The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Purchasing and Supplier Quality System Development 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 Supplier Quality System Development

2.0 Turtle Diagram of Process of Supplier Quality System Development

3.0 Purchasing Policy

• PURPOSE:         

The purpose of this procedure is to lay down defined guidelines for Delegation of Purchase Order processing & procurement of materials by defining authority levels for P.O clearance for smooth running of production.

• SCOPE:  

This procedure is applicable to Procurement of all types of materials required to run Production smoothly.

• RESPONSIBILITY:

HOD Purchasing is overall responsible for this procedure

• KEY PROCESS INDICATORS (KPI’s)

1. Internal Customer Complaints ( Nos.)
2. Cost Savings ( Rs.)
3. Loss of production due to non availability of material ( Rs.)
4. Line Stoppages due to non- availability of material ( Nos.)
5. Physical v/s ERP Inventory variation ( %age)
6. Material Stock Ledger for Consumables & Raw Material

• PROCESS FLOW

Procedure of Material procurement for various categories is as follows:

1. Raw Material & BOP’s: As per customer schedule, raw material planning is done by considering the Raw Material inventory, Defined Buffer Stock, WIP of every line and Finished Goods inventory. Accordingly, indents are raised by Purchase Department for approval as per Authority Level defined in Annexure – 1. After approval of indents, P.O. is generated by Purchase Department and sent to respective suppliers through fax, mail or by hand. Once the P.O is sent to the supplier, Purchase Department regularly follows up with the supplier to receive the material as per delivery schedule to ensure there are no line stoppages and defined buffer stock is maintained.

• Job Work related to Production:  As per the production requirements, the material is sent to the supplier through Excise Annexure. Subsequently, the Purchase Department regularly follows up with the supplier to receive the material as per delivery schedule.  After completion of material as per the Annexure, the bill is raised by the supplier.

• Job Work related to Tool Room / Maintenance: Requirement is generated by Tool Room & Maintenance departments for different types of Job Work such as Slot Cutting, Spline Cutting, Shaper, Temper, Wire Cut, EDM, Grinding, CNC Milling, Gear Cutting etc. After confirming the rates, Purchase department raises the indents for approval as per Annexure – 1 and after   generation of PO, material is sent to supplier, and after completion of work, the material is received back from the supplier along with proper invoice. Rates for Temper, Wire Cut and EDM are fixed as per Qty/Hrs and for Slot Cutting and other operations, the purchase department takes the rates from different suppliers as per the job.  

• Packing Material: As per production planning, requirement of packing material is generated and after approval as per Annexure – 1, Purchase order is generated and sent to supplier. Subsequently, Purchase department follows up with the supplier to get the material on-time.

• Consumables:  There are two sub categories in this,

Items in Minimum Level

Requirement for items in Minimum Level are generated by Purchase department on daily basis to maintain the stock for the same. After approval of indents, PO is generated and sent to supplier to get the material.                                                  

Items required by different departments as and when reqd.

Respective departments fill a “Requirement Form” against their requirements and sends to the purchase department. Purchase department generate the indents after confirming the prices i.e. whether that item has been procured in the past or else, locates the suppliers and take quotations. After comparison and negotiation, Purchase department raises the Request for Rate Approval to higher authority. Once the rates are approved, indent and PO is generated

• Capital Goods: For all thecapitalmachinery and other costlyequipments, prices are negotiated by Directors and/or G.M Operations. Purchase Department only generates the Draft PO’s as per finalized terms and sends them to respective suppliers after necessary approvals. Subsequently, Purchase department follows up with suppliers for getting the material on-time.

• Purchase Order Amendment: P.O Amendment is raised in some cases due to following reasons:

1. Change in prices in Raw Material PO’s
2. Change in P.O. quantity in some PO’s

All Purchase Order Amendments are approved as per authority levels defined in ………………and after approval sent to supplier by purchase department.

4.0 Purchase Intent

ABC Pvt. Ltd.

User ID.:

Print Date :

Page No.:

Indent No

Item Name

Size

UM

Min. Level

Rep. Qty.

Stock

Order Qty

Req. Qty

Rate

Supplier

Required For

Remarks

Approved By:-

5.0 Price Comparative Statement

Sub : Approval for purchase of required for  indent No._
S.No.	Item	Qty/Unit	Party’s Name	Rate	Party’s Name	Rate	Party’s Name	Rate	Party’s Name	Rate
General Terms:-   1. F.O.R                                                        2. Packing & Forwarding                                        3. Taxes                                                                                                                                                      4. Delivery Period                                                                                              5. Payment Terms                                                                                                                                    6. Discount                                        7. Validity of Quotation                                                           Kindly accord your approval to place our order on M/S    General Terms:-   1. F.O.R                                                        2. Packing & Forwarding                                        3. Taxes                                                                                                                                                      4. Delivery Period                                                                                              5. Payment Terms                                                                                                                                    6. Discount                                        7. Validity of Quotation                                                           Kindly accord your approval to place our order on M/S                                         [Prepared  by)                                                                                  [Approved By]
DOCUMENT No.		PREPARED BY	REVIEWED BY		APPROVED BY			DATE	PAGE
		HOD Materials	MS		Director				1 OF 1

6.0 Material Requisition slip

From…………………                                                                                                             No. To: store                                                                         MATERIAL REQUISITION SLIP
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:

7.0 Purchase Order – Verbal

PURCHASE ORDER – VERBAL							Date :
S. No.	Item Description	Material Specification	Unit	Quantity	Rate/Unit	Supplier Name	Delivery  Date
Prepared By				Approved By

8.0 List of ISO / Non ISO Certified Suppliers

S.NO	SUPPLIER NAME	ADDRESS	ISO	NON ISO
PREPARED BY		APPORVED BY

9.0 YEARLY PLAN FOR  SUPPLIER DEVELOPMENT

S.NO.	SUPPLIERS NAME	MONTH(s)
		Apr	May	June	July	Aug	Sep	Oct	Nov	Dec	Jan	Feb	March
1
2
3
4
5
6
7
8
9
10
11
12
13
14
	Approved                           Not Approved   If not approved, attach reasons for the same Management  Representative
	Implementation Date:
	PREPARED BY:						APPROVED BY:

SUPPLIER AUDIT CHECK SHEET
Score Evaluation Criteria		“2” =  Documented System & Full Compliance “1” =Documented System & Partial Compliance-(Action plan required) “0” =No Documented System-(Action plan required) “NA” = Not Applicable
Supplier :			Audit Date :
Auditor/s :		Auditee/s :	Reason for Audit :
Sr#	Area of Evaluation	Key Check points (Guidelines to be referred)	Observations/Notes	Score	%
A	General Organisation & Management Structure
1	The Mangement Structure and resource allocation sufficient to support all necessary disciplines	Organization Chart with key positions filledResources appear adequate to fulfill all tasks
2	Responsibilities and authority are defined and evidence supports effective employee training	Job descriptions for all levels of the organizationEmployee training defined & implementedSkill matrix
3	Management defines quality and performance objectives that promote Continuous Improvement	Goals defined in the Business PlanGoals reflect continuous improvementMinutes of Management Review MeetingsEvidence of Cost of Poor Quality analysis
4	Workplace Health, Safety, Cleanliness, and Environmental Protection practices are in place and are consistently adhered to	Plant is clean, orderly and well lit5S disciplines are in placeAppropriate machine guarding and safeties are evidentNo signs of visible pollution or spills
	Total Score General Organisation & Management Structure
B	Advanced Product Quality Planning
1	System in place to define approved packaging for storage and preservation of product	Approved packaging plans Warehouse is clean & orderlyPackaging ensures protection of product
2	Product Realization Process provides clear linkages between Product and Process Design and Control Methods	Presence of PFD, PFMEA & Control Plans – Linkage between PFMEA, Control Plan and inspection/control methods
3	Organization is equipped to support necessary verification, validation and monitoring of characteristics	Presence of critical inspection equipment (i.e. CMM, laboratory equipment, etc.)Availability of 3rd party certified test facilitiesInspection/test records to validate testingResponses to out of specification conditions
4	PPAP Sign Off	SPC Studies,Process and product qualification.

Sr#	Area of Evaluation	Key Check points (Guidelines to be referred)	Observations/Notes	Score	%
	Total Score  – Advanced Product Quality Planning
C	Product Realization, Measurement, Analysis & Improvement
1	The continuous conformance of purchased product is ensured	Requalification documents Incoming inspection recordsCorrective actions to non-conformancesThird-Party validation of material certificates
2	An adequate and effective Supplier Management Process is in place	– Supplier performance records Records of supplier response to non- conformancesSupplier Development of poor suppliersProcess to ensure use of customer approved suppliers, when appropriate
3	Process & System are regularly audited to ensure compliance and continuous improvement	Internal Audit recordsAudit schedule based on process requirements
4	Adequate method for Operation Control	-Setting Approval ‘-Inprocess Inspection ‘-Final Inspection ‘-PDI Inspection
5	Adequate method for Gauge Control	-Gauge Identification ‘-Master List of Gauges & Instruments ‘-Calibration Certificates
6	Work Instructions are implemented for all employees affecting product quality, including repair and re-work operations	Evidence of Work Instructions posted on lineRe-Work Instructions are aveilable
7	Production planning and control	-Planning of production and interlink with customer requirements and sub suppliers schedules. Capacity V/s Actual UtilizationProduction Plan V/s AchievedDelivery performance is monitored
8	There is an effective Predictive & Preventive equipment maintenance system	‘-Preventive maintenance schedule & records, including downtime analysis Master List of MachinesVisual condition of equipmentNo leaks, excessive grease, etc.

Supplier :			Audit Date :
Auditor/s :		Auditee/s :	Reason for Audit :
Sr#	Area of Evaluation	Key Check points (Guidelines to be referred)	Observations/Notes	Score	%
	Total Score  –  Product Realization, Measurement, Analysis & Improvement
D	Material, Facilities, Logistics & Tooling
1	Effective material identification and control is in place. Lack of visible bottlenecks or material constraints or tight and strict control of those. Material identified at all stages of operation	Suspect material identified and segragated in a secure and segregated areaProper storage of raw & finished materialsEvidence of FIFOSystem to monitor inventory levels and to drive stock size reduction
2	Material and lot traceability is implemented	Lot traceability records Receiving records with lot numbers recordedShipping records indicating lot numbersIn-process material with lot numbersShipped product can be traced back to received materialBar code labelling
3	System ensures preservation of Customer Tooling	Proper tool storage facilitiesTool maintenance records -Preventive maintenance schedule & records, including downtime analysis Master List of Tools
4	Plant capacity planning is up to date & Emergency strategies are available	-Current capacity studies and resource planning Evidence of contingency plansPotential bottlenecks identificationsafety stock identification
	Total Score  – Material, Facilities, Logistics & Tooling
	Over all Score (A+B+C+D)			0
Auditor Signature:			Supplier Signature:

10.0 Supplier CAPA

Supplier :		Audit Date :
Auditor :	Auditee :	Reply required by :
Description of Non-compliance
Root Cause
Corrective and Preventive action
Implementation date
		Signature
		Date

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Supplier Selection, Evaluation and Monitoring 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 Supplier Selection, Evaluation and Monitoring.

2.0 Turtle Diagram of Process of Supplier Selection, Evaluation and Monitoring.

3.0 Supplier Performance Rating

MONTH:

S.No

Supplier Name

Total  Qty Supplied

Total Qty Received (QR)

Total Qty Accepted (QA)

Quality Rating QA/QRx100

Delivery Rating DR=Quantity Received in a specific time/Quantity Scheduled

Line Disruption due supplier fault (OR1)

Customer Notification/ Disruption /Field Return (OR2)

Premium Freight Rating (OR3)

Other Rating OR= (OR1+OR2+OR3)x20

Quality System Audit Rating (QS )

Supplier Performance

Prepared By:   Supplier Performance in % = (0.50QR+ 0.20 DR + 0.15 OR+ 0.15 QS )

4.0 Supplier Assessment Form

5.0 Supplier Registration form

Date:

Company Name:

Address:

Supplier No:

Phone:

1. Contact Person:

Cell #

Fax:

2. Contact Person:

Cell #

Email:

3. Contact Person:

Cell #

Note: Failure to send the enclosures (documents of proof) will be treated as non-compliance in that area. Type:                                          Manufacturing Unit                           Trading Ownership:                               Proprietorship                                        Private Limted                      Limited For Manufacturing Units: Competency Matrix of the Workforce:

Total No of Employees

SSC (10th)

HSC (12th)

Diploma

Graduate

Post Graduate

Years of Experience

Education Base

Section

Up To 5

5-10

10-15

15-20

20-25

> 25

Total

Manufacturing Capacity Total Production Capacity:           Shifts/Day:               Day / Night / Both Manufacturing Facilities Available: (Attach Separate Sheet, if reqd. ) Financial Strength Turnover of the Company (In Lacs):                                                                                                                                                 Are there any Expansion Plans:                                                                                                                                                                (Attach Separate Sheet, if reqd. ) Quality System Do you have a Third Party Certified Quality Management System?                Yes                          No If yes, which certification?               ISO 9001:2015                    IATF16949 : 2016                 ISO14001:2015 (Please enclose a copy of your certificate)? If no, do you have plans for any of the Certifications ?                 Yes                          No (If yes, please enclose activity time-plan for Certification) Customer Dependency (Indicate following data for top 5 customers)

Customer Name

Location

% Turnover

# of years associated with them

	SUPPLIER REGISTRATION FORM					Page 2 of 2
Environment & Safety The unit is registered under Factory Act?                  Yes                     No                  If yes, Reg. #                                                                                                          List the applicable Legal Requirement/Standard/Code of Practices:                                                    Number of Prosecutions, if any:                                                                                                No. of Reportable Accidents / Fatalities:  Major                                                          Minor                                     Are you aware of all existing and impending legislation influencing your business with us. (Please Attach the list). Under which category, does your Products/Processing Activities fall under the preview of Pollution Control Boards? Red         Green Please indicate your Source of Energy: Electricity/ Captive Generation /    Both Inspection & Testing Facilities
Give details of all Inspection & Testing Facilities available: ( Equipment name, year of mfg, LC, range, supplier, cal frequency, calibrated from etc )
Equipment Name		Least Count	Range	Supplier	Calibration Frequency	Calibration From (Internal / External)
Company Rubber Stamp (Stamp below):                                  Authorized Signatory:                                                                                                                          Designation:                                                                       Date & Place:

6.0 List of Approved Supplier

S. No.	Name	Approved for Part No. / Description	Address	Contact Person	Phone No.
					Mobile No.	Landline No.
Prepared By				Approved By

7.0 WORK INSTRUCTION FOR CALCULATING SUPPLIER RATING

1.0 PURPOSE:

To generate instructions for calculating supplier rating to improve the performance & to ensure Customer Satisfaction.

 2.0 SCOPE:

Applicable to all raw material / job work suppliers.                                                             

   QUALITY RATING (QR)-

•              QR=QA/QRX100
•              QA=Quantity Accepted
•              QR=Quantity Received
•              Qty accepted under deviation/ After Rework/ Rejected at Incoming
•              Stage shall be treated as Rejection.

DELIVERY RATING (DR)-

•             DR=QT/QSX100
•             QT=Quantity Received In Specific Time
•             QS=Quantity Scheduled

OTHER ISSUE RATING (OR)-

•            OR= (OR1+OR2+OR3+QR4) X20
•            OR1=Internal Line Disruption due To Supplier Fault

                                                                                 MARKS

•            None during Period                                    2
•            Once during Period                                    1
•            More than Once During Period                  0

  OR2=Customer disruption/Field/Customer return due to supplier Fault

                                                                                 MARKS

•            None during Period                                   1
•            Once or More during Period                      0

  OR3 =Premium Fright Rating

                                                                                 MARKS

•            None during Period                                  1
•            Once During Period                                  0

OR4 = Stock updation on weekly Basis by supplier end

                                                                                 MARKS

•           Stock update on weekly basis                     1
•           Stock not update on weekly basis              0

QUALITY SYSTEM RATING (QS)-

The score achieved by the supplier during the Quality System audit would get the 0.15 weightage.

 SUPPLIER PERFORMANCE IN %= (0.50QR+0.20DR+0.15OR+0.15QS)

CATEGORIZATION OF SUPPLIER–

1.         SPR- ABOVE 90 – CATEGORY ‘’OUTSTANDING’’
2.         SPR-> 80 < 90 – CATEGORY ‘’EXCELLENT’’
3.         SPR-> 70 < 80 – CATEGORY ‘’GOOD’’
4.         SPR-> 60 < 70 – CATEGORY ‘’SATISFACTORY’’
5.         SPR- < 60        – CATEGORY ‘’UNSATISFACTORY’’

• If Supplier Is categorized as ‘’Satisfactory’’ Inform to supplier to Improve and closely Monitor the Vendor Performance.
• If Supplier Is Categorised as ‘’Unsatisfactory’’ Send Two Month Notice cum-Warning Letter
• to supplier and monitor the supplies.
• If after two months No Improvement are evident, Disqualify the same and delete from ‘’List of Approved Supplier’’

.

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Production Process 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 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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
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

1. Shop HOD to prepare weekly rejection & rework material disposal note and handover to quality HOD.
2. Quality HOD will examine all shop rejection & get it signed from DGM manufacturing and Director.
3. Same signed disposal note to be handed over to dedicated person at scrap yard. Ownership of quantity verification is with HOD quality.
4. 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.
5. If any mismatch observed in quantity, informed to DGM manufacturing.
6. Only locked area rejection to be scrapped as parts/Assys. This is responsibility of security supervisor

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Plant Maintenance Process 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 Plant maintenance process

2.0 Turtle diagram of Plant maintenance process

3.0 Master list of Machines

S. No	Machine Name		Equipment Code	Dept/Area	Line no.	Range	Make
Prepared By :						Approved By :

4.0   List of Critical Spares

S.NO.	Name of parts	Min.stock level	Max.Stock Level	Remarks
A.	Mechanical
B.	Hydraulic
C	Electrical
D	Pneumatic
PREPARED BY                                                                                                                     Approved By

5.0 Preventive Maintenance Schedule

S. No

Machine Name

Equipment Code

Dept/Area

AMC REQ

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Prepared By :

Approved By :

6.0 Predictive Maintenance Schedule

S. No

Machine Name

Equipment Code

Dept/Area

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Prepared By :

Approved By :

7.0 Why-Why Analysis

Machine Code:	Date:		Report No :
PROBLEM OBSERVED :
CONTAINMENT ACTION :
RESULT :
WHY	ANSWER	ACTION	ANALYSIS
TEAM MEMBERS :
Root Cause:
Prepared by:	Approved by:

8.0 Monthly Breakdown Summary

Month :

Sr. No.

Area Wise

Machine B/D Frequency (No.s)

Machine B/D Time (Hrs.)

MTTR (Hrs.)

MTBF (Hrs.)

MECH

ELECT

ELECT & MECH

MECH

ELECT

ELECT & MECH

MECH

ELECT

ELECT & MECH

M/C AVL. Hrs.

MECH

ELECT

ELECT & MECH

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

PLANT LEVEL

B/D FREQUENCY MECHANICAL (No.s)

B/D FREQUENCY ELECTRICAL (No.s)

B/D FREQUENCY ELECT & MECH (No.s)

B/D TIME MECHANICAL (Hrs.)

B/D TIME ELECTRICAL (Hrs.)

B/D TIME ELECT & MECH (Hrs.)

MTTR MECHANICAL (Hrs.)

MTTR ELECTRICAL (Hrs.)

MTTR MECHANICAL & ELECTRICAL (Hrs.)

MACHINE AVAILABLE HOURS (Hrs.)

MTBF MECHANICAL (Hrs.)

MTBF ELECTRICAL (Hrs.)

MTBF MECHANICAL & ELECTRICAL (Hrs.)

PREPARED BY:            APPROVED BY :

9.0 Diesel Consumption Record

Diesel Consumption for the Month:

Sr. No.

Date

Start Time

Close Time

Total Hours

Cause of runing

Fuel opening Liters

Fuel close Liters

Diesel Consum.

Consum. Per Hours

Diesle Refling Qty Ltrs

Diesle Purchase QTY. Ltrs

Stand By Stock Ltrs

Total cost Per Day

Cost Per Hour

Prepared By

Approved by

10: Overhauling schedule

OVERHAULING SCHEDULE

S. No

Machine Name

Equipment Code

Dept/Area

kw

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Prepared By :

Approved By :