MNT-40-03 SAMRAT FORGINGS LIMITED Maintained by

03 Mar 2005 DERABASSI HOD

CONTINGENCY PLANS : LABOUR & FIELD RETURNS

Emergency Situation
Standby Responsibility
Contingency Responsibility in case of non-
Sl No
Severity
Contingency Plan
(Primary) availability of Main Location Remarks
Situation Person
Area
(Type)

This Contingency is
Manager (Production) to
in development Stage
Confirm On job training Manager (Prod) Manager (Maintenance) Mfg and as such has not
status of all Supervisors
taken a final shape
En-mass Total Absentee of Service levels will
1 Absentee by Skilled and severely dip
Skilled Labour Unskilled Labour down
Labour Availability (Refer Undertaking
Assurance from Ex (HRD) Ex (HRD) HR from Agency held by
Contracting Agency HRD)

If case proves to be
Factory Chargeable,
Sales & Batch Rejection Customer Release goods from Ex-
2
Marketing at Customer End Satisfaction Stock or if needed
VP (S&M) National Sales Manager S&M
ensure supply from other
Gates Locations

CONTENGENCY PLANS : UTILITIES

All Production Change over to 1750 Manager

Power Failure Manager (Maint)
comes to a Stop KVA DG Set (Utility)

Not to use the

Area Manager Manager (Prod)
Vulcunnizer
Vulucnizers will
not run and as
Boiler
such finishing
Unserviceable
area of product
will suffer Sw on 2 Ton Boiler for Manager
Manager (Maint)
chiller operations (Utility)

Chiller All Production Call the Thermax Engg. Manager

Utility Manager (Maint)
3 Unserviceable comes to a Stop From chandigarh (Utility)
Breakdown

0172-2638381

Compressor Total Prod Sw on the Standby 225 Manager

Manager (Maint)
Unserviceable Comes to a stop CFM compressor (Utility)

Total Prod
Borewell Proposal for spare in Manager
Comes to a stop Manager (Maint)
Unserviceable pipeline (Utility)
after 24 Hrs

CONTENGENCY PLANS : KEY EQUIPMENTS

Approved by
Rev 00 Reviewed by MR
DY MD
 MNT-40-03 SAMRAT FORGINGS LIMITED Maintained by
03 Mar 2005 DERABASSI HOD

Emergency Situation
Standby Responsibility
Contingency Responsibility in case of non-
Sl No
Severity
Contingency Plan
(Primary) availability of Main Location Remarks
Situation Person
Area
(Type)

Spare motor of 250 HP

Motor Failure Manager (E/M) Manager (Maint)
available

Extruder

Spare Drive cards

Drive Failure Manager (E/M) Manager (Maint)
available

Trolley
Spare available Manager (E/M) Manager (Maint)
movement motor

Vulcaniser

PLC Spare PLC available Manager (E/M) Manager (Maint)

Key
Manufacturing Spare Motor of 10 HP
Motor Failure Manager (E/M) Manager (Maint.)
Machines available
( HFM )

Stripper Drive Failure Spare Drive available Manager (E/M) Manager (Maint.)

Roll Damage 1 set of Roll available Manager (E/M) Manager (Maint.)

Haskel Pump not

Spare Haskel available Manager (E/M) Manager (Maint.)
building pressure

Proof Tester New

PLC defective Spare PLC available Manager (E/M) Manager (Maint.)

Main Motor
Mill Room Banbury Spare motor available Manager (E/M) Manager (Maint)
Failure

Drive Failure Spare not available Manager (E/M) Manager (Maint)

Hyd. Motor failure Spare motor available Manager (E/M) Manager (Maint)

Rotary Joint
Spare not available Manager (E/M) Manager (Maint)
failure

Dump Mill Motor Failure Spare motor available Manager (E/M) Manager (Maint)

Drive Failure Spare Drive available Manager (E/M) Manager (Maint)

Roll Damage Sheath mill to be used Manager (E/M) Manager (Maint)

Approved by
Rev 00 Reviewed by MR
DY MD
 MNT-40-03 SAMRAT FORGINGS LIMITED Maintained by
03 Mar 2005 DERABASSI HOD

Emergency Situation
Standby Responsibility
Contingency Responsibility in case of non-
Sl No
Severity
Contingency Plan
(Primary) availability of Main Location Remarks
Situation Person
Area
(Type)

VMI (Rubber
Spare motors not
Cooling & Motor Failure Manager (E/M) Manager (Maint)
available
Batching up)
Pratap Elect.

Belt Damage Spare Belt available Manager (E/M) Manager (Maint)

Spare motor of 250 HP

Motor Failure Manager (E/M) Manager (Maint)
available

Extruder

Spare Drive cards

Drive Failure Manager (E/M) Manager (Maint)
available
Key
Manufacturing
Machines
( PB )
Trolley
Spare available Manager (E/M) Manager (Maint)
movement motor

Vulcaniser

PLC Spare PLC available Manager (E/M) Manager (Maint)

Servo Motor
Spare motors available Manager (E/M) Manager (Maint)
(2 Nos.) failure

Key
Manufacturing Servo Drive
Wrapping M/C Servo drive not available Manager (E/M) Manager (Maint)
Machines failure
( PB ) Pratap Elect

System available but for

NC Control
commissioning Engineer Manager (E/M) Manager (Maint)
System failure
reqd. from Italy

Hyd.Motor failure Spare motor available Manager (E/M) Manager (Maint)

Pratap Elect

Hyd.Pump , Spare Pump , valves

Valves & Hydro and Hydro motor Manager (E/M) Manager (Maint)
motors failure available
Finishing
Catapuller
Rubber Belt
Belt available Manager (E/M) Manager (Maint)
damage

Pneumatic
Locally available Manager (E/M) Manager (Maint)
cylinders damage

Hoist Motor Motorised Chain Pulley

Manager (E/M) Manager (Maint)
failure Block
Pratap Elect
3 Ton Crane
Tie Up with Pratap
Traverse Motor
Electricals (24 Hr Manager (E/M) Manager (Maint)
failure
Downtime)
Pratap Elect

Hoist Motor Motorised Chain Pulley

Manager (E/M) Manager (Maint)
failure Block
Pratap Elect
2 Ton Crane

Approved by
Rev 00 Reviewed by MR
DY MD
 MNT-40-03 SAMRAT FORGINGS LIMITED Maintained by
03 Mar 2005 DERABASSI HOD

Emergency Situation
Standby Responsibility
Contingency Responsibility in case of non-
Sl No
Severity
Contingency Plan
(Primary) availability of Main Location Remarks
Situation Person
Area
(Type)
2 Ton Crane
Tie Up with Pratap
Traverse Motor
Electricals (24 Hr Manager (E/M) Manager (Maint)
failure
Downtime)
Pratap Elect

Tie Up with Pratap

Motor failure Electricals (24 Hr Manager (E/M) Manager (Maint)
Downtime)
Pratap Elect
OMA Braider

Drive failure Drive available Manager (E/M) Manager (Maint)

Date : 1-Jan-05 (Mukesh Malhotra)

President
Gates India Pvt Ltd

Approved by
Rev 00 Reviewed by MR
DY MD
 MNT-40-03 Gates India Pvt Ltd Maintained by
03 Mar 2005 HOD

CONTINGENCY PLANS : MANUFACTURING

Clause 6.3.2 of the ISO/TS16949:2002 standard calls for an organisation to have contingency plans for Utilities, Labour, Key Machines and Field Returns. Manufacturing being the main operation
to meet the customer requirements, it is decided that besides a routine course (backup contracted manpower) identified by most of the organisations, we at Gates India Pvt Ltd are planning to
training our Executive Cadre to meet this challenge through their professional excellence fully backed up by On-Job-Training and Hands-on-Experience imparted to them in peace times. This
plans is prepared in that context. All Executives are to be fully prepared for playing their role. This plan shall put on trial in January and December every year.

Name of Executive Identify Training

Sub Sl Activity
Sl No Plan Aspect Action to be Taken Responsible for during all stages of Target Date
No /Implementation
manning Position Contingency Plans

Mandrel

Wire Braiders

Yarn Braiders
List out Machines to
(a)
be Manned for HFM
Extruder

Vulcanizer

Proof Tester

Extruder

List out Machines to

Identify Mfg and Non-Mfg (b) Tubing
be Manned for PB
1 Operations that are VITAL to the
Customer Requirements
Covering

Mixing
(c) Mill Room
Calendaring

Utilities
(d) Maintenance
Machine
Maintenance

Office Operations

List out the Non-Mfg

(b)
Operations
Material Handling
in the Plant

Prepare Training
(a) For All Machines
Calendar

Plan Training for Executives for

2
abovementioned deficient areas
Finalize Training
(b) For All Machines
Faculties

To Hold Special
Review the Capability Status to Meeting or Discuss For all Mfg
3 (a)
manage the Contingency during Management Operations
Review Meeting

Executives to
Working staff to
Put the Contigency Plan on Trial in perform all
4 (a) operative as helper
one of the Shift functions of the
force
Operators

Certified that I have read and understood the special requirements and responsibilities attached with the Contingency Plans. As such I shall make
all efforts to remain fully prepared to meet any contingency of mass absence by our associates.
Contingency Plan Approved/Not Approved
(Lalit Mohan) (Chetan Kapoor) (Rajesh Chopra) (Vinay Taneja)

(Ajay Kumar) (Mukesh Malhotra)

Rev 00 Reviewed by MR Approved by

President
 MNT-40-03 Gates India Pvt Ltd Maintained by
03 Mar 2005 HOD
Clause 6.3.2 of the ISO/TS16949:2002 standard calls for an organisation to have contingency plans for Utilities, Labour, Key Machines and Field Returns. Manufacturing being the main operation
to meet the customer requirements, it is decided that besides a routine course (backup contracted manpower) identified by most of the organisations, we at Gates India Pvt Ltd are planning to
training our Executive Cadre to meet this challenge through their professional excellence fully backed up by On-Job-Training and Hands-on-Experience imparted to them in peace times. This
plans is prepared in that context. All Executives are to be fully prepared for playing their role. This plan shall put on trial in January and December every year.

Name of Executive Identify Training

Sub Sl Activity
Sl No Plan Aspect Action to be Taken Responsible for during all stages of Target Date
No /Implementation
manning Position Contingency Plans
(Vinay Taneja) (RK Saxena) (Gajender Singh) Date: Aug 05 Manager (Production) Date: Aug 05 President

Rev 00 Reviewed by MR Approved by

President