |||||||
4. | GLOVES | |||||||
5. | GOGGLE | |||||||
6. | SHOES | |||||||
7. | EAR PLUG | |||||||
8. | SHIELD | |||||||
F. | HOUSE KEEPING | |||||||
NOTE: IN CASE, ANY OF WORK ENVIRONMENT PARAMETER IS NOT SUITABLE TO MEET PERFORMNACE INDICATORS, MAKE ACTION PLANS WITH TARGET DATE AND RESPONSIBILITY
(HOD) (UNIT HEAD)
10.0 Identification and Motoring of Work Environment
PROCESS NAME :
NAME OF DEPT : DEPT. HEAD:
AS ON DATE: REVISION NO.: Monitoring Details | ||
Name | Date | Sign |
S. No. | Environmental Parameters | Controlling Means (If any) | Resp. | Qty. | Goods Conditions | Remarks | ||
Reqd. | Avail. | OK | Not OK | |||||
A. | TEMPERATURE | |||||||
B. | LIGHTING | |||||||
C. | NOISE | |||||||
D. | HUMIDITY | |||||||
E. | PERSONAL PROTECTIVE EQUIPMENTS | |||||||
1. | MASK | |||||||
2. | HELMATE | |||||||
3. | APREN | |||||||
4. | GLOVES | |||||||
5. | GOGGLE | |||||||
6. | SHOES | |||||||
7. | EAR PLUG | |||||||
8. | SHIELD | |||||||
F. | HOUSE KEEPING | |||||||
NOTE: IN CASE, ANY OF WORK ENVIRONMENT PARAMETER IS NOT SUITABLE TO MEET PERFORMNACE INDICATORS, MAKE ACTION PLANS WITH TARGET DATE AND RESPONSIBILITY
(HOD) (UNIT HEAD)
11.0 CONTINGENCY PLAN
Department :
As On Date: / /
S.No. | Stage | Type of Contingency | Action Required | Responsibility |
Note : All contingencies like Utility Failures; Heavy Absenteeism, Key Machine Failures; Field Returns (Warranties); non-availability of raw materials / tools / consumables be considered.
(Signature)
12 Responsibility Matrix
DEPTT: | ||
DOC.REF. | DEPTT/RESPONSIBILITY MATRIX | DATE: |
`REVISION: | 00: | Page : 1 of 1 |
S.NO. | Name of Person | Designation | Responsibility |
13.0 WI FOR REJECTED MATERIAL DISPOSAL
- Shop HOD to prepare weekly rejection & rework material disposal note and handover to quality HOD.
- Quality HOD will examine all shop rejection & get it signed from DGM manufacturing and Director.
- Same signed disposal note to be handed over to dedicated person at scrap yard. Ownership of quantity verification is with HOD quality.
- The dedicated person will physically check the rejected quantity by counting as mentioned in disposal note and put in defined scrap area under lock and Key.
- If any mismatch observed in quantity, informed to DGM manufacturing.
- Only locked area rejection to be scrapped as parts/Assys. This is responsibility of security supervisor