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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
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Manual production planning

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1.Scope:
This SOP is applicable to Production planning and control activities in plant and between mfg. plant & customer.
production planning and control is Annexure number: MS-DM-PPC-00 and all activities are mentioned in this Sop.
2. Objective:

The objective of Production planning and control is a predetermining process which includes the use of human
resource, raw materials, machines etc. This is the technique to plan each and every step in a long series of
separate operation. It helps to take the right decision at the right time and at the right place to achieve maximum
efficiency.

Inventory
Controlling
Timely
Schedulling
Delivery

Man ,
machine
Execution material
resource
objectives utilisation
production
planning and
control
Follow up Process
and ex planning

Reduce Line
losses planning
cost
control
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CONTROL NO.
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DEPT IN.CHARGE
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PPC

2.1 : KPIs
To control and measure the departmental objectives, the deptt has established its KPIs
as follows:
a: Customer delivery –Oe & Spd-uom %
b: Customer Line stoppage: uom – nos. & min.
c: Finish goods stock: uom: Nos.
d: Wip goods stock: uom: Nos
e: Assy Shortage: uom: Hrs.
f: C shift production: uom : Nos.
g: Model change uom: nos. & min.

3. Definition/Abbreviation:
• 4W – Four Wheeler
• BT – Bottom Tube, FG - Finished Good, FIFO – First-In First-Out, HOD – Head of the Department, HR –
Human Resource Department, NPD – New Product Development ,OE – Original Equipment (Factory
fitted part) ,PM – Preventive Maintenance ,PPC – Production Planning & Control Department ,SOP –
Standard Operating Procedure ,SPD – Sequenced Parts Delivery ,QC – Quality Control Department
• MSIL - Maruti Suzuki India limited, HCIL - Honda card India limited, Mkt – Marketing Deptt
• ACC – Accounts deptt, IE - Industrial engineering deptt, MSLG- Munjal Showa Limited (Gurgaon plant)
• MSLM- Munjal Showa Limited (Manesar plant), MSLH- Munjal Showa Limited (Haridwar plant)
4. Terms and definitions:
Terms Definitions

Monitoring Monitoring is observed and check the progress or production of lines over a period.
Preservation To keep safe from or protect from harm or external sources
Non-conforming product Product not meets within given specifications.
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CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
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PPC

5. Organization Structure:

Mr Gurdeep singh ( Head of deptt. PPC & Despatch )

Rajeev sharma (Manager )

Ajay rana Amit krishan Sohan rao kuldeep vacant

(4w ppc) ( 4w ppc) (2w ppc) (Despatch ) (Despatch ) (Despatch)

Dinesh negi Vikram Mahaveer Raghuveer Kuldeep Sanjay

Bijender (2w OE ) (Msil spd) Hcil spd Hero spd
(P.worker) (4w OE )
p.workers p.workers P.workers P.workers P. workers

6. Production planning Procedure:

6.1.1 Production planning
1. Customer production plan Firm for next Month will be shared by marketing for all customer OE & Spd via e
mail assigned Annexure number for customer MS-MKT-CUSTPRD-00-00/00 and if any revision will be there,
will be assigned as Annexure number MS-MKT-CUSTPRD-00-01/00 (customer – hero moto Gurgaon,
Dharuhera, Haridwar, MSIL Manesar and Gurgaon, HCIL tapukera, Noida, Yamaha, Honda scooter Manesar
and tapukera plant)
2. All customer schedule will be entering in Combined production plan which annexure number is MS-PPC-MP-00-
00/00.
3. Day wise vehicle plan (Annexure number MS-MKT-CUSTPRD-01-00/00) to be calculated from Hero moto and
Honda customer given schedule and comparation to be done for vehicle for current month (annexure number
and next month customer schedule, based on Hero moto plan total front fork and total rear cushion is
calculated in whole month, and based on working days of customer per day requirement is calculated.
4. Hero moto Haridwar supply is planned in MSLH only and hero Gurgaon plant full requirement is planned from
MSLG only and Hero moto Dharuhera plan supply is planned from MSLM only
5. Gas filled 2w shockers are planned in MSLM only for Hero moto Gurgaon and Dharuhera plant.
6. All supply of Yamaha and Honda 2 w scooter is planned in MSLM only.
7. New development will be share any new model with customer details and manufacturing plant.
8. Based on new model development marketing will share drawing and all necessary requirement.
9. New product development will make Bill of material and will hand over to IE deptt for designing the Jig &
Fixtures for production in manufacturing plant.
10. IE deptt calculate the total cost of Jig & Fixtures estimated and handover to marketing for approval from
customer for initiating process.
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11. All necessary points are to be kept in loop worth PPC deptt for adding in combined production plan (Annexure
no: MS-PPC-MP-00-00/00) presentations. which is presented on last day of month for next month expected
issues discussion and brining in knowledge to top management.
12. Breakup production plan (Annexure no: MS-PPC-MP-00-01/00) is made based on customer wise production
distribution and working done to meet capacity line wise. Offloading / partially increase in done in MSLG of
hero Dharuhera plant, and sharing model is presented in Production sales meeting. Marketing deptt will mail
customer production plan (Annexure number: MS-MKT-CUSTPRD-01-00/00) daily to ppc deptt for 5 days, ppc
deptt will make Synchronized production plan its Annexure.
13. Based on daily plan (Annexure number: MS-MKT-CUSTPRD-01-00/00) and weekly inventory (Annexure
number: MS-PPC-PI-WIP-01/00) of machined and painted, plated Wips ppc will make painting, plating and
machining plan and Assy plan for same day confirmed (including previous day backlog) next day tentative .
PPC enggr. will monitor the Model change cumulative basis @ 11 model per shift for 1 line @ 3 min
per model. Data of model Change is controlled by Annexure no : MS-PPC-SPP-MSLG-4WA-M0del-
00/00
14. This machining, paining and plating, Assy plan will be mailed to purchase for material availability
confirmation.
15. Ppc will do planning by system i.e.: synchronized production planning, Details with objective is mentioned
hereunder.
16. PPC will gather data of losses on daily basis from E mail _Loss time monitoring sheet and with the of trend
available release a RCD reports for cause and action plan taken from respective areas.
Objective of Synchronize ppc plan: To ensure material flow based on FIFO principle with optimum
inventory in between the lines, to ensure the product traceability from store material receipt to FG
dispatch, to ensure the material reconciliation and to provide the means for ensuring the operation of the
plant in accordance with the customer dispatch plans this SOP has been prepared
15.1. Customer production Firm (Annexure number MS-MKT-CUSTPRD-00-00/00 plan for 3 days and
tentative plan for 1 week to be shared by Marketing with PPC on daily basis and changes will be
entertained (2 days’ advance information) only if customer demand changes suddenly
15.2. NPD team should share the new product pilot lot plan before 7 days and sample development plan
at least one-day prior intimation to PPC.
15.3. Maintenance team should share the monthly PM plan with specific machine requirement with PPC
by date wise after discussion with Production Head.
15.4. Customer production plan (Annexure number MS-MKT-CUSTPRD-00-00/00) received from all
customers to be updated by PPC in the dispatch plan on daily basis by 8:00 AM.
15.5. Customer production plan (Annexure number MS-MKT-CUSTPRD-00-00/00) should be available for
all customer for OE and Spd both.
15.6. Actual production report Against Synchronized production plan machine shop (Annexure number:
MS-PPC-SPP-MSLG-M/C-00/00), Synchronized production plan 4w Assy (Annexure number: MS-PPC-SPP-
MSLG-4WA-00/00), Synchronized production plan CED painting (Annexure number MS-PPC-SPP-MSLG-
CED-00/00, Synchronized production plan Plating Annexure number: MS-PPC-SPP-MSLG-PLT-00/00 for the
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
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PPC

previous day (All shifts) to be provided to PPC by Production teams (Machine Shop, Paint Shop, Assembly)
by 8:30 AM against the synchronized PPC plan only (Don’t share deptt log book/register/MIS formats)

15.7. Actual dispatch done from Dispatch register maruti (Annexure number MS-PP-DDP-4WM-00/00 &
dispatch register Honda (Annexure number MS-PPC-DDP-4WH-00/00) during the previous day and FG
details (calculated) to be updated by 8:30 AM by PPC in the plan file
15.8. PPC planner to update actual production details from synchronized production plan vs actual in the
plan file based on the reports from Machine shop, Paint-shop and Assembly
15.9. PPC planner to update the dispatched material details to Manesar plant in the plan file, Planner to
add one day assembly production plan and dispatch plan, also ensure while updating dispatch plan
should be considering any additional e-Nagare, SPD preponed, Honda OE preponed or any change in
current or next day customer plan
15.10. Closing of calculated painted and machined stock to be updated as opening for next day , Weekly
Physical inventory (Annexure no MS-PPC-PI-FG-00/00) from handover register data (Annexure number
MS-2WASSY-HO-00/00 and takeover register data ( Annexure number MS-2WASSY-FG-TO-00/00 , MS-
4WASSY-FG-TO-00/00 ) to be verified, the handover-takeover register for QC cleared machined bottom
tube and painted bottom tube by 8:00 AM by PPC supervisor to be done regularly (Calculated opening
stock should be equal to physically counter which will validate the production reports as well as handover
–takeover reports)
15.11. Backlogs/excess production of Assembly of previous day to be calculated and to be adjusted in the
plan file for the next days
15.12. PPC planner to Escalate if safety stock is in reducing trend, take help of management to run assy to
cover previous cumulative losses to consume wip which was made already.
15.13. PPC planner to ensure that there is no negative closing against any model and if found please check
with the concerned department HOD for verifying the production reports and handover registers.
15.14. Safety stock to be maintained by PPC as per the e-mail instructions given by Marketing team with
mutual agreements to see the Fg trolleys availability with part experience. Safety stock will be revised on
every after 3 month based on customer delivery schedule (Niguri & P.R.T) with the mutual consents of ppc
& marketing.
15.15. Excel generated model wise plan to be verified by PPC planner to ensure the following
15.15.a. Model wise minimum production quantity should not be less than 30 for regular OE items and
20 for SPD non-regular items.
15.15.b. Line wise capacity utilization to be checked based on the number of shifts. Mention adjustment
partially qty manually in Machine shop plan (BT), but this qty should be in planned for next day .and
should be confirmed from purchase based on material availability. And Production plan should be based
on work load plan which will come after multiplication of cycle time and required qty. ( it may be front ,
rear or common ).
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15.15.c. Model shifting between lines to be done to meet the line capacity utilization_15.15. Shift the
assembly production plan for few models to next day based on the dispatch priority if the plan quantity
exceeds the maximum capacity.
15.15.c.1 Operating rate setting which is the ratio of (Actual operation time less downtime control items /
Total available time less lunch) *100 % as per I.e. is 95 %, Check Loading hrs. requirement should be Equal
to set out operating rate setting: 95 % (this clause is for regular productions only) and for sample or new
models Actual time will be taken from concerned deptt (Npd/ Ie) then operating rate setting will be
change and line loading hrs. requirement should match it.
15.15.e. Other plant requirements to be combined with Gurgaon plant requirements and to be mentioned
as single line item
15.16. Adjust the FG plan to meet the above-mentioned criteria by 8:45 AM
15.17. Share the preliminary plan of BT line machine shop (Annexure number MS-PPC-SPP-MSLG-4WBT-
00/00) and 4w piston rod line plan (Annexure number MS-PPC-SPP-MSLG-4WRD-00/00 for the 3 days
(Today, tomorrow and day after tomorrow) and for Assembly (Annexure number MS-PPC-SPP-MSLG-
4WA-00/00) for the next 5 days with Purchase and Store teams to get the confirmation of material
availability by 9:30 AM .This clause is required when Bop stock is less than 2 days , but if stock level if 2
days of more than 2 days , then Sequence planning will be done by ppc only be their self-decisions. But if
stock is less than 2 days there need a confirmation of sequential planning with mutual consents of
purchase on priority.
15.18. Based on the confirmation from Purchase and Store team, prepare the shift wise production
sequence and release the plan by 10 AM for the same day
15.19. Release or Print out to be given to production departments with counter sign of authorized person
with date and time and by e-mail to all other departments
15.20. Synchronized Firm plan to be sent by PPC by 4 PM for Next day to all the concerned departments
after getting the sequence confirmation from Purchase and Store departments and maintenance deptt.
15.21. Next day A-shift plan will be firm plan and no changes will be entertained by Production
department
15.22. Production department should follow the sequence as mentioned by PPC without fail
15.23. Production teams should share the actual shift wise production reports within half-an-hour after
the completion of shift without fail
15.24. Previous day losses to be produced on the next day at the startup of the shift (Synchronized firm
plan to be prepared without considering previous day losses but Production department will make
previous day loss plus firm plan circulated), Firm plan sequence to be followed after covering the losses to
ensure smooth running of Assembly operations (Note: Previous day losses to be mentioned in separate
column which is separate from firm plan).
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15.25. PPC deptt will make manpower plan (Annexure number MS-PPC-DMN-MSLG-00/00) for next 2 days
line wise and will share with all production deptt , production head and HR head to ensure manpower
availability shift wise this plan for same may be bit change due to previous day loss or excess production
that impact will come in same day plan (same day plan = firm plan made on previous day + previous day
losses) HR department to provide manpower to Production department for making the total production
(i.e., firm plan + previous day losses)
15.26. HR department must ensure the skilled manpower availability as per the PPC plan released at 10
AM
15.27. All material availability (Machine shop, Paint shop and Assembly) to be ensured by PPC for all the
lines based on the production sequence
15.28. PPC planners to check actual production done in the A-shift between 7.30 am to 10 am on the
same day before releasing firm plan for same day.
15.29. PPC planner to do the breakup of Assembly plan for same day line wise and shift wise with fixed
sequence which cannot be changed without any major and critical issues
15.30. The points no 29 will be changed in case of major issue which effected the previous day plating
and paint shop production and inventory for assy could not made ready timely.
15.31. All the concerns and grievances related to the regular operations while implementing this SOP to
be escalated to Plant Head if the concerns are not resolved at HOD level so that

15.32. Companywide events (ceremonies, drill, safety programs & other events) into planned losses to be
considered during making production plan. Based on cycle time per pc, correspondingly production qty
will be less in production plan on event, drill, ceremony, etc. day

Example: if 2 hrs. is drill event is planned, 580 nos. will be less in production plan.15.33. Consider
production capacity and operating ration i.e. 88% which is given by IE as per their Manual during making
the production plan.

15.33. Marketing will share revised Safety Stock norms veh. wise based on Customer prod plan for 3
months and PPC will make a safety stock variant wise based on it and will share to marketing, marketing
will approve, then ppc will consider this safety stock in Synchronization production planning sheet.

Pictorial view of Synchronized plan (without back loss):

s.n Open Loss

o Customer Part Item stk previous Production Despatch plan(nos) Closing stk(nos)
Front
part code code desc day(nos) plan(nos)

2ma 3ma 4ma 2ma 3ma 4ma 2mar 3mar 4mar

r r r r r r
1 X1 Abc Fr Wbc 18 22 24 55 33 11 23 7 20 52
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Pictorial view of synchronized plan (considered back loss):

s.n Open Loss

Customer Part Item
o Front stk previous Production plan(nos) Despatch plan(nos) Closing stk(nos)
part code code desc
day(nos)
3mar 4mar 5ma 3ma 4ma 5ma 3ma 4mar 5mar
r r r r r
1 X1 Abc Fr Wb 7 12 28 59 37 11 23 31 24 60 66
c
2S/ 2S/ 2S/
2.5S/ 2.5S/ 2.5S/
3S 3S 3S

Note: priority will be given to shift wise loading when back loss is normal but when back loss is abnormal then back loss
will be divided in next w/ days (matching with shift capacity)

6.1.2 Manpower planning:

1. Based on breakup production plan (Annexure no: MS-PPC-MP-00-01/00) plant wise, manpower plan required
in shifts line wise is calculated. Std data (line wise & capacity line wise) is used from IE deptt manual, for Std
data see points no: 8. Standard data (shared by IE deptt.
2. Direct and overall Productivity (Annexure number MS-PPC-MN-MSLG-00/00, MS-PPC-MN-MSLM-00/00, MS-
PPC-MN-MSLH-00/00) is maintained while making the machine, painting, plating & assy plan. Direct
productivity, overall productivity, manpower required line wise plant wise, shockers plan per day wise is
calculated and presented in Month production sales meeting. Based on clarification, breakup production plan
(Annexure no: MS-PPC-MP-00-01/00) is e mailed to MSLG, MSLM, MSLH
3. While making production plan daily basis ppc person will follow IE std data for cy time and operating ratio and
all downtime control items
6.1.3 Material requirement (Issue slips) generation:
1. Based on next day production plan, ppc will give issue voucher Annexure number MS-PPC-IV-MSLG-00/00
same day before 2 pm to store, for material timely issuance.
2. All issue voucher is based on Bill of material which is certified by NPD deptt and saved in Masters.
3. Store will issue material based on issue voucher Annexure number MS-PPC-IV-MSLG-00/00 at ending of
shift for next day opening for at-least 4 hrs. and store will post issue vouchers voucher real issuance.
6.1.4 Production targets Monitoring (Follow-up):
1. Ppc will ensure line production loss, line wise and will discuss to line manager for loss cover and in case of
running extra shifts, line manager and ppc manager will discuss with ppc head and plant head.
2. Ppc ensure all deptt should follow ppc prod plan and ensure material availability and timely feeding on
lines.
3. After shift end, production reports will be given to ppc by line manager and ppc engineer will see the
balance production to be in b & c shift.
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4. Next day complete production Annexure number MS-PPC-SPP-MSLG-4WRD-00/00, MS-PPC-SPP-MSLG-

4WBT-00/00, MS-PPC-SPP-MSLG-4WA-00/00, MS-PPC-SPP-MSLG-CED-00/00, MS-PPC-SPP-MSLG-PLT-
00/00) report of previous day will be given by line manager, based on this reports a MIS summary will be
made by ppc for display board and for analysis.
5. Ppc enggr. will get all production reports from each plant and Manpower MIS from HR Mslg for displaying
on display board.
6. PPC head will bring in knowledge to top management all losses and critical dispatch issues on day wise
and will present deptt performance in predefined KPI’s on monthly basis. KPI are set out in team 1
presentation as follows. And Action taken to reduce them with the reduction targets given by mgmt.
a: Customer delivery –Oe & Spd-uom %
b: Customer Line stoppage: uom – nos.
c: Finish goods stock: uom: Nos.
d: Wip goods stock: uom: Nos
e: Assy Shortage: uom: Hrs.
f: Un planned c shift:
g: Model change uom: min
6.1.5 Inventory Planning:
1. Ppc deptt will make production plan based on meeting inventory setout norms
2. Which is hereunder given in no of days and qty
2w:
Finish goods -
front fork - 1 to 1.5 days, rear cushion = 1 to 1.5 days
work in progress -
Fork pipe machined: 1 day as per plating plan, Fork pipe plated: 1-day coverage as per Assy plan
Piston rod machined: 1 day as per plating plan Piston rod plated: 1-day coverage as per Assy plan
4w:
Finish goods:
front struts: 2 days’ coverage, Rear dampers: 2 days’ coverage
work in progress -
Front Bottom tube machined: 1-day coverage as per painting plan, Rear bottom tube machined: 1-day
coverage as per painting plan, P.rod machined: 1-day coverage as per plating plan, P.rod plated 1-day
coverage as per UB & megna plan,
P.rod ready for Assy: 1-day coverage as per Assy plan
6.1.6 Dispatch planning:
1. Dispatch supervisor will report at 7.30 am daily to ppc if any dispatch left in 'c' shift, first that left material
will be Dispatch based on Dispatch plan made on previous day.
2. Dispatch supervisor will Take weekly FG inventory and he will give inventory to Engineer ppc (model wise).
3. Logistic supervisor will inform to Dispatch / ppc supervisor for opening of packing standard inventory
(trolleys & bins). Engineer ppc / Dispatch supervisor will create shortage for same day Dispatch.
4. Engineer PPC release will release dispatch plan of Honda (Annexure number MS-PPC-DDP-4WH-00/00) &
of Maruti Annexure number MS-PP-DDP-4WM-00/00) - one copy to dispatch supervisor, one copy to PDI
inspector (this dispatch plan have the details of OE & SPD supply - customer wise, model wise, time wise,
location pant wise for same day and next day.
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5. Dispatch supervisor will receive FG OK tagged from assy deptt thru handover (Annexure number MS-
2WASSY-HO-00/00) and take over (Annexure number MS-2WASSY-FG-TO-00/00) & Annexure number MS-
4WASSY-FG-TO-00/00) system, Dispatch supervisor will physically verify the received material and will
write trolley number, model details, qty in trolley.
6. Movement person will keep the Finish goods as per specified location ( For honda front in cap 30 nos ,
honda rear all models 120 nos ) , location defined for honda front and rear is near shed ( H1)
7. Dispatch supervisor will handover Finish goods in OK trolleys to QC PDI as per dispatch schedule.
8. Logistic supervisor will confirm truck availability to dispatch supervisor.
9. Logistic supervisor will confirm trolley availability in (Annexure number MS-LOGT-PI-E. TROLLEY-00/00)
each after every truck receiving to Dispatch supervisor / assy supervisor / ppc supervisor.
10. Dispatch supervisor will share trolley requirement based on Dispatch priority customer wise to logistic
supervisor.
11. In case of any change in customer Dispatch schedule, Revision Dispatch plan will be shared by mkt with
ppc, then to review again
12. PDI inspector will Put “OK” identification Tag on Final PDI completed trolley (Annexure number MS-QC-
OKTAG-00/00)
13. Dispatch supervisor will Verify Dispatch material as per check sheet of Dispatch section before loading
into trucks
14. Dispatch supervisor will write loaded material details in Dispatch plan note (Annexure number MS-DPN-
ACC-00-00/00) and he will give this dispatch plan note (Annexure number MS-DPN-ACC-00-00/00) to
Accounts for invoicing.
15. Dispatch supervisor will check made invoice’s all parameters like model, qty, no of trolleys against loaded
material if all details are found ok, then he will initiate Dispatch process otherwise in case of any error
found he will return back to Accounts for invoice correction.
16. Dispatch supervisor will mention Dispatch details like invoice number, truck no, time. Date, Finish goods
details, driver name, no of trolleys, seal number in Dispatch register (for 2 w Annexure number MS-PPC-
DRM-4W-00/00, Annexure for 4 w MS-PPC-DRM-4W-00/00 and handover invoice to logistic supervisor
for out from main gate.
17. Logistic supervisor will ensure truck reaching in customer premises and get receipt and handover to Dispatch
supervisor. logistic supervisor will get material dispatched receipt from customer after material receipt at
customer end.
18. Dispatch supervisor will Handover copy of invoice - dispatched receipt to accounts.
19. Excise work standard format –Annexure no defined: MS-PPC-DESP.WORK.STD-00/00

7 Material Preservation:
1. Dispatch supervisor will receive FG OK tagged from assy deptt thru handover (Annexure number MS-
2WASSY-HO-00/00) and take over (Annexure number MS-2WASSY-FG-TO-00/00) & Annexure number MS-
4WASSY-FG-TO-00/00) system, Dispatch supervisor will physically verify the received material and will
write trolley number, model details, qty in trolley.
2. Dispatch supervisor will handover Finish goods in OK trolleys to QC PDI as per dispatch schedule.
3. Dispatch supervisor will Ensure old stock Dispatching in FIFO order.
4. Dispatch supervisor will Take weekly FG inventory and he will give inventory to Engineer ppc (model wise).
Check on check mechanism will be: first counting person will count, later on permanent worker will do
sample, same process will be followed by Dispatch supervisor for sample check for physical stock
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DEPT IN.CHARGE
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verifications. Ppc engineer will verify the stock against syncronisisation sheet, in case of any doubt again
particulars will be counted again.
5. Dispatch supervisor will Keep FG stock as per their identified location.
6. Dispatch supervisor will ensure all material should be kept in covered, all should be identified, rework
stock should not be mixed with Ok FG, all inventory should be ok tagged.
7. Dispatch supervisor will ensure all trolley check sheet should be filled properly, each dispatched trolley
condition should be properly verified by sender.

Work standard of excise deptt: Linked with annexure no: Annexure no defined: MS-PPC-DESP.WORK.STD-00/00
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＜ GL SQS0832P Work Standards & Process Control Sheet Operating Standards App-1 GL SQS0832P 作業標準/工程確認表運用規定　 付表－ 1＞
Color the circle at upper left to identify the level of criticality of process (Critical safety process - red; critical process - yellow; inspection process - blue; general process - white)

3
2

Work Standards 1
－ ######## First issue Karan Aj ay Gudeep si ngh

Prepare Check Approve Check

No. Date Reason of revision
Production Quality
Line M/C
EXCISE N/A Control
name name Movement Ticket,Invoice Paper, Q.C

document
Related
Sequence
Process

FRONT FORK & REAR CUSHION DISPATCH WS-8.5.1-PPC-01-00/00

Model

Process Tag, E-Way bill No.

DISPATCH Material FRONT FORK & REAR CUSHION
name
Protective items Helmet Safety glasses Gloves Leather gloves Rubber gloves Ear plugs Mask Boots ／
Process description
DISPATCH OF 2W SHOCKER
・At shift change, break time, line stoppage, etc., attach designated
Safety ・ All specified protective equipment must be worn.
Non-steady "process-completed" card on the part.
・ During abnormal working, ・Trial parts must be clearly identified prior to testing to ensure that
1) Press the emergency stop button or turn off the power and operation they are disposed of after the test.
confirm safety, and then switch to manual mode to start
operation, ・Any abnormal situations must be reported to team leader or
2) Check surroundings and if any operators is around, call out to Abnormal assistant team leader.
・Nonconforming parts must be handled strictly according to
each other to ensure safety, and then start operation. operation "Nonconforming parts handling procedures".

№ Description of operation Key steps Control points （Safety, Quality, Equipment) Why? (Past trouble, work accidents, must-not item)

1 फा इनल शो क र असें बली से एक् साइज स्टोर में मू वमें ट टिके ट के द्व ारा रे सिएव कि या जा ता 1. एक् साइज सु प रवा इजर / ओ पे रटर ये ह सु नी श्चीत क रे की ट्राली N.G न
है ! हो ! डिली वरी :-- -
* ओ पे रटर को मॉ डल का क स्टमर पा र्ट नं ब र का पता हो !. * रॉं ग मटेरियल डि स्पै च हो सक ता है !
क स् टमर डि स्पे च प् लान के अनु सा र एक् साइज सु प रवा इजर मर्तेरीअल P.D.I को दे ता है
2. एक् साइज सु प रवा इजर / ओ पे रटर ये ह सु नी श्चीत क रे की मटे रियल की * ओ पे रटर को मॉ डल की स्टैं डर ट्राली का पता हो !. * ट्राली स्टैण् डर्ड न हो तो क स् टमर सप् लाई रे जेटक् ट क र सक ता है !
2 ! ट्राली सा फ़ हो ! ओ पे रटर सु ने सची त क रे की मटे रियल ट्राली में पू रा हो / मि क् स न हो !.
* * मटे रियल शो र्ट हो गा तो क स् टमर कं प्लेंट / प्लेंटी क र सक ता है !
* ट्राली N.G हो गी तो दु र्घटना हो सक ती है !
3 P. D. I हो ने के बा द मटे रियल को ट्रक में लो ड क रवा ता है !
3. एक् साइज सु प रवा इजर / ओ पे रटर ये ह सु नी श्चीत क रे की मटे रियल
स्टैण् डर्ड ट्राली में ही हो ! क्वालिटी :----
*ओ पे रटर को मॉ डल का क स्टमर पा र्ट नंब र का पता हो !.
MOVEMENT TICKET RECORD RIGESTER 4. एक् साइज सु प रवा इजर / ओ पे रटर ये ह सु नी श्चीत क रे की ह र ट्राली में *ओ पे रटर को मॉ डल की स्टैंडर ट्राली का पता हो !.
Q. C टै ग हो !
*ओ पे रटर सु ने सची त क रे की मटे रियल ट्राली में पू रा हो / मि क् स न हो !.
5. एक् साइज सु प रवा इजर मटेरियल लो ड हो ने के बा द इनवॉ इस पे पर के *डि स्पै च मटे रियल ट्राली Q.C टै ग के सा थ हो .
सा थ मै च क रे !
से फ् टी :-----

*ओ पे रटर से फ् टी प् रोसी जर फॉ लो क रे !
6 पे प र मै च हो ने के बा द एक् साइज सु प रवा इजर रिकॉ र्ड मे न्टेन क रने के लिए
पा र्ट नं ब र/ क्वां टिटी /ट्राली नं बर/ ट्रक नं बर को रजिस्टर में एं टर क रे !

7. सा रा प् रोसी जर OK हो ने के बा द ट्रक को गौ र्ड से सी ल क रवा एं औ र

इनवॉ इस पे प र को गौ र्ड के ह न् दोवे र क रे !
Operato r
Validity
Acknowledg
verificatio
ment
n s ignature
s ignature

Application No.170401(Operations Div ision)

8 Coordinating areas:
1. Maintain balancing between manufacturing and delivery.
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ppc

manufacturing

2. Coordinate with all departments:

store deptt

Production
purcashe
machine
deptt
shop

ppc deptt
maint. marketing
deptt deptt

paint and Human

plating resource
deptt deptt

1.9 Contingency plan:

1. Assy line & machine shop, ced painting, Plating (partially) is idle in ‘c’ shift of working days and Sunday is also
available for contingency plan. And in MSLM assy line also available for 2200 nos per day production
2. Front line and rear line and strut /damper is having alternate lines for production.
3. 4w bottom tube line is spare in ‘c’ shift & 4w rod line (MSLM) approx. 1800 nos per day can be produced.
4. For logistic points of view, Company has dedicated transporters, no any union transporter is used.
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7. PPC Flow Chart (5W1H) chart:

Responsibil Control/
S. Output Format No.
Input Process Activity Flow (what ) ity Criteria
No (where)
(who) (When )

Customer schedule Customer delivery monthly plan all for all plant data will enter
in Combined production plan (for hero location wise ) will 27th of
Honda: Niguri 6month MS-PPC-COMBINED.
1 update , for Hcil and Msil in particular cells will update then Engineer ppc MONTHLY.PLAN-00-00/00
every
Maruti: Monthly plan
Will Prepare Combined Requirement of front & rear cushion month
Hero: Firm prod plan
& Strut & open stay (month)

Check Combined Overall prod plan for all MSL plant vs Prod
Std data Line wise , shift capacity of All shops 27th of
MS-PPC-COMBINED.
wise (std manpower & std Engineer ppc MONTHLY.PLAN-00-00/00
every
production ) month

Safety stock every after 3

month based on 3 month In case of plan > capacity, Details will be shared with 28th of
customer delivery schedule check bottleneck line mgt & will get approval to Hod ppc every
run on Sundays. month

Will Prepare monthly breakup plan plant wise & model wise MS-PPC-COMBINED.
MONTHLY.PLAN-00-
for Finish goods (2W & 4W) MSLG/00

MS-PPC-COMBINED. 27th of
Engineer PPC MONTHLY.PLAN-00- every
MSLM/00 month
MS-PPC-COMBINED.
MONTHLY.PLAN-00-
MSLH/00
Prepare per day plan plant wise shockers (2W & 4W MS-PPC-PERDAY.PLAN-
00-MSLG/00
considering No of max. model changed as per IE manual.
MS-PPC-PERDAY.PLAN- 27th of
Engineer PPC 00-MSLM/00 every
month
MS-PPC-PERDAY.PLAN-
00-MSLH/00

Check with If plan (plant Make Off load MS-PPC-PERDAY.PLAN-

capacity shop 00-MSLG/00
wise) > plan to inter
wise Capacity plant transfer or MS-PPC-PERDAY.PLAN- 27th of
Sunday plan Engineer PPC 00-MSLM/00 every
month
MS-PPC-PERDAY.PLAN-
If plan is >=ok
00-MSLH/00

Hod ppc MS-PPC-PERDAY.PLAN- 27th of

Details share with Top mgt in prod sales 00-MSLG/00 every
meeting & get approval for Sundays month
MS-PPC-PERDAY.PLAN-
Go to next step
00-MSLM/00

Parallelly inform to I.E deptt for Cycle Time Restudy MS-PPC-PERDAY.PLAN-

00-MSLH/00
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Std data Line wise , shift MS-PPC-MAN-MSLG-

Prepare daily Manpower plan / Shift wise / Line wise 00/00
wise (std manpower & std 27th of
MS-PPC-MAN-MSLM-
2 production ) Engineer PPC every
00/00
MS-PPC-MAN-MSLH- month
00/00
Review of shortage / excess manpower based on current available
man available in respective plants ( 2W & 4W)
27th of
Hod ppc every
Inform to HR required man for next month month
E mail/Online meeting

Present data of combined plan, manpower plan for next month in

prod sales meeting with planned /targeted Pdty
29th of
Hod ppc Vc_ Mslg , mslm , Mslh every
month
Release the same

MONTHLY.PLAN-00-
In case of any Customer revision plan change
MSLG/01

Will Revise the prod plan, breakup plan & manpower plan after MS-PPC-COMBINED.
 
again verification with Std. capacity MONTHLY.PLAN-00-
MSLM/01
Within 2
Revised customer plan MS-PPC-COMBINED. days after
3 (Customer email) Engineer PPC MONTHLY.PLAN-00- customer
MSLH/01 plan
revision
MS-PPC-MAN-MSLG-
00/01
MS-PPC-MAN-MSLM-
00/01
MS-PPC-MAN-MSLH-
00/01
MS- MONTHLY.PLAN-00-
Release the same Email to all conc deptt with Mutual consent
MSLG/01
with Hod ppc hod’s
MS-PPC-COMBINED.
MONTHLY.PLAN-00-
MSLM/01
Within 2
MS-PPC-COMBINED. days after
Engineer PPC MONTHLY.PLAN-00- customer
MSLH/01 plan
revision
MS-PPC-MAN-MSLG-
00/01
MS-PPC-MAN-MSLM-
00/01
MS-PPC-MAN-MSLH-
00/01
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Updation of actual prod, Updation of actual prod,

Actual prod reports
(Line Wise)
4 verification against planned.
Actual desp reports
(Customer Wise)
Actual dispatched qty in
synchronization plan 4 w) In
previous day
Actual dispatched qty in 2 w MS-PPC-SPP-MSLG-4WRD-
00/00
planning sheet in previous day MS-PPC-SPP-MSLG-4WBT-
and Actual model changed 00/00
Engineer PPC
MS-PPC-SPP-MSLG-4WA- Daily basis
( 2w , 4 w) 00/00
MS-PPC-SPP-MSLG-CED-00/00
MS-PPC-SPP-MSLG-PLT-00/00
MS-PPC-2WPS-MSLG-00/00

-Customer Wise Dispatch Generate prod plan firm for today and next 2 days for assy,
plan
machining, paint, plating for 4 w
Customer Dispatch plan Generate prod plan firm for today and next day for
MS-PPC-SPP-MSLG-
-Honda Milk run delivery assy, machining, paint, plating for 2 w 4WRD-00/00
sch MS-PPC-SPP-MSLG-
-Maruti (OE Enagare) 4WBT-00/00
5
- Msil Spd delivery sch. MS-PPC-SPP-MSLG-4WA- Daily basis
-Hero OE Conveyor plan Engineer PPC 00/00
MS-PPC-SPP-MSLG-CED-
At 9 am
-Hero spd delivery schedule ( 2w , 4 w
-Msil Bangalore spd 00/00
delivery schedule MS-PPC-SPP-MSLG-PLT-
00/00
-HMI delivery schedule MS-PPC-2WPS-MSLG-
00/00
-Opening stock from
previous day sheet
-Event sheet from Hr. deptt
Reviewing the prod plan & discussion with
production (plan vs capacity)
MS-PPC-SPP-MSLG-
Safety stock every after 3
4WRD-00/00
month based on 3-month MS-PPC-SPP-MSLG-
customer delivery schedule 4WBT-00/00
If prod plan is agreed by If prod plan is Not agreed by any MS-PPC-SPP-MSLG-4WA- Daily basis
concerned deptt, check and review the Engineer PPC 00/00
6 MS-PPC-SPP-MSLG-CED-
At 9 am
bottleneck area ( 2w , 4 w
00/00
MS-PPC-SPP-MSLG-PLT-
00/00
MS-PPC-2WPS-MSLG-
00/00

Release to all by E mail -Synchronization

plan for 4 w
Engineer PPC Daily basis
( 2w , 4 w) At 9 am
-2w prod planning
sheet
Daily MIS HR
Prepare next day manpower plan line wise shift wise MS-HR-MIS-MSLG-00-
00/00 Releasing
machine shop/Assy shop/ surface finish, Engineer PPC MS-HR-MIS-MSLM-00-
7 00/00
time Daily
( 2w , 4 w)
MS-HR-MIS-MSLH-00- At 12 noon
00/00
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PPC

Review the manpower planned with Concerned deptt

MS-HR-MIS-MSLG-00-
00/00 Releasing
Engineer PPC MS-HR-MIS-MSLM-00-
00/00
time Daily
( 2w , 4 w)
Review the with Concerned If need change, go back MS-HR-MIS-MSLH-00- At 12 noon
deptt, if ok then release and again review 00/00

Release to all concerned by email & hard copy

Releasing
Engineer PPC Manpower planning
time Daily
( 2w , 4 w) sheet for 2 w and 4 w
At 12 noon

Check previous day booked production data in Sap MS-PPC-DPR-4WA-00/00

Engineer PPC MS-PPC-DPR-4W4-00/00
MS-PPC-DPR-4WB-00/00

Production Report / SAP if in totality not matching with production ,report to manager Engineer PPC MS-PROD-SAP-00-00/00
8 Daily basis
ppc / head ppc

Engineer PPC MS-PROD-SAP-00-00/00

discus with booking person , revise order qty if reqd & in case
of deficit stock coordinate with previous deptt
Taking weekly FG inventory model wise and handover to ppc
deptt
Physical stock taking Supervisor weekly
MS-PPC-PI-FG-00/00
Dispatch inventory

inform to ppc for packing standard inventory (empty trolleys

& empty bins for Assy prod planning & dispatch planning)
marketing MS-LOGT-PI-E.TROLLEY- By 9 am on
Physical stock taking 00/00
deptt daily basis

Receive finish Goods from Assy with OK tagged

Sign on handover and takeover register by ppc /excise /assy
persons jointly after physically verification . Supervisor
MS-2WASSY-HO-00/00
handover register-assy (Hanover /takeover daily
Dispatch
register )

Release dispatch plan to qc PDI time wise for Hcil milk

run for same day and next day
Customer Dispatch plan
Between
-Honda Milk run delivery Supervisor
8 Release dispatch plan to Excise super visor for - 8-9 am on
sch Dispatch
daily basis
-Maruti (OE Enagare)
- Msil Spd delivery sch.  Maruti OE Enagare.
-Hero OE Conveyor plan  Msil Spd delivery sch.
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-Hero spd delivery schedule  Hero OE Conveyor plan.

-Msil Bangalore spd
 Hero spd delivery schedule.
delivery schedule
-HMI delivery schedule  HMI delivery schedule.

For Maruti OE Enagare.

Physically Check Material kept in trolley as per e
nagare
Physically Offer to Qc for Pdi.
Inform to ppc in case of any shortage.
Between
Convert stock from non std to std trolleys as defined Excise
- 8-9 am on
by customer P. Worker
daily basis
Model ye3 – 70 nos
Model yg8 – 70 nos

For HCIl Milk Run.

Physically Check Material kept in trolley as per
Pickup plan
Physically Offer to Qc for Pdi.
Between
Inform to ppc in case of any shortage. Excise
- 8-9 am on
Convert stock from non std to std trolleys as defined P. Worker
daily basis
by customer
Model Front – 30 nos.
Model Rear – 120 nos.

For Msil Spd delivery sch

Physically Check Material kept on trolley in boxes as
per Msil Spd delivery Sch.
Between
Physically check part description properly written on Excise
- 8-9 am on
boxes. P. Worker
daily basis
In case of any unable to read return to Assy for
correction.
Check boxes condition from outer side
For OE conveyor plan.
Physically Check Material kept on trolley as per
dispatch plan given by mkt in morning at 9am.
Physically Offer to Qc for Pdi.
Inform to ppc in case of any shortage.
Convert stock from non std to std trolleys as defined
by customer
Between
Model Front Excise
- 8-9 am on
Kwag & Kstk – 70 sets / 140 nos P. Worker
daily basis
AAFF drum – 40 sets / 65 sets.
Absa /Aawd /Abga – 100 sets /200 nos (double
decker)

Rear:
All model – 240 nos (double decker)

Between
For Hero Spd delivery sch. Excise
- 8-9 am on
Physically Check Material kept on trolley in boxes as P. Worker
daily basis
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per Msil Spd delivery Sch.

Physically check part description properly written on
boxes.
In case of any unable to read return to Assy for
correction.
Check boxes condition from outer side
For HMIl Spd delivery sch
Physically Check Material kept on trolley in boxes as
per Msil Spd delivery Sch.
Between
Physically check part description properly written on Excise
- 8-9 am on
boxes. P. Worker
daily basis
In case of any unable to read return to Assy for
correction.
Check boxes condition from outer side
As and
In case of any abnormalities , Follow Non Conformities GL SQS0840P-01 when
part handling procedure: GL SQS0840P-01 required
In case of any change revise Dispatch plan shared by mkt with
Changed plan intimation MS-PPC-DDP-4WH-00/00
ppc, then to review again marketing
to receive from Mktg.by MS-PPC-DDP-4WM-00/00 Daily
supervisor MS-PPC-DDP-2W-00/00
mail
Put identification Tag on Final PDI completed trolley
PDI
OK Tag MS-QC-OKTAG-00/00 Trolley wise
inspector

Verify Dispatch material as per check sheet and packing

Check sheet / Invoice / standard before loading into trucks Supervisor
Truck wise
Dispatch plan Dispatch

give Dispatch plan to Accounts for invoicing

Supervisor Dispatch invoice
Trolley wise
Dispatch plan
check invoiced all parameters like model, qty, no of trolleys
against loaded material Supervisor Dispatch customer
Trolley wise
Dispatch invoice

if ok, then initiate Dispatch process, if find error return back

invoice to Account person for correction Supervisor
MS-DPN-ACC-00-00/00 Trolley wise
Dispatch

Enter truck no, time. Date, material details, driver name, no of

trolleys, seal number in Dispatch records and handover
Supervisor MS-PPC-DRM-4W-00/00
Dispatch documents invoice to logistic supervisor for out from main gate MS-PPC-DRH-4W-00/00
Daily
Dispatch

Ensure truck reaching at customer premises and get receipt

and handover to main gate, Logistic
Account deptt collect from main gate. Invoice receipt copy Truck wise
supervisor
 
Handover a duplicate copy from dispatch deptt
Supervisor Invoice duplicate
Truck wise
Dispatch receipt copy
 
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Keeping stock as per their identified location customer wise.

Supervisor Customer
-
Dispatch wise
 
Ensure old stock Dispatch in FIFO order
Supervisor Customer
Date wise
Dispatch wise

Check each trolleys after unloading from truck & in case of

Trolleys Ng,
super visor will handover to trolleys maintenance deptt and Supervisor
9 MS-PPC-TM-4W-00/00 Daily
trolley maintenance deptt will not number of trolleys Dispatch

Trolley maintenance
Maintenance person will repair and will handover to excise
person with duly receipt trolley number wise MS-PPC-TR-2w/4W-00/00 Weekly

8. Standard data (shared by IE deptt):

8.1. Production Capacity Line wise (Assy)

1. Prepare long term capacity enhancement plan in line with customer requirement. For this consult
marketing section.
2. Review long term capacity enhancement plan yearly & make necessary updates
3. Add production line, bottleneck equipment for production enhancement in line with customer requirement
taking inputs from marketing for customer plan.
4. As a standard assembly production requirement should complete within two shifts operation of Assembly.
3rd Shift should remain vacant as a risk management against any, kind of losses taking place in shift A & B.
5. Machine shop & surface treatment lines i.e. painting and plating.
a. Machine shop Capacity: That maximum two & half shift capacity should complete days’ plan. Remaining
half of 3rd shift should remain vacant to cover any losses during ‘A’ & ‘B’ shift. This ensures no loss of
production in assembly.
b. Normally continues process area like paint and plating are operated continuously to avoid re-heating of pre-
treatment solution, which causes losses. However, capacity of plant should be such that it is able to cover
machine shop 2-½ shift production & Assembly’ 2 shift production in 80% of net available time for
production.
Example- 4W
Customer HCIL MSIL
Peak Plan 4000 Shock absorber/Day 4500 Shock absorber/Day
MSL Peak Plan 8500 Shock absorber/Day
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Action: Check assembly capacity 8500 should be made in 2 shift

i.e. Capacity 1 Line 2300/shift (Average)

_Cycle time: Front model 11.5 sec, the Line capacity will be: 2285 nos,
_Cycle time: Rear models 10.9 sec, then Line capacity will be 2411 nos
(Line plan will be based on running models of front & Rear, Total required qty including back loss will be check
for loading hours, excess with be offload or less will be added, Total load will be match to shift capacity)

4600/2 shift
Capacity 2 Lines 92002 shift
It means assembly capacity is OK
Similarly machining line should be able to make 8500+ rejection quantity within 2/ 1/2 shift i.e. per shift
capacity should be 3400 Nos.

8.2 Available time shift wise:

In 3 shift working Hours are divided as follows:
‘A’ shift 7:30 AM to 4:00 PM 8.5 Hrs.
‘B’ shift 4:00 PM to 12:30 PM 8.5 Hrs.
‘C’ shift 12:30 PM to 7:30 AM 7.0 Hrs.
Total 24.0 Hrs.
Down time classifications, definition and example:
1. Fixed down time
2. As fixed down time
3. Planned unfixed down time
4. Abrupt unfixed down time

1. Fix Down time: No man operation possible for example (During this time No Man will be in working on

machine/process)

a) Meal break, Tea break, : 30 min /S, Tea break: 10 x 2-time min / S

b) overlapping of shift during shift change: 5 min / S

2. As fix down time: Planned losses in advance for example: 9.87 Min / S

a) New model event loss: 1.6 min / S

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b) preventive maintenance: nil

c) Planned Pooja: 0.1 Min / S

d) Top management address: 0.1Min / S

3. Planned Unfix Downtime: 34 Min / S (category of losses is planned but limit is not fixed Such losses are

Planned Unfix Downtime)

a) Morning meeting

b) Preparation time check

c) 3S 2 Min / S

d) Model Change: 3 Min x 11 models: Avg. taken: 33 Min / S

e) Part feeding

f) Autonomous activities for example cleaning, lubrication, tightening etc.

4. Abrupt Unfix down time:

a) Machine trouble 4.3 min / S

b) quality trouble: 0.42 Min / S

c) sudden model change

d) sudden tool/die/Jig change

e) part shortage 0.5 min / S

f) Waiting time.

g) Man power shortage (P& A)

Down time setting: Based on past experience and based on past down time history if available of similar product,
set the respective down time. One example-4 w assembly model Honda Amaze ‘A’ shift & ‘B’ shift of 8.5 Hrs.
Total time of 8.5 Hrs. 510 Minutes
 Fixed Down Time Lunch 30 Minutes
Tea 10x2 20 Minutes
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ISSUE DATE 14 FEB 2020

CONTROL NO.
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Standard operation time 510-50 460 Minutes

 As fixed down time new model activity:

Duration of New model activity depends on type of activity which may vary from ½ shift. On
such days’ regular production should not be planned.

 Preventive maintenance: Duration of PM activity will be depending upon extend of Preventive maintenance

planned by maintenance department. For this one shift or over may be required, which is informed by

maintenance to PPC for sparing machine & not to plan any production on such agreed day.

 Operation Rate: F/C X 100% (F= Actual operation time, C= Loading Time)

Line efficiency & process balance:

Line efficiency= (Sum of all cycle time/ cycle time of Line X No. of stations) X 100

Process balancing = 100- Line efficiency

Process balance condition should be minimum 85%

PART-III

Operation rate Setting

1. Operating time available for production is

Total Shift time i.e 510 Min.

Less Fixed loss time (-) 50 Min.
Less variable loss time on the basis of last year down time (-) 22 Min.

Time actual for operation 438 min say 26280 sec.

Operating rate:

Time available for operation 438 Min (26280 Sec.)

____________________ x100 = 95.0%
Max time available of shift 460 Min (27600 Sec.)
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2. If the available loss time of model change is less or more at any line. Operating rate of the line will be higher or
lower.

9. Training procedure:
Dispatch
supervisor will give training weekly or fortnightly to all Dispatch workers regarding the problems came in
current. He will update the training record (Annexure number MS-PPC-TM-4W-00/00)

10. packing standard Control procedure:

Responsibil Control/
S. Output Format No.
Input Process Activity Flow (what ) ity Criteria
No (where)
(who) (When )
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1 Customer e mail During

model
Marketing change

Packing standard receiving

Packing standard reviewing Marketing

Marketing
If Not Ok,
If Ok, forward to IE
IE
Same e mail

Check Customer requirement

Drawing IE
Trolleys inventory drafting &
master sheet Check Existing trolleys availability share with
(spare stock / same kind of trolley/) Ppc /qc/mkt

IE
If Ok,
Take permission for existing trolleys proceed
modification from PPC / MKT/QC for
sample

Drawing sheet of
sample trolley If Not Ok,
Redesign as per
feedback IE

If Not agreed by If Ok, forward to IE Within

mkt/ppc/qc

Generation of Conversion as per

requirement as per drawing of one sample
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For 2w Spd packing Box procedure:

Dispatch supervisor will ensure trolleys condition before Dispatch, in case of trolleys finds Ng, he will hand over to
Trolley repairing maintenance deptt will proper recording (Annexure Number MS-PPC-TR-4W-00/00, spec is defined
by HMCL customer and approved the size and colour,
Packing instructions: First person will pick the empty box properly and will check the quality first whether
this is properly hard as per the normal practice. Then will make the empty box closed from one side and will
put a tap for closing it. Along with this he will check the box strength and corners conditions, there should not
be any wear and tear. next he will pic the pc and will insert ine poly bag as pee size mentioned in std. and then
he will put the part with polythene packed in boxes. And will put a tap from another side. The will put the
stamp on box as per Part packed and main person (permanent worker) of that area will check the packed
conditions and will approve for dispatch.
Then all finish goods model wise will be kept on pallet as per std qty defined.
Customer e mail attached for reference:
P11 box size:
P11 polythene size:
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Packing standard check points for Hcil trollley:

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Trolley check sheet ( Format )

MUNJAL SHOWA LIMITED, GURGOAN MS-QF-8.5.1.7-PDI-05-00/00
CHECK SHEET : DESPATCH SECTION
CHECKING FREQUENCY : DURING EVERY DESPATCH DATE :

CUSTOMER MSIL HCIL - GNU HCIL - TKR

12 N O O N

T R U C K -1

T R U C K -2

T R U C K -1

T R U C K -2
1 :0 0 P M

3 :0 0 P M

6 :0 0 P M

2 :0 0 A M

8 :0 0 A M
Sr.
DESCRIPTION

2 AM

3 AM
No.
ENAGARE / PRT's

HOOKS NOT BROKEN

1 ( T R O LLE Y S &
W IT HIN T R U C KS
F OR S A F ETY R O D ) NOT MISS / NO RUST/NO DUST

ALL WHEELS ARE AVAIL.

2 WHEELS NOT LOOSE

NOT JAMMED / NO DUST

NOT BROKEN /NO DUST

3 POCKETS
NO WEAR OUT/BENT/RUST

FRAME,ANGLE NOT BROKEN / NOT MISS /

4 CHAIN & NO WEAR OUT / NO RUST /
NAME PLATE NO DUST
MATERIAL & QTY. IN
MATL.& QTY. TROLLEYS ARE
5
(SHORT/EXCESS) ACCORDING TO TROLLEY
TAGS
TROLLEY TAGS AS PER THEIR
PARTICULAR COLOUR OF
TROLLEY
6 M ODELS ARE AVAILABLE IN
TAGS ALL TROLLEYS W/O ANY M IXING
OR WRONG MODELS

TROLLEY
CONDITION TO
TROLLEYS TO CHECK FOR
CHECK BEFORE
7 ALL POINTS i.e. FROM
LOADING &AFTER
LOADING INTO SR.NO.1 TO 4
THE VEHICLE

IT SHOULD
VEHICLE
ACCOMMODATE ALL
8 RECD./TRUCK
REQD.TROLLEYS AS PER
NO.
INVOICE PLAN

NO. OF THESE SHOULD BE AS

9 INVOICES PER PRT PLAN /
RECD. ENAGARE

COMPLETE CHECK QTY.OF ALL ITEMS

QTY.OF ITEMS AS PER PRT PLAN /
10
AS PER PRT / INVOICE BEFORE
INVOICE LOADING INTO TRUCKS

VEHICLE
IT SHOULD NOT LESS
11 DESPATCH
THAN 2HRS.OF SCHE.TIME
TIME

HANDOVER OF IT SHOULD BE ACCURATE,

DOCUM ENTS & DULY SIGNED AND
12 M ATRL.(INV./ASN ACCEPTED BY TRUCK
/CC/E-WAYBILL) DRIVER

OPERATOR (NAME)

EXAMINED BY SHIFT SUPERVISOR (SIGN.)

AUDITED BY Mr.AJAY RANA/Mr.KARAN (SIGN.)

√
X
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11. Logistic procedure:

Marketing will always follow the instructions rules & Mutual agreements made between MSL
and transporters.
Locations From MSlg to Customers Transporter name
1 HMCL-Gurgaon Pinky sharma
2 HMCL-Manesar Shiv Shakti
3 HMCL-Neemrana Tvs
4 MSIL-Gurgaon Pinky sharma
5 MSIL- Manesar Pinky sharma
6 HCIl –Tpk NKID customer controlled
7 HCIl –Noida Shri Ram Road lines

Note: in case of any abnormalities or any strike by transporters the situations will be handles
by Pinky sharma. Each truck driver will fill the Bilty based the information written on
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respective customer invoices. and will get the gate out approval from Main gate of Gurgaon
plan(MSlg) and truck will be sealed after verification by security guard at main gate. Driver
Minimum qualification will be 10th and Will have license of heavy truck.

12: GLSQS standard system integration:

in case of any GL SQS0840P Nonconforming Part Handling, hereunder sheet will be followed
Standards Appendix-1 GL SQS0840P 不適合品処理規定 付表-1＞
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ISSUE DATE 14 FEB 2020

MS-DM-PPC-06
CONTROL NO.
CONTROL REVISION NO

DEPT IN.CHARGE
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PPC

＜ GL SQS0840P Nonconforming Part Handling Standards Appendix-1 GL SQS0840P 不適合品処理規定 付表- 1＞

Nonconforming Part Handling

　 　 　 　 Dept. 課　 　 　 Sec. 係 　 　 　 　 Line 班
Procedures Line name ラ イ ン 名： ― First issue 新規作成

不適合品処理手順書 Process Name 工程名： yyyy/mm/dd Description of revision

Q. Rep. 品責 Mgr. 課長 A. Mgr. 係長
Prepared by
№ Check 確認 Approve 承認 Check 確認
年月日 改訂内容 作成

Catego r
Description of action and method Responsible PIC Nonconforming Part Handling Route 不適合品処理ル ー ト
y
№
分類 処置内容及び 方法 責任者 担当
不適合品処理手順
Nonconforming Part Handling Procedures

Corrective Action Report Route　 　 　 是正処置打ち 上げ ル ー ト

Opera t or
／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／ ／
ac knowledgment
signa t ure
作業 者確認サ イ ン

Application No. 170401(Operations Division) 適用 No.170401版（事業本部） Latest version 最新版

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in case of any Sorting Request / Report: Follow GL SQS0840P Nonconforming Part Handling Standards
Appendix-2 Reference Asaba Plant Ver. GL SQS0840P 不適合品処理規定 付表-2 参考 浅羽工場版＞
＜GL SQS0840P N onconforming Part H andling Standards A ppendix -2 Reference A saba Plant Ver. GL SQS0840P 不適合品処理規定 付表- 2 参考 浅羽工場版＞
Showa Corporation Plant
㈱シ ョ ー ワ
工場 Control No.
T o b e f ille d b y t h e s o r t in g d e p a r t m 選e n t別b e実f o 施r e 前s o にr t in実g 施 部 門 が 記 入

AT TN: Operation Quality Representative 　 　 事 業 品 質 責 任 者 殿 管理№ ：

Requesting Dept 申 請 部 門 Request date 申請日

Sorting Request / Report 年 　 　 　 　 月　 　 　 　 日
PIC 　 担 当 Responsible person 責 任 者

選別申請・ 報告書
M odel 機種 Part No. （ Upper ： Show a No. 　Low er： Cus tom er No. ） Part name 部品 名 称
部品番号（上段：ｼｮｰﾜ部番　 下段：顧客部番）

Reason for sorting 選 別実 施 理 由 Target QTY 選 別 対象 数 量 Basis (reason) used to determine the sorting range

選 別 対象 範 囲 を 決 定し た 根 拠 （理 由 ）

Target lot 選 別 対 象 ロ ッ ト

Sorting criteria (Please describe specifically using rough diagram, etc. If m ore space is needed, use separate s heet and attach.)

選 別 実 施 基準 （ 略 図 等で 具 体 的 に 記述 す る こ と 、 ス ペ ー ス が 不 足す る 場 合 、 別 紙 に 添 付し て く だ さ い ）
① Area to be inspected 確 認 部 位 ②Inspection m ethod (Indicate points to be cautioned to ③ OK/NG judgm ent criteria 合否 判定 基 準
prev ent secondary problem )

②確認方法（二次災害な き よ う 留意点も 記述）

T o b e fi l l e d b y th e s o rti n g d e p a選rtm別e n実t a施f te 後r s o、 rt i実n g 施 部T o 門b e がf ille d記b y入d e c is決io n裁 m者a k記e r 入

C o nfir me d b y Pr o d . C o nt ro l
Co mmen ts (Ta rge t so rtin g ra ng e / sorting criteria) 　 指示事項（選別対象範囲・ 選別実施基準）
Signature Dep t .

Accept 生 産 管理 課 確 認
D e c is 決io n 裁

決 裁 者 ｻ ｲﾝ Product logistics GL (or PIC

Operation
Quality Rep 可 　 ／
if the GL is not av ailable)

事 業 品質
・ 製品物流GL( 不在時は 担当者)

責任者
Not Accept /
否

Sorting personnel (Indicate nam e and department) Sorting results 選別実施結果

選 別 実 施 者（ 部 門 名 ・ 氏名 を 記 入 ） ① Sorting date 実 施日 時

② Sorting location 実施場所

③ Sorting results (Indicate total and by lot) 選 別実 施 結 果 （合 計 及 び ロ ッ ト 単位 で 表 記 の こ と ）

④ Action of nonconforming parts (scrap, rew ork) 不 適 合 品 の 処 置 （ 廃 却・ 修正）

R eport date Requesting dept. PIC Dept. Representativ e Operation Quality R ep. Com ment (Instruction for recurrence prev ention, etc.) Prod. Control Dept.
報告日 申 請 部門 担当 者 部門 責 任 者 事 業 品質 責 任 者 コ メ ン ト (再 発 防止 指 示 な ど ) 生 産 管理 課
y y y y /m m/dd ／ ／

年　 　 月　 　 日
〔 Route for the form 〕 ① Requesting dept . develop Sorting Request ⇒②Operat ion Quality Rep ⇒③ Prod. Control Dept.⇒④Results ent ered by Requesting Dept ⇒⑤Operation Quality Rep ⇒⑥Prod. Control Dept. ⇒⑦Request ing Dept (keep original）

〔 帳票ル ー ト 〕 ①申請部門起票⇒②事業品質責任者⇒③生産管理課⇒④申請部門実績記入⇒⑤事業品質責任者⇒⑥生産管理課⇒⑦申請部門（原紙保管）
Application No. 180401(Operations Division) 適 用 No.180401版 （ 事 業 本 部 ） Retention period: 20 y ears 保 管 期 間 ： 20 年

in case of any: Deviation Request: Follow this format as per GLSQS: GL SQS0840P Nonconforming Part
Handling Standards Appendix-3 GL SQS0840P 不適合品処理規定 付表-3＞
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ISSUE DATE 14 FEB 2020

MS-DM-PPC-06
CONTROL NO.
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

＜ GL SQS0840P Nonconforming Part Handling Standards Appendix-3 GL SQS0840P 不 適 合品 処 理 規定 付 表 -3＞

Showa Corporation 　 Plant Control No.
㈱シ ョ ー ワ 　 工場 管理 № ：
ATTN : Operation／Subsidiary /Affiliate Quality Representativ e
*If yo u wa nt to a pp ly fo r d e via t io n a no n-c o nfo rm in g pro d u c t, it m us t be a ppro v e d b y the Ope ra t io n Qua lit y R e pre s e nt a t ive .
事業／拠点品質責任者 殿 ※不 適合 品を 特採 申 請 す る 場合 は 、 事業品 責の 承 認が 必要 で す 。
Requesting Dept/ Supplier Request date 申 請 日
Deviation Request (Result Report) 申請 部門 又は サ プ ラ イ ヤ ー 名 年 月 日
r 引 先 ）記 入

Person responsible 責 任 者
特 採申請書 (結果 報告 書 )
Model 機 種 Part number 部 番 Part name 部 品 名 Part criticality rank 部 品 重 要 度 ラ ン ク

Ｓ ・ Ｒ・ Ａ ・ Ｂ ・ Ｃ
T o b e f ille d b y t h e r e q u e s t in g 申d e 請p t /部s u門p p（lie 取

Reason for request 申 請 理 由 Target Qty 対 象数量

Requesting Qty 申 請 数量

Des cription of nonc onforming part 不 適 合 品 の 詳 細 Handling meth od and Re-inspection me tho d *If mo re space is nee ded, use se parate sheet an d attach.

処 理 方法 及び 再検 査方法 　 ※記 入が で き な い 場 合は 、 別紙 添付 の こ と

F uture actions 　 　 今 後 の 対 策

NOT E: Original form must be submitted w ith measurement data, test data and actual part.

（ 注）　 測 定デ ー タ ・ テ ス ト デ ー タ ・ 現品 を 添 付 し 、 原紙 を 提出 す る 。
Dept receiv ed Dept receiv ed Com ments by Operation Purchasing Dept (only w hen dev iation is reques ted by supplier) 　 　 事 業 購 買 部 門 意 見 （ サ プ ラ イ ヤ ー 申 請 の 場 合 の み 記 入 ）

　課受付 　課受付
　 ／ 　 ／

Results of Quality Check (test)　*If more space is needed, use separate sheet and attach.

品 質 確 認 (テ ス ト )結 果 　 ※ 記 入 が で き な い 場 合 は 、 別 紙 添 付 の こ と
in g 門d e記p t 入
T o b e f ille d in b y t h e e x審a m査in 部 .

R e la te d de pt. n a m e Ex amination Result Ex aminer signature

C omments by ex pert エ キ ス パ ー ト 意見
関連 部門 名 審 査可否 審 査 者 ｻ ｲﾝ
Accept / Not accept 　 ／

可 ・ 否

Accept / Not accept 　 ／

可 ・ 否

Accept / Not accept 　 ／

可 ・ 否

Signature Dev iation C onditions and Instructions 特採条件 及び 指示事項

Operation／Subsidi Acc ep t
D e c is決io n裁

サ イ ン
ary /Affiliate Quality 採用
　 ／
Rep ・
事 業／拠 点 No t Accep t
品 質責任 者 不採用

〔 Route for this form 〕

・ For internal request: ① Requesting dept. dev elop Dav iation Request ⇒② Operation Quality Rep ⇒③ Requesting Dept (keep original)
・ For supplier request: ① Supplier ⇒② Operation Purchasing Dept ⇒③ Incom ing Quality Dept ⇒④ Operation Quality Rep ⇒⑤ Incoming Quality Dept (keep original) ⇒⑥ Supplier (return copy )
・ F or Show a Group subsidiary / affiliate request: ① Subsidiary /affiliate requesting department dev elop Dev iation Request⇒②Subsidiary /affiliate ⇒③ Operation ／Subsidiary /Affiliate Quality
Rep⇒④ Subsidiary /affiliate quality department⇒⑤ Subsidiary /affiliate requesting departm ent (keep original)

〔 帳 票ル ー ト 〕
・ 日 本 シ ョ ー ワ 申 請 の 場 合 : ① 申 請 部 門 起 票 ⇒② 事 業 品 質 責 任 者 ⇒③ 申 請 部 門 （ 原 紙 保 管 ）
・ サ プ ラ イ ヤ ー 申 請 の 場 合 : ① サ プ ラ イ ヤ ー 起 票 ⇒② 事 業 購 買 部 門 ⇒③ 受 入 品 質 部 門 ⇒④ 事 業 品 質 責 任 者 ⇒⑤ 受 入 品 質 部 門 （ 原 紙 保 管 ） ⇒⑥ サ プ ラ イ ヤ ー （ ｺﾋﾟｰ返 却 ）
・ シ ョ ー ワ グ ル ー プ 各 拠 点 申 請 の 場 合 : ① 拠 点 申 請 部 門 起 票 ⇒② 拠 点 品 質 部 門 ⇒③ 事 業 ／ 拠 点 品 質 責 任 者 ⇒④ 拠 点 品 質 部 門 ⇒⑤ 拠 点 申 請 部 門 （ 原 紙 保 管 ）
Application No. 200701(Operations Division) 適 用 No.200701版 （ 事 業 本 部 ） Retention period: 20 y ears 保 管 期 間 ： 20 年

in case of any: Rework request GL SQS0840P Nonconforming Part Handling Standards Appendix-4 GL SQS0840P
不適合品処理規定 付表-4＞
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ISSUE DATE 14 FEB 2020

MS-DM-PPC-06
CONTROL NO.
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

＜ GL SQS0840P Nonconforming Part Handling Standards Appendix -4 GL SQS0840P 不 適 合 品 処 理 規 定 付 表 - 4＞

Showa Corporation
　 　 Plant
㈱シ ョ ー ワ 　 工場 Control No.
AT TN: Operation Quality Representativ e 　 　 事 業 品 質 責 任 者 殿 管理№ ：
R equesting Dept　 　 申 請 部 門 Request date　 申 請 日
Correction Request (Report) y y y y /mm/dd
Person responsible　 責 任 者
修正作業申請書 ( 結 果報 告 書 )
Model 機 種 Part number 部 番 Part nam e 部 品 名 Pa rt criticality ra nk
部品重要度ラ ン ク

Ｓ ・ Ｒ・ Ａ ・ Ｂ ・ Ｃ
Reason for reques t 申請 理由 Target Qty 対 象 数量

Target period 対 象 期 間
Ha vin g cu stomer req uire me nts or n o t 　 顧客要求事項の 有無 Summary of c ustomer requirements 　 顧 客 要 求 事 項 の 概 要
Ex istence 有 Nothing 　 無
Desc ription of nonconforming part 不 適 合 品 の 詳 細 Future actions
T o b e f ille d in b y t h e r e q u e s t in g d 申e p 請a r t 課m e記n t 入

今後の 対 策

Correction method and re-i nspecti on method *If more space i s needed, use separate sheet and attach. R esults of Quality C hec k (tes t) *If more space is needed, us e separate sheet and attach.

修 正方 法 及び 検 査方法 　 ※別 紙 、 修 正 作 業標 準 添 付 の こ と 品 質 確認 ( テ ス ト ) 結 果　 ※記 入 が で き な い 場合 は 、 別 紙 添付 の こ と

NOTE: Original form mus t be submitted w ith m easurement data, test data and actual part. 注：測定デ ー タ ・ テ ス ト デ ー タ ・ 現品を 添付し 、 原紙を 提出す る 。

Subsidiary Correction conditions and instructions　 　 修 正 条 件 及び 指示事項

Operation Quality R ep
Affiliate Quality R ep Decision　 　 　 　 決 裁
事 業 品 質 責 任者
拠 点 品 質 責 任者
Date 日 付 ： Date 日 付 ：

Accept 　 　 No t Accep t
可　 　 　 　 　 否

〔 Route for the form 〕 ① R equesting dept. dev elop C orrec tion Request ⇒② Subsidiary / Affiliate or Operation Quality Representativ e ⇒③ Requesting Dept (Keep original)
〔 帳 票ル ー ト 〕 ① 申 請 部 門 起 票 ⇒② 拠 点 ／ 事 業 品 質 責 任 者 ⇒③ 申 請 部 門 （ 原 紙 保 管 ）
Application No. 190101(Operations Div ision) 適 用 No.190101 版 （ 事 業 本 部 ） Retention period: 20 y ears 保 管 期 間 ： 20 年
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

13. Classification of duties that require qualification:

List of
Annexures:    
Personnel that Duties that require qualification / Skill and Name of Knowledg experience
S.no requires qualification expertise qualification e level

 loading /unloading / lift operating

Qualified loading  identification of Finish goods from outer
/unloading operator  Counting and dispatch plan writing on As per
despatch plan sheet company
Average policy
1 10th
 loading /unloading / lift operating
 identification of Finish goods from outer
area
 Counting and dispatch plan writing on
despatch plan sheet
Excise Supervisor
 Excise report maintaining
 Independent shift handling Average As per
 Able to handle abnormalities company
 Should be able to take decisions policy
2 independently Min Graduate
 Able to identification of Finish goods
from outer area
 Counting and dispatch plan writing on
despatch plan sheet
 Excise report maintaining
 Independent shift handling As per
Engineer
 Able to handle abnormalities Average company
 Should be able to take decisions policy
independently
 Able to make prod planning / taking
inventories / able to work in MS office /
3 familiar with Sap system Min Graduate
4 Manager  Able to identification of Finish goods Min Graduate
from outer area
 Counting and dispatch plan writing on
despatch plan sheet
 Excise report maintaining
 Independent shift handling
 Able to handle abnormalities Average As per
 Should be able to take decisions
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

independently company
 Able to make prod planning / taking policy
inventories / able to work in MS office /
familiar with Sap system

14. Training procedure for new comers:

Each person will get training as per company Qms system before coming in excise
and ppc deptt which is hereunder mentioned,

Induction training for new Operator:

The new operators are provided with 3 Days common induction training before
starting direct operations in the
line which contains On the Job Training and Off the Job Training. (Format No MS-QF-
7.2.1-HRD-10-00/00).
Some of the main contents are:

Induction Training for new Staff:

Similarly, for Staff category (New entry) 10 days’ induction training programme is prepared by HR
Deptt where
the new comer gets awareness about different departmental functions. (Format No
MS-QF-7.2.1-HRD-10-00/00). Some of the main contents are:
Duration Contents:
Day-1 Minimum knowledge of company profile and customers
Day-1 Rules & Regulation of Company
Day-2 Training on Product & product application
Day-2 Repeated Customer Complaints
Day-2 Process Specific Training.
Day-2 Special characteristics identified by MSL & customers,
Day-3 Differences of models and parts
Day-3 Use and functional importance of parts in finished vehicle
Day-3 Impact of failure of parts on vehicle.
Day-3 Material handling, use of PPEs, why-why analysis, thorough understanding of documents like W.I
(Work
Instruction), OCS (Operational Control Standard), DIS (Daily Inspection Sheet), awareness of OK, NG and
REWORK part handling route and about material handling(Dent/Scratch), work permit system, emergency
preparedness, HIRA etc.

Duration Deptt Contents

Day-1 HR/Personnel About Company Profile, Policy, System, Attendance & leave management system
Day-2 2W Assembly System implementation, process flow & material flow
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

Day-3 4w Assembly System implementation, process flow & material flow

Day-4 Production System Implementation, Process Flow, Material Flow
Day-5 Store FIFO System/MSDS/Old Maintenance Spare Part Inventory
Day-6 Quality Control Quality Policy, Problem Solving, Defects Gallery, Control Plan
Day-7 IE, PPC System implementation, Process Flow, Material Flow
Day-8 Marketing Marketing Concept

14. Documented (Annexures details):

List of Annexures:    
S.no Process Activity Flow Format No. Retention period
1 customer production schedule (Month) MS-PPC-COMBINED. MONTHLY.PLAN-00-00/00
Monthly
MS-PPC-COMBINED MONTHLY.PLAN-00-MSLG/01
customer production schedule (breakup in veh and MS-PPC-COMBINED. MONTHLY.PLAN-00-MSLM/01
2 shockers per day ) MS-PPC-COMBINED. MONTHLY.PLAN-00-MSLH/01 Monthly
3 combined monthly plan (2W & 4W) MS-PPC-COMBINED. MONTHLY.PLAN-00-00/00 Monthly
MS-PPC-MAN-MSLG-00/01
Monthly Breakup production plan plant wise (2W &
MS-PPC-MAN-MSLM-00/01
4 4W) MS-PPC-MAN-MSLH-00/01 Monthly
Average / day Breakup production plan plant wise
MS-PPC-MP-00-02/00
5 (2W & 4W) Monthly
Manpower plan (MSLG) Avg per day line wise , shift
MS-PPC-MN-MSLG-00/00
6 wise Monthly
Manpower plan (MSLM) Avg per day line wise ,
MS-PPC-MN-MSLM-00/00
7 shift wise Monthly
Manpower plan (MSLH) Avg per day line wise , shift
MS-PPC-MN-MSLH-00/00
8 wise Monthly
9 MIS manpower ( MSLG) MS-HR-MIS-MSLG-00-00/00 Monthly
10 MIS manpower ( MSLM) MS-HR-MIS-MSLM-00-00/00 Monthly
11 MIS manpower ( MSLH) MS-HR-MIS-MSLH-00-00/00 Monthly
12 Revised Customer production plan MS-PPC-CUSTPRD-00-01/00 Monthly

13 Production plan (4w rod line ) MSLG MS-PPC-SPP-MSLG-4WRD-00/00 Daily

14 Production plan (4w Bt line line ) MSLG MS-PPC-SPP-MSLG-4WBT-00/00 Daily

15 Production plan (4w assy line ) MSLG MS-PPC-SPP-MSLG-4WA-00/00 Daily

16 Production plan (ced painting ) MSLG MS-PPC-SPP-MSLG-CED-00/00 Daily

17 Production plan (4W p.rod plating ) MSLG MS-PPC-SPP-MSLG-PLT-00/00 Daily
18 Daily customer plan MS-MKT-CUSTPRD-01-00/00 Daily
19 Daily manpower plan ( today & next day) MS-PPC-DMN-MSLG-00/00 Daily
Line wise model wise issue vouchers ( for next day) MS-PPC-IV-MSLG-00/00
20 Daily
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

previous day booked production data in Sap( 4W

MS-PPC-DPR-4WA-00/00
21 ASSY ) Daily
previous day booked production data in Sap( 4W
MS-PPC-DPR-4WRD-00/00
22 Rod line ) Daily
previous day booked production data in Sap( 4W BT
MS-PPC-DPR-4WBT-00/00
23 line ) Daily
24 production report (SAP) MS-PROD-SAP-00-00/00 Daily
25 Inventory FG (weekly ) MS-PPC-PI-FG-00/00 Daily
26 Daily Dispatch plan ( Honda ) MS-PPC-DDP-4WH-00/00 Daily
27 Daily Dispatch plan ( Maruti ) MS-PP-DDP-4WM-00/00 Daily
28 Inventory FG (Daily empty trolley ) MS-LOGT-PI-E.TROLLEY-00/00 Daily
29 FG handover report assy to Dispatch MS-2WASSY-HO-00/00 Daily
30 FG takeover from Dispatch to assy ( 2w) MS-2WASSY-FG-TO-00/00 Daily
31 FG takeover from Dispatch to assy (4w ) MS-4WASSY-FG-TO-00/00 Daily
identification 'OK' Tag on Final PDI completed
MS-QC-OKTAG-00/00
32 trolley Daily
Dispatch maruti register
(Enter truck no , time . Date , material details , driver name , no of trolleys ,
seal number in Dispatch records and handover invoice to logistic
MS-PPC-DRM-4W-00/00
33 supervisor for out from main gate ) Daily
Dispatch Honda register
Enter truck no , time . Date , material details , driver name , no of trolleys ,
seal number in Dispatch records and handover invoice to logistic
MS-PPC-DRH-4W-00/00
34 supervisor for out from main gate Daily
As per company
Qms system
MS-PPC-TM-4W-00/00 At the time of new
Training register comers and at time
As per Qms MS-QP-7.0 on any abnormalities
finding and regular
35 monthly wise

Trolley repairing handover register MS-PPC-TR-4W-00/00

36 Daily

Safety stock sheet MS-PPC-SS-4W-00/00

37 Qtrly
As and when
MS-QMS
38 GLSQC check sheet for NON conformities required

39 Dispatch work standard MS-PPC-DESP.WORK.STD-00/00 Qtrly.

40 Packing standard Control ledger MS-DM-PPC-PSCL-00/00 Qtrly.

15: Customer reactions: enclosed

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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

SAFETY STOCK MIN / MAX LEVEL BASED ON 3 NEXT 3 MONTH CUSTOME NIGURI ( VEH WISE)
MININUM MAXIMUM
20 20 20
LEVEL LEVEL
Max
per day per day per day Norms =@3 Norms =@4
MODEL GRADE T YPE VOLUME Jan'21 Feb Mar jan/feb/m
jan21 feb21 mar21 DAYS DAYS
ar'21
1.2 E MT EG0 300 15 180 9 300 15 15 45 60
1.2 S MT EH0 2100 105 2220 111 2040 102 111 333 444
1.2 V MT EJ0 360 18 540 27 600 30 30 90 120
AMAZE PRODUCT I
1.2 VX MT EK0 480 24 780 39 600 30 39 117 156
2UL - PE ON
1.2 S CVT EH5 240 12 120 6 180 9 12 36 48
1.2 V CVT EJ5 300 15 60 3 120 6 15 45 60
1.2 VX CVT EK5 540 27 480 24 300 15 27 81 108
TOTAL 4320 4380 219 4140 207
0 0 0 0 0
1.2 T rend MT NA2 EXPORT 30 1.5 30 1.5 0 0 1.5 4.5 6
AMAZE RH
1.2 Comfort MT NB2 PRODUCT I 0 0 30 1.5 0 0 1.5 4.5 6
EXPORT
1.2 Comfort CVT NB7 ON 0 0 30 1.5 0 0 1.5 4.5 6
2UL - PE
TOTAL 30 1.5 90 4.5 0 0
0 0 0 0
1.5 E MT EE0 60 3 60 3 60 3 3 9 12
1.5 S MT EF0 400 20 320 16 240 12 20 60 80
1.5 V MT EG0 120 6 60 3 60 3 6 18 24
PRODUCT I
AMAZE 1.5 VX MT EH0 180 9 60 3 180 9 9 27 36
ON
2UL - DE 1.5 S CVT EF5 0 0 0 0 0 0 0 0 0
1.5 V CVT EG5 0 0 60 3 0 0 3 9 12
1.5 VX CVT EH5 60 3 60 3 60 3 3 9 12
TOTAL 820 41 620 31 600 30
0 0 0 0
1.5 SV NR MT EJ0 PRODUCT I 90 4.5 30 1.5 0 0 4.5 13.5 18
CITY
1.5 V NR MT EK0 ON 120 6 420 21 240 12 21 63 84
2UT - PE
TOTAL 210 10.5 450 22.5 240 12
1.5 V MT EB2 480 24 690 34.5 570 28.5 34.5 103.5 138
1.5 VX MT EC4 270 13.5 420 21 330 16.5 21 63 84
1.5 ZX MT ED1 PRODUCT I 420 21 660 33 420 21 33 99 132
NEXT CITY
1.5 V CVT EB9 ON 360 18 240 12 330 16.5 18 54 72
2TG PE
1.5 VX CVT EJ6 270 13.5 90 4.5 240 12 13.5 40.5 54
1.5 ZX CVT ED8 810 40.5 630 31.5 750 37.5 40.5 121.5 162
TOTAL 2610 130.5 2730 136.5 2640 132
1.5 LX MT XA0 120 6 120 6 150 7.5 7.5 22.5 30
1.5 LX CVT XA5 0 0 0 0 0 0 0 0 0
1.5 SPORT CVT XB5 240 12 390 19.5 300 15 19.5 58.5 78
1.5 EX CVT XC5 450 22.5 750 37.5 480 24 37.5 112.5 150
1.5 DX-G CVT YA6 0 0 0 0 0 0 0 0 0
1.5 DX-G CVT YA7 120 6 90 4.5 90 4.5 6 18 24
1.5 DX-G CVT YA8 0 0 0 0 30 1.5 1.5 4.5 6
1.5 LX-G CVT YB6 0 0 0 0 0 0 0 0 0
CITY 1.5 LX-G CVT YB7 EXPORT 30 1.5 0 0 0 0 1.5 4.5 6
EXPORT 1.5 LX-G CVT YB8 PRODUCTI 0 0 0 0 30 1.5 1.5 4.5 6
(LHD) 2TG - 1.5 LXSP-G CVT YC6 ON 30 1.5 30 1.5 30 1.5 1.5 4.5 6
PE 1.5 LXSP-G CVT YC7 0 0 0 0 30 1.5 1.5 4.5 6
1.5 LXSP-G CVT YC8 0 0 30 1.5 0 0 1.5 4.5 6
1.5 EX-G CVT YD6 0 0 0 0 0 0 0 0 0
1.5 EX-G CVT YD7 0 0 0 0 30 1.5 1.5 4.5 6
1.5 EX-G CVT YD8 0 0 30 1.5 30 1.5 1.5 4.5 6
1.5 LX-A CVT YF5 30 1.5 0 0 30 1.5 1.5 4.5 6
1.5 LXSP-A CVT YG5 0 0 30 1.5 0 0 1.5 4.5 6
1.5 EX-A CVT YH5 0 0 0 0 0 0 0 0 0
TOTAL 1020 51 1470 73.5 1230 61.5
1.5 COMF MT ND0 0 0 0 0 0 0 0 0 0
CITY 1.5 COMF CVT ND5 EXPORT 0 0 0 0 0 0 0 0 0
EXPORT 1.5 ELEG MT NB4 PRODUCT I 0 0 0 0 0 0 0 0 0
(RHD) 2TG - 1.5 ELEG CVT NB9 ON 0 0 30 1.5 30 1.5 1.5 4.5 6
PE 1.5 RS CVT NC8 30 1.5 0 0 30 1.5 1.5 4.5 6
TOTAL 30 1.5 30 1.5 60 3
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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

SAFETY STOCK MIN / MAX LEVEL BASED ON 3 NEXT 3 MONTH CUSTOME NIGURI ( VEH WISE)
MININUM MAXIMUM
20 20 20
LEVEL LEVEL
Max
per day per day per day Norms =@3 Norms =@4
MODEL GRADE TYPE VOLUME Jan'21 Feb Mar jan/feb/m
jan21 feb21 mar21 DAYS DAYS
ar'21
0 0 0 0
1.5 V MT EB2 60 3 60 3 30 1.5 3 9 12
PRODUCTI
NEXT CITY 1.5 VX MT EC4 60 3 30 1.5 60 3 3 9 12
ON
2TG DE 1.5 ZX MT ED1 120 6 90 4.5 150 7.5 7.5 22.5 30
TOTAL 240 12 180 9 240 12
0 0 0 0
1.2 V MT EN4 120 6 0 0 60 3 6 18 24
1.2 VX MT EM4 60 3 60 3 60 3 3 9 12
1.2 ZX MT EP0 PRODUCTI 60 3 60 3 120 6 6 18 24
JAZZ
1.2 V CVT EN7 ON 60 3 60 3 0 0 3 9 12
2WV - PE
1.2 VX CVT EM9 240 12 300 15 180 9 15 45 60
1.2 ZX CVT EP5 360 18 300 15 300 15 18 54 72
TOTAL 900 45 780 39 720 36
0 0 0 0
JAZZ Comfort CVT NG8 EXPORT 0 0 0 0 0 0 0 0 0
EXPORT Elegance CVT NC5 PRODUCTI 0 0 0 0 0 0 0 0 0
2WM - PE TOTAL 0 0 0 0 0 0
Trend MT NA2 0 0 0 0 0 0
Comfort MT NB1 EXPORT 0 0 0 0 0 0
JAZZ
Comfort CVT NG8 PRODUCTI 0 0 0 0 0 0
EXPORT
Elegance MT NC0 ON 0 0 0 0 0 0
2WV - PE
Elegance CVT NC5 0 0 0 0 0 0
TOTAL 0 0 0 0 0 0
0 0 0 0
Trend MT NA0 0 0 0 0 0 0 0 0 0
Comfort MT NB0 EXPORT 0 0 0 0 0 0 0 0 0
BRV EXPORT Comfort CVT NB5 PRODUCTI 0 0 0 0 0 0 0 0 0
2KB- PE Elegance MT NC0 ON 0 0 0 0 0 0 0 0 0
Elegance CVT NC5 0 0 0 0 0 0 0 0 0
TOTAL 0 0 0 0 0 0
0 0 0 0
1.2 SV MT EB2 PRODUCTI 360 18 180 9 330 16.5 18 54 72
WR-V
1.2 VX MT ED1 ON 540 27 480 24 360 18 27 81 108
2LT - PE
TOTAL 900 45 660 33 690 34.5
0 0 0 0
WR-V Comfort MT NA0 PRODUCTI 30 1.5 60 3 90 4.5 4.5 13.5 18
EXPORT Elegance MT NB0 ON 60 3 90 4.5 60 3 4.5 13.5 18
2LT- PE TOTAL 90 4.5 150 7.5 150 7.5
0 0 0 0
1.5 SV MT EB2 PRODUCTI 60 3 120 6 120 6 6 18 24
WR-V
1.5 VX MT ED0 ON 240 12 120 6 180 9 12 36 48
2LT - DE
TOTAL 300 15 240 12 300 15
0 0 0 0

16. Documents Revision Summary:

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ISSUE DATE 14 FEB 2020

CONTROL NO.
MS-DM-PPC-06
CONTROL REVISION NO

DEPT IN.CHARGE
6
PPC

s.no Activity details Format Revision Prepared by Verified by Audited by Approved

number dates (QMS) by
Manual production Planning IE Downtime MS-DM- 20th Rajeev Gurdeep Santosh M.saxena
1 controls items added PPC-00 nov’2021 Sharma Singh
2 Customer safety stock and customer , MS-PPC- 2nd Rajeev Gurdeep Santosh M.saxena
customer reactions , Trolleys hook Customer TM-4W- feb’2021 Sharma Singh
complaint points added 00/00
3 Packing procedure customer wise added. 1st jan2022 Rajeev Gurdeep Santosh M.saxena
Training procedures for new comers, MS-PPC- Sharma Singh
Classification of duties that require TR-4W-
qualification added. GLSQS standard system 00/00
integration
4 Desp word standard and packing std control MS-PPC- 21st Rajeev Gurdeep Santosh M.saxena
procedure , packing ledger added TR-4W- july2022 Sharma Singh
00/00
5 Max no of model change defined in section 16th Aug Rajeev Gurdeep Santosh M.saxena
MS-DM-
6.1.1-production planning as 11 model per 2022 Sharma Singh
PPC-6.1.1
Shift for 1 line @ 3 min per model.
6 Departmental KPI defined in Section 2- MS-DM- 16th Aug Rajeev Gurdeep Santosh M.saxena
Objectives of MS-DM-PPC-06 PPC-2.1 2022 Sharma Singh