The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Control Of Non Conforming Products in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. ​​If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.

1.0 Process Approach of Process of Control of Non Conforming Products

2.0 Turtle diagram of Control of Non Conforming Products

3.0 Corrective & Preventive Action ( 8-Discipline Report)

Part Name

Model

Part No.

Supplier part No.

Drg. Ref.

Drg. Modification status

Date

Feedback form

(1) PROBLEM AWARENESS

Problem Scope

Problem Severity

Problem Source                                           % Defect

New

Safety

Regulatory

Functioonal

Existing

Aesthetic

Reliability

Reopened

Others

(2) PROBLEM DEFINITION

(3) CONTAINMENT ACTION / SHORT TERM ACTION

NO.

Immediate Action Taken

Completion

Responsible

Date

(4) ROOT CAUSES (ttached root cause analysis Sheet -Fish Bone, Brainstorming,Pareto analysis,Why-Why analysis etc.)

(5) CORRECTIVE ACTIONS

VERIFICATION

DATE

METHOD

RESULTS

TARGET

EFFECTIVE

(6) PREVENTION

(6) VERIFICATION

DATE

METHOD

RESULTS

RESPONSIBILITY

TARGET

EFFECTIVE

(7) REVIEW -DOCUMENTS / SYSTEM(Attach copies of all revised documents)

No.

QMS DOCUMENT

IF YES

RESPONSIBLE

PLANNED DATE

ACTUAL DATE

STATUS

1

Control Plan

2

Process sheet

3

Drawing / Process flow diagram

4

PFMEA / DFMEA / PPAP

5

Process Map

6

Acceptance Standard

7

PM checklist

8

Work Instruction / Calibration Plan

(8) PROBLEM CLOSURE & SIGN-OFF

PROBLEM PROGRESS SUMMARY

CLOSURE SIGN-OFF

S.No.

Phase

Start date

End date

Team Member

Area

Sign-off

1

Problem Definition

2

Containment action

3

Root cause analysis

4

Corrective action

5

Solution confirmation

6

Closure

MANAGEMENT VERIFICATION & CLOSURE

Sign

Date

Name

Head

Manufacturing Chief

Quality Chief

Design chief

management Represntative

Plant Head

4.0 Deviation Request

DEPT.                                                                                PROCESS/AREA :                                                    DATE:                                  TIME:     MACHINE :                                                              PART DESCRIPTION :                                              PART NO:     CUSTOMER:                                                                                          IR NO:                                                      DEV. QTY:   LOT NO :                                                                                          MRN NO:                        MATERIAL:                           GRADE/FINISH :
NATURE OF DEVIATION							REASON
S.NO.	PARAMETER		SPECIFICATION		ACTUAL
							REQUESTED BY:
DETAILS OF ATLEAST 3 PREVIOUS LOTS
S.No	Supplied Qty	Actepted Qty.		Rej Qty.	Deviation if Any
CORRECTIVE ACTION SUGGESTED
ACTION PLAN						RESP.		TG. DATE	SIGN
CORRECTION & DISPOSITION:   ACCEPTED UNDER DEVIATION WITH /WITHOUT REPAIR:   TO BE REWORKED /CHANGED:   REGRADED FOR ALTERNATIVE APPLICATION:   REJECTED OR SCRAPPED:   TO BE SORTED NOW/ LATER STAGE:
FINAL REMARKS
DISPOSITION AUTHORITY

5.0   Disposal Note cum Rework Data

DISPOSITION AUTHORITY:

Deptt.:-

Period :-

S.No.

Part Name

Prod

Rej Pcs.

PPM (Rej.)

Nature of Rej.

Root cause

Action Plan

Cost/piece

Total Rej.cost

Rework Pcs.

PPM (Rew.)

Nature of Rework.

Root cause

Action Plan

Remarks

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Prepared By

Verify By

Approved by (DGM)

Approved by ( Director )

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Control of Records in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. ​​If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.

1.0 Process Approach of Process of Control of Records

2.0 Turtle Diagram of Process of Control of Records

3.0 Master list of Record Matrix

RECORD MATRIX						DATE
Department:					Process Owner:
Sl .No	Record Description		Record No		Location	Retention Period	Disposal Method	Disposal Authority
Prepared By:							Approved By:

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Control of Documents in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. ​​If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.

1.0 Process Approach of Process of Control of Document

2.0 Turtle Diagram of Process of Control of Document

3.0 Work Instruction of Document Numbering

4.0 Document Change Request

Change Request No:                                                                                                                             Date:
Document Ref.:                                                                                                                    Function /Area:
Detail(s) of Change :
Reason for Change :
REQUESTED BY : (NAME & INITIALS)			REVIEWED BY HOD Requesting Dept
MODIFICATION NOTE: (FOR M.R OFFICE USE ONLY)
Impact on :	a) Cost
	b) Quality/Productivity
	c) QMS system
	d) Any other Process
Management Representative’s  Remarks:
Approved                                    Not Approved   If not approved, attach reasons for the same Concerned approving authority of original document
Implementation Date:
Revision  No.:

5.0 MASTER LIST OF DOCUMENTS (INTERNAL)

Sr.No

Document Description

Document No.

Retention Period

Rev No

Rev date

Distribution

PREPARED BY:

APPROVED BY:

6.0 Master List of Documents (External)

Sr.No	Document No	Document Description	Issue No	Distribution
PREPARED BY:			APPROVED BY:

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Continual Improvement in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. ​​If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.

1.0 Process Approach of Process of Continual Improvement

2.0 Turtle diagram of Process of Continual Improvement

4.0 Kaizen sheet

5.0 Things Go Wrong/ Thing Go Right

Things Go Wrong / Things Go Right
Customer Name :			Project Name & No :
Project Start Date :-			Project Completion Date :-
S.No.	Description of Things Go Wrong		S.No.	Description of Things Go Right
PREPARED BY				Approved By

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Tooling Mfg & Management in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. ​​If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.

1.0 Process Approach of Process of Tooling Mfg & Management

2.0 Turtle Diagram of Process of Tooling Mfg & Management

3.0 TOOL , GUAGE JIG AND FIXTURE REQUEST FORM

From Engg. Department to Tool Room

Date ……. Project Name. ………. Tooling Drawing no. ……….   Part Name …………….                                          Part No. ………….. Customer Code  ………………… To be developed for (Modification,New,Spare,Prototype or other)…………….     Items attached are;-   1) Part Dwg.   2) Sample part ( if available )   Received by   Signature of Engg. HOD:                                                     Signature of T/R HOD:

4.0 Activity Timing Plan (PERT)

Part  Name

Project Name ;-                                                                                     Tool , Gauges, Jig & Fixtures Descripation ;–

Date Updated :

Die Fitter Name

Sl No

Activity

Weeks

Days

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

Legend

PM

Planned Marked

CM

Completed Marked

MP

Progress Marked

DM

Delay marked

HM

Holiday marked

MM

Planning after Modification

Remarks

Prepared By

Approved by

5.0 Tool, Gauges, Jig & Fixture Development Plan

Date

Tool Name & ID Code ;————————————–

Project Name ;-

S. No.

Activity Planned

Responsilbility

Starting Date

Completion date

Remarks / status

Planned

Actual

Planned

Actual

Cost Calculation:

S.No

Material Specfication

Total Qty. required

Material Cost

Man-Hour

Total Man hour Cost (b)

Machining Cost (C )

Miscellaneous cost (d)

Total Planned Cost(a+b+c+d)

Total Actual Cost(a+b+c+d)

Planned

Actual (a)

Planned (a)

Actual (a)

Planned (b)

Actual (b)

Planned

Actual (c)

Prepared By Approved By

6.0 Inspection Report

PROJECT NAME:

DATE:                                                                                                                             IR NO ;

COMPONENT NAME               :-

TOOL NAME                              :-

S.NO

STAGE

SUPPLIER NAME

CHECK PARAMETER

SPEC. WITH TOLR.

OBSERVATIONS

STATUS

Remarks

INTERNAL

EXTERNAL

1

2

3

4

5

CHECKED BY:-                          APPROVED BY:-

7.0 Job Card

JOB CARD						COMPONENT NAME :
						REF. DRAWING NO.    :
S.NO	TOOL, GAUGES , JIG& FIXTURE DESCRIPTION	OPREATOR NAME	MACHINE NAME	MACHINE NO.	SPECIFICATION	TYPE OF OPERATION	STARTING DATE & TIME	COMPLETION DATE	REMARKS

8.0 Rejection Disposal Note

Disposal Note for Rejected Tools

Deptt.:

Period :

S.No.

Material receipt Date

External /Internal agency Name

Tool Name

Individual part name

Operation perfomed

IR No

Receipt Qty

Reject Qty

Reason of Rejection

Action on Rejection

Loss ( In Rs. )

Remarks

Prepared By

Verified By

Approved by

9.0 Inspection Checklist For Tools,Gauges ,Jig & Fixture

Inspection Checklist For Tools,Gauges ,Jig & Fixture
Project Name.;-		Die Fitter Name  :-		Select Tool Operation
				BL	DR	PI	BND	NTC	JIG & FIXTURES
Part Name;-		Date;-		STM	FLT	BEED	CRUSH	ASSY.	Gauges
				Part No ;-
Class.	Inspection parameters	STATUS		Remarks
		OK	NOT OK
1. Safety	a) Are tapped shank and loading bolts safe?
	c) Is there any sharp corner ?
2. Tightening of bolt	a) Is tightening of normal kinds of BOLT good?
	b) Is the fitted-length of DOWEL PIN over 2 times of diameter?
3. Draw die And location check	a) Are necessary/sufficient sheet gauges/location pins and stopper available?
	B) Are the position of location pins and stopper at correct/appropriate location?
	c) poke yoke for blank location.
	d) Is there any movement in location pins and stopper due to unavailability/loose condition of screw?
	e) Are stoppers fixed with dowel pins?
4.sliding parts & ejection	A) Slide of Bush, Pillar, Alignment pins is good contact? (Contact 80%)
5.Surface finish	a) Is SURFACE FINISH of PUNCH / DIE OK?
6. Clearance	a) Is clearance of Die/Punch proper?
7. Trim steel condition punch and die condition	a) Is there any dangerous pin hole, crank on cutting edge?
	b) Is Bottom die 2nd relief proper?
	c) Is punch peneteration into die enough?
	f) Is SCRAP falling directly into chute/scrap box after triming?
8. component Loading and Unloading	a) Is component location easier for operator ( check gauge and locators) ?
	b) Is there any possibility of mislocation ?
		Required	Observed
Checking parameters	Punch size
	Die size
	Stopper size
	Locater/Strip guide size
	Ejector size
ABB. USED- BL=Blanking, DR= DRW, PI=piercing, BND=bending, NTC=notching, STM=stamping , FLT=flattning, BEED=beeding, CRUSH=crushing, ASSY.=assembly

10.0 Tool History Card

Tool name:

Tool ID CODE:

TOOL SERIAL NO.:

Tool Life Monitoring

Designed tool Life

Date

Sl. #

Breakdown Detail

Observed Reasons of Breakdown

Maintenance done

Detail Of Pending Points

Final Comment of Tool Room After Rectification

No, of Stroke before tool Rec. to Tool Room

Record.

Detail of Breakdown Time

Total Maint. Cost

Production Dept.

Tool Room

Cumm. Strokes

Die life %

Start

Compleation

Total Time (Min)

Date

Time

Date

Time

PREPARED BY

APPROVED BY

11.0 Master List of Tools

COMPONENT NAME :
S. NO.	TOOL  DESCRIPTION	PROJECT	MINIMUM TONNAGE	LOCATION	ID CODE	Remarks
Prepared BY:		APPROVED BY:

12 Tool Life Monitoring Card

Location ( Dept ) :					Operation :
Tool Description. :					Part Name :
Sr.#	Date	Strokes Per Day				Detail of Tool Movement			Sign. ( Tool Room HOD )
		Shift A	Shift B	Total Nos Of Stocks	Commu.	Tool Move For Preventive Maint/For Repaird /For Production
	NOTE : CHANGE THE PART AFTER 99.5% OF PART LIFE CONSUMPTION..
S.NO	PERISHABLE PART NAME				PART REPLACEMENT DUE (STROKES)			REMARKS
Prepared By    Approved By

13.0 Preventive Maintenance Schedule

PREVENTIVE MAINTENANCE SCHEDULE & MONITORING SHEET FOR TOOLS, JIG & FIXTURES																																		Year :
TOOL NAME :																			TOOL ID.-												Dept.:
(MOINTORING SHEET )																																SCHEDULE
																																Week				Mth.	Qtr.	H-Yr	Year
Month	1	2	3	4	5	6	7	8	9	10	11	12	13	14	15	16	17	18	19	20	21	22	23	24	25	26	27	28	29	30	31	1	2	3	4
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
MAJOR WORK DONE DURING PREVENTIVE MAINTENANCE
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
LEGEND		Weekly			▲			MONTHLY					♦			Quaterly						●			Half Yearly					■				Yearly			∏
PREPARED BY:-                                                                                                                                                                                                     APPROVED  BY:-

14.0 Preventive Maintenance Checklist

Inspection Checklist For  preventive maintenance of Tools, Jig & Fixtures
Project Name.;-		Die Fitter Name  :-			Select Tool Operation
					BL	DR	PI	BND	NTC	JIG & FIXTURES
Part Name;-		Preventive Frequency ;-
					STM	FLT	BEED	CRUSH	ASSY.
Part No ;-		Date ;-
Class.	Inspec. Items		STATUS		Remarks
			OK	NOT OK
1. Safety	a) Are tapped shank and loading bolting safe?
	b) Is there any sharp corner ?
2. Tightening of bolt	a) Is tightening of normal kinds of  BOLT good?
	b) Is the fitted-length of DOWEL PIN over 2 times of diameter?
	c) Are DOWEL PIN,BOLT prevented from falling?
	d) Are tightening of SPRING GUIDE PIN, equaillary GUIDE PIN good?
	e) Are tightening of sleeve BOLT, safe BOLT good? Is it prevented from untightening surely ?
3. Prevention of key turning of turning	a) Is there any key to prevent turning at form-changeable part and  hard part’s PIERCE PUNCH and DIE BUSH ?
4. Draw die And location check	a) Are necessary/sufficient sheet gauges/location pins and stopper available?
	b) Are the condition of location pins and stopper good without any damage?
	c) Are the position of location pins and stopper at correct/appropriate location?
	d) Is there any movement in location pins and stopper due to unavailability/loose condition of screw?
	e) Are stoppers fixed with dowel pins?
	f) Is there pin hole in metal flow areas ?
	g) Is there any wear of coating in Punch,Blank Holder,Die surface?
5. Sliding parts	a) SLIDE of BUSH PILLAR, ALIGNMENT PINS is good contact ? (Contact 80%)
	b) Is there any play or lateral movement found in cam?
	c) Is CAM SLIDE  in good contact ? ( More than 70%contact)
6.Surface finish	a) Is SURFACE FINISH  of  PUNCH / DIE OK?
	b) Is metal flow Surfaces should be free from scratches
	* a),b)NOTE : POLISHED by oil stone, it must not be scratched

Class.	Inspec. Items	STATUS		Remarks
		OK	NOT OK
7. CLEARANCE	a) Is CLEARANCE of  DIE/PUNCH proper?
	b) CLEARANCE of TRIM, PIERCE is proper ?
8.Trim steel condition , punch and die condition	a) Is there any dangerous pin hole, crack on cutting edge ?
	B) Is Bottom die 2nd relief proper ?
	C) Is punch peneteration into die enough ?
	D) Scrap cutter height checking – weather hitting top die or not ?
	E) Is spring relief for all punches and trim inserts proper ?
9.Condition of die spring	a) TRIMMING and STROKE pressing spring are proper?
	b) Pad and PUNCH DIE gap ok?
10.Disposition of scrap	a) Is Flow of piercing scrap is good ?
	b)PI SCRAP falls one by one surely?If dropping left thing slightly,then does it fall ?
	c) Any possibility that SCRAP is connected continually?
	d) Is extension scrap chute proper ?
	e) Is cam piercing slug falling freely without stacking ?
	f) Is SCRAP falling directly into chute/scrap box after triming?
	g) IS PI SCRAPcoming out of insert? C/PI and  SCRAP should directly go into chute/scrap box?
	h) Is SCRAP BOX size OK and slug to be cleared properly ?
11.Lifter	a) Is lifter’s function proper ? Is lifter lifting  strip proper  ?
12.component Loading and Unloading	a) Is component location easier for operator ( check gauge and locators) ?
	b) Is there any possibility of mislocation ?
ABB. USED- BL=Blanking,DR= DRW, PI=piercing,BND=bending, NTC=notching,STM=stamping ,FLT=flattning ,BEED=beeding , CRUSH=crushing , ASSY.=assembly,NA= Not Applicable

15.0 Tool Intimation Slip

Brakedown	Preventive maintenance				Resharpening
Department : PRD/                   /        /              To:-      TRM/Mech./Elect.						Date :
Equipment Name :			Equipment No.:
STATUS ( BEFORE MAINTENANCE )
Problem Observed/Condition of Equipment :					Production Stopped		YES / NO
					Produce Qty ;
					Breakdown Date:
					Breakdown Time:
					Signature of concerned dept.
STATUS ( AFTER MAINTENANCE )
Handover Date :		Equipment Status			Signature of concerned dept.
Handover Time :		GOOD		YES /  NO
Total Breakdown Time :		TEMPORARY WORKING		YES /  NO
ANALYSIS
Immediate Action :					OCCURANCE
					Repeat	YES / NO
					First time	YES / NO
					Production Stoppage Time	Hours
Root Cause :						Minutes
					PRODUCTION LOSS
					Production  Loss(shots)
					Production  Loss(Rs.)
Counter measure after determining root cause of breakdown :					Idle Time Manpower Loss (Rs.)
					TOTAL LOSS (Rs.)
					Parts Replaced ;
MAINTENANCE COST			REMARKS
Replacement Part Cost(Rs.)
Man power Cost(Rs.)
Subcontractor  Cost(Rs.)
TOTAL COST (Rs.)
Attended By                                                                               Sign (Incharge)
Prepared By                                                                                 Approved by

16.0 Breakdown Summary Sheet

BREAKDOWN SUMMARY SHEET						Review Date
SR. No.	Date	Tool/Fixture Description (ID)	Dept	Project	Status of B.D	Root Cause  Analysis	Sign of T/R Incharge
PREPARED  BY						APPROVED  BY

17.0 WHY – WHY ANALYSIS

PROBLEM OBSERVED :	Tool name :                               DATE:
CONTAINMENT ACTION :	Tool no. :
RESULT :
WHY	ANALYSIS	ACTION
TEAM MEMBERS :

18.0 MATERIAL REQUISITION SLIP

From…………………                                                                                                   No.     Date:………………… To: store
Please issue the following material:
S.NO.	PARTICULARS	STOCK NO.	UOM	QUANTITY				REMARKS
				Reqd.	To be filled by store department
					Issued	Available	To be procured
(Shop Incharge) Issued by: STORE INCHARGE