1.

COPQ- Incoming Rejections Resp: Sonar / Vinod

S.No Day 1 2

1 No of Items received 406 2

Cost debitted to Supplier for quality

2 0 0
problem -- A

Cost absorbed by ATP due to rejections

3 0 0
@ incoming quality --B

4 Labor hours spent in rework/segregation 0 0

5 @ 240 Rs/Day, Labor cost -C 0 0

Remark _ _

COPQ.1 = B+C 0 0

COPQ.1 = B+C 0.00 0.00

Sonar / Vinod

3 4 5 6 7

180 420 24 0 100

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

_ _ _ _ _

0 0 0 0 0

0.00 0.00 0.00 0.00 0.00

COPQ- August 2021

8 9 10 11 12

0 437 292 0 80

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

_ _ _ _ _

0 0 0 0 0

0.00 0.00 0.00 0.00 0.00

13 14 15 16 17

314 40 0 0 184

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

_ _ _ _ _

0 0 0 0 0

0.00 0.00 0.00 0.00 0.00

18 19 20 21 22

340 360 120 120 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

_ _ _ _ _

0 0 0 0 0

0.00 0.00 0.00 0.00 0.00

23 24 25 26 27

192 0 428 455 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

_ _ _ _ _

0 0 0 0 0

0.00 0.00 0.00 0.00 0.00

28 29 30 31 Total

40 400 0 80 5014

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

_ _ _ _

0 0

0.00 0.00 0.00 0.00 0.00

 0

0.00
2.COPQ- Incoming Rejections Resp: Vyankatesh Sonar

S.No Day 1 2 3 4

1 No of Items received 16000 55497 15997 48634

Cost debitted to Supplier for quality

2 0 0 0 0
problem -- A

Cost absorbed by ATP due to

3 0 0 0 0
rejections @ incoming quality --B

Labor hours spent in

4 0 0 0 0
rework/segregation

5 @ 340 Rs/Day, Labor cost -C 0 0 0 0

Remark _ _ _ _

COPQ.3 = B+C 0 0 0 0
Resp: Vyankatesh Sonar COPQ August 2021

5 6 7 8 9 10 11 12 13

37700 800 47033 0 143032 71954 184619 73078 65028

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

_ _ _ _ _ _ _ _ _

0 0 0 0 0 0 0 0 0
 14 15 16 17 18 19 20 21 22

42028 2619 38620 52752 25019 58673 130272 7926 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

_ _ _ _ _ _ _ _ _

0 0 0 0 0 0 0 0 0
 23 24 25 26 27 28 29 30 31

51418 146335 77594 39313.2 37659 109954 2740 0 63944

0 0 0 0 0 0 0 0 112

0 0 0 0 0 0 0 0 11081.28

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

2302GS200030N - 112
NOS WATER MARK
S201-EMBLEM-
_ _ _ _ _ _ _ _

0 0 0 0 0 0 0 0 11081.28
11081
 COPQ - DATA - SUPLIER REJECTION (ASSY.)

S.No Day 1 2 3 4 5

1 No of Items received 2592 38381.26 53149.24 57277.58 63417.03

Cost debitted to Supplier for

2 0 0 0 0 0
quality problem -- A

Cost absorbed by ATP due to

3 0 0 0 0 0
rejections @ incoming quality --B

Labor hours spent in

4 0 0 0 0 0
rework/segregation

5 @ 240 Rs/Day, Labor cost -C 0 0 0 0 0

Remark _ _ _ _ _

COPQ.3 = B+C 0 0 0 0 0
CTION (ASSY.) COPQ August - 2021

6 7 8 9 10 11 12 13 14

70656.53 53204.367 0 62404.03 58155.27 64345.49 50908.9 69638.95 83635.09

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

_ _ _ _ _ _ _ _ _

0 0 0 0 0 0 0 0 0
 15 16 17 18 19 20 21 22 23

25745.09 52914.53 66288.49 48615.46 53723.15 48057.21 32868.32 0 29175.49

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

_ _ _ _ _ _ _ _ _

0 0 0 0 0 0 0 0 0
 24 25 26 27 28 29 30 31 Total Value

75488.93 65692.36 65933.94 76453.017 69088.17 0 58181.36 85149.21 1581140

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

_ _ _ _ _ _ _ _ 0

0 0 0 0 0 0 0 0 0

0
0
 3. COPQ - DATA - Dock August 2021

1 2 3 4 5
S.No Day

1 No of Items dispatched 200 100 0 0

WEEKLY OFF
Cost absorbed by ATP due to
2 0 0 0 0
rejections

Labor hours spent in

3 1.5 1 0 0
rework/segregation

4 @ 340 Rs/Day, Labor cost -C 63.75 42.5 0 0

(U321) 2- Rib lock missing 1

REAR RH-S201 3 Metal clip
TRIM ASSY SCUFF PLATE

SCUFF PLATE REAR RH

missing -1 NOS

NOS
Remark

COPQ.3 = B+C 0 63.75 42.5 0 0

 gust 2021
SEAL ASSY CONDENSER TOP

0
6
(W109) Engine wash sticker

1.5
216

63.75
63.75
Missing 1NOS

TRIM ASSLY B PILLAR

0
7
LOWER LH - W501 Without

1.5
160

63.75
63.75
Assy. 4NOS

0
8

WEEKLY OFF

0
0
0
0
0
9

0
0
0
0
0
10

TRIM PAD ASSY A PILLAR

1
0

LWR RH-S201 Without Assy.

11

100

42.5
42.5

1NOS

0
0
0
0
0
12

0
0
0
0
0
13

0
0
0
0
0
14
0
15
WEEKLY OFF

0
0
0
0
0
16

0
0
0
0
0
17

0
0
0
0
0
18

0
0
0
0
0
19
20

0
0
0
0
0
20

TRIM PAD ASSY B PILLAR

LWR RH - S201 (HH+)
Without Assy. 1NOS
2
0

85
85

TAILGATE GARNISH ASSY

21

230

W/O CAMERA-PEARL
WHITE-S201 Without Assy.
1NOS

0
22

WEEKLY OFF

SEAL ASSY CONDENDSER

0

FRONT RH Foam missing 1

23

2.5
400

106.25
106.25

NOS

0
0
0
0
0
24
 SEAL ASSY CONDENSER LH

0
25

1.5
240
Foam missing 1 NOS

63.75
63.75

0
0
0
0
0
26

0
TRIM PAD ASSY B PILLAR LWR RH - S201 (HH+) Metal clip missing 1 NOS
27

1.5
160

63.75
63.75

0
0
0
0
0
28

0
29

WEEKLY OFF

0
0
0
0
0
30

0
0
0
0
0

0
0
TOTAL

2.5

595
595
3.COPQ- Moulding Shop August 2021

M/C details
S.No Parameter Responsibility
Repair Cost (i)

Downtime cost (Machine rate * No of hrs) -(ii)

Radheshyam
Machine Breakdown
1 (A)
**Downstream loss -(iii)

Total (i+ii+iii)

2 Manpower Absenteeism (B) Machine Stop Hours *Cycle time * Moulded part cost Radheshyam

Machine Stop Hours *Cycle time * Moulded part cost

Radheshyam
3 Power Loss (C) Cost diff bn regular supply & DG/Hour * No of hours
of breakdown

Total

4 Packing material non availability (D) Downtime cost (Machine rate * No of hrs) Radheshyam

5 Raw Material Non availability (E) Downtime cost (Machine rate * No of hrs) Radheshyam

6 Set Up Loss (F) No of pieces rejected * Moulded part cost Rajesh

7 Process Rejections (J) No of pieces rejected * Moulded part cost Rajesh

8 Grinding Cost (K) Hourse spent on grinding * Labor cost Rajesh

9 Performance Loss (L) (1-P/100) * Run Qty * Moulded part cost Rajesh

10 Lump Loss (M) Lump Weight * Mould part cost Rajesh

Excess Consumption/piece* No of pieces produced *

11 Weight Loss (N) Moulded part cost
Rajesh

12 Machine stoppage due to supplier quality(o) Machine Stop Hours *Cycle time * Moulded part cost Rajesh

13 Line stoppage due to Moulded part quality(P) Production loss hrs * Loss qty * SP Rajesh

14 Rework Cost(Q) Labour cost + reinspection cost Rajesh

15 Inspection cost

PERFORMANCE COPQ
 COPQ ( Quality) Exc Insp. Cost

COPQ ( Quality) With Insp. Cost

Performance Loss (L) 0

Lump Loss (M) 0
Grinding Cost (K) 0
Rework Cost(Q) 0
Inspection cost 0
Manpower Absenteeism (B) 0
Raw Material Non availability (E) 0
Power Loss (C) 0
Set Up Loss (F) 384452
Process Rejections (J) 337790
Machine Breakdown
(A) 0
Packing material non availability (D) 0
Weight Loss (N) 0
Machine stoppage due to supplier quality(o) 0
Line stoppage due to Moulded part quality(P) 0
Responsibility- Rajesh.

1 2 3 4 5 6 7 8 9

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
10 11 12 13 14 15 16 17 18

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
19 20 21 22 23 24 25 26 27

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
ff
O
y
kl
ee
W
 0 0
0 0 0 0 0 0 0

0 0
0 0 0 0 0 0 0

400000
300000
200000
100000
0 0 0 0
0
28 29 30 31

0
0

384452

337790

0 0 0 722242 0
 0 0 0

0 0 0

COPQ-Molding
384452
337790

0 0 0 0 0 0 0 0 0 0 0 0 0
 4.COPQ- Assembly Shop Resp
COPQ: August 2021

S.No Parameter 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 Total Value

Over time cost or customer
1 Child part non availability-A 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
penalty
Over time cost or customer
2 Absenteeism -B 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
penalty
Repair cost 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 Tool Breakdown -C
Production loss hrs * Loss qty
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
* SP
Line Stop Hours *Cycle time *
4 Power Loss (D) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Selling price
Packing material non Production loss hrs * Loss qty
5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
availability (E) * SP
No of pieces rejected * Part
6 Start Up rejection (F) 190 0 520 0 260 0 0 0 160 0 0 0 450 0 0 0 0 0 190 0 520 0 260 0 0 0 160 0 0 0 450 3160
Cost
No of pieces rejected * Part
7 Process Rejections (G) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Cost
Line stoppage due to Production loss hrs * Loss qty
8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
supplier quality(H) * SP
Labour cost + reinspection
9 Rework Cost(I) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
cost
10 OTHER 0

890 3200 0 0 0 0 0 0 1520 0 980 0 0 0 920 860 0 210 0 0 0 0 0 0 0 420 0 760 0 0 9760

Rework Rate=R/W optr + F/W Insp.

Per Hrs Rate both optr As per part cycle time 0 0 0 0
(6+6=12)-( per 5 min1 part )

PERFORMANCE
890 3200 0 0 0 0 0 0 1520 0 0 980 0 0 0 920 860 0 210 0 0 0 0 0 0 0 420 0 760 0 0 9760
COPQ.=A+B+C+D+E
0

COPQ ( Quality)
190 0 520 0 260 0 0 0 160 0 0 0 450 0 0 0 0 0 190 0 520 0 260 0 0 0 160 0 0 0
=F+G+H+I (Exc Insp Cost)

COPQ ( Quality)
=F+G+H+I (with insp. 1080 3200 520 0 260 0 0 0 1680 0 0 980 450 0 0 920 860 0 400 0 520 0 260 0 0 0 580 0 760 0 450 12920
Cost)
7.COPQ-Customer Returns Resp - August

S.No Parameter 1 2
1 Time spent on Customer concern(A) Hours spent * XXXX Rs 0 0

2 Returned parts(B) Part cost of returns 0 0

3 Penalty ( C) 0 0

COPQ.5 = A+B+C 0 0
3 4 5 6 7 8 9 10 11
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
12 13 14 15 16 17 18 19 20
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
21 22 23 24 25 26 27 28 29
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
30 31
0 0

0 0

0 0

0 0 0
7.COPQ- Responsibility - Yogesh

S.No Parameter 1 2
1 Rejection Cost for Transportation & Handling(A) Part cost 0 0

COPQ.7 = A 0 0
ility - Yogesh

3 4 5 6 7 8 9 10 11 12
0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0
13 14 15 16 17 18 19 20 21 22
0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0
23 24 25 26 27 28 29 30 31
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
 Responsiblity

S.No Parameter 1

1 Incoming moulding COPQ Raw Material 0

2 Incoming COPQ 0

3 Supplier Rej. Assembly 0

4 Dock Audit Rejection 0

5 Moulding shop COPQ 0

6 Assembly Shop COPQ 1080

7 Customer Returs COPQ 0

8 Rejection Cost for Transportation & Handling 0

TOTAL COPQ 1080

NET SALE

NUMBER OF PART DESPATCHED

COPQ ( CONSIDERING SALE) COPQ/RS #DIV/0!

COPQ ( CONSIDERING VOLUME) COPQ/PIECE #DIV/0!

sponsiblity

2 3 4 5 6 7 8 9

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

64 43 0 0 64 64 0 0

0 0 0 0 0 0 0 0

3200 520 0 260 0 0 0 1680

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

3264 563 0 260 64 64 0 1680

#DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0!

10 11 12 13 14 15 16

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 43 0 0 0 0 0

0 0 0 0 0 0 0

0 0 980 450 0 0 920

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 43 980 450 0 0 920

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

17 18 19 20 21 22 23

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 85 0 106

0 0 0 0 0 0 0

860 0 400 0 520 0 260

0 0 0 0 0 0 0

0 0 0 0 0 0 0

860 0 400 0 605 0 366

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

24 25 26 27 28 29 30

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 64 0 64 0 0 0

0 0 0 0 0 0 0

0 0 0 580 0 760 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 64 0 644 0 760 0

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

 31

0 0

11081 11081

0 0

0 595

722242

450 9760

0 0

0 0

11531 743679

53935871

#DIV/0! 1.38 Including inspection cost

#DIV/0! #REF!
 Responsiblity

S.No Parameter 1

1 Incoming moulding COPQ Raw Material 0

2 Incoming COPQ 0

3 Supplier Rej. Assembly 0

4 Dock Audit Rejection 0

5 Moulding shop COPQ 0

6 Assembly Shop COPQ COPQ ( Quality) =F+G+H+I (Exc Insp Cost

7 Customer Returs COPQ 0

8 Rejection Cost for Transportation & Handling 0

TOTAL COPQ 0

NET SALE

NUMBER OF PART DESPATCHED

COPQ ( CONSIDERING SALE) COPQ/RS #DIV/0!

COPQ ( CONSIDERING VOLUME) COPQ/PIECE #DIV/0!

sponsiblity

2 3 4 5 6 7 8

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

64 43 0 0 64 64 0

0 0 0 0 0 0 0

190 0 520 0 260 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

254 43 520 0 324 64 0

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

9 10 11 12 13 14 15

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 43 0 0 0 0

0 0 0 0 0 0 0

0 160 0 0 0 450 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 160 43 0 0 450 0

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

16 17 18 19 20 21 22

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 85 0

0 0 0 0 0 0 0

0 0 0 0 190 0 520

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 190 85 520

7158

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! 0.000 #DIV/0! #DIV/0! #DIV/0!

23 24 25 26 27 28 29

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

106 0 64 0 64 0 0

0 0 0 0 0 0 0

0 260 0 0 0 160 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

106 260 64 0 64 160 0

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

30 31

0 0

0 11081

0 0

595

0 489077

0 9760

0 0

0 0

0 0 510513

53935871

#DIV/0! #DIV/0! 0.95 Excluding Inspection Cost

#DIV/0! #DIV/0! #REF!

Excl A Pillar OTR

311096.69

177980.03

489076.72