Risk & Opportunities Assessment for individual process

Severity Occurrence Contingency plan

Sr Process Risk Risk description Effect of the risk Present controls Recommended actions Target date Resp Opportunities
(H/M/L) (1/2/3/4) (if required)

Internal First piece Verification of BCL No at the Check possibility of any

1 Coiling Wrong programme selection Rejection of the whole lot H 1 Not Required Continuous Production
issues inspection time of initial set up poka yoke

One or two parameter out of First piece Wire size wise numbering to Control at the time of tool
Wrong tool used M 1 NR 30.07.17 Production
spec inspection be provided on tools issuing (BCL No wise)

External Production delay, leading to Minimum stock level Monitoring of stock level on
Tools not available H 2 Critical tools list Continuous Stores Re-order level to be defined
issues delay in delivery of tools regular / defined basis

Unskilled contractual man First piece

Rejection of product L 1 Multi skilling Training of product Continuous Production
power inspection & OJT

Compatible other
Proper induction training
Breakdown M 2 OJT machine / Training of machines Continuous Production
programme for operators
Outsource

Accidents H 1 Safety awareness NA Training on safety Continuous HR

Internal All plants having Capacity planning inline with Re-evaluation of capacities
2 Marketing Low capacity Business loss H 1 Feasibility study 30.09.17 S&M
issues similar facilities business plan through lean concept

External Sudden fluctuations in All plants having Application of SMED

Business loss H 2 PPC Improve set up times 30.09.17 Production
issues customer schedules similar facilities concept

Productivity enhancement
Create spare capacity 30.09.17 PPC
through kaizens

Can be sale to spare Alternate customer for same Market base can be
Over inventory M 2 PPC 30.09.17 S&M
market product increased

Severity H - High Direct customer impact ,businees impact

M - Medium Internal customer impact
L - Low potential impact to internal and external parties

Occurrence 0-25% 1
25-50% 2
50-75% 3
75-100% 4
Recommended actions Target date Resp
 Risk & Opportunities Assessment for individual process

Severity Occurrence Contingency plan Target Target

Sr Process Risk Risk description Effect of the risk Present controls Recommended actions Resp Opportunities Recommended actions Resp
(H/M/L) (1/2/3/4) (if required) date date

Severity H - High Direct customer impact ,businees impact Occurrence 0-25% 1

M - MediumInternal customer impact 25-50% 2
L - Low potential impact to internal and external parties 50-75% 3
75-100% 4
ESP MR
 Risk & Opportunities Assessment for individual process

Severity Occurrence Contingency plan

Sr Process Risk Risk description Effect of the risk Present controls Recommended actions Target date Resp Opportunities Recommended actions Target date Resp
(H/M/L) (1/2/3/4) (if required)

Cutting & Internal Wrong programme First piece Check feasibility of

1 Rejection of total lot qty. H 2 Not Required Cross checking by QA Continuous QA
Crimping Issue selection inspection pokayoke

Wrong crimping blade crimp height & width not First piece Min Spare stock to be Check feasibility of
M 1 Not Required Continuous Maint.
use as per specification inspection decided. pokayoke

First piece
External Prpoer training
Unskilled man power used Rejection of products L 1 inspection & ON Job Multiskilling product training Continuous Production
Issue programme for operator.
training

other machine will Prpoer training

Break down M 1 ON Job training Machine training Continuous Production
be use. programme for operator.

Severity H - High Direct customer impact ,businees impact

M - Medium Internal customer impact
L - Low potential impact to internal and external parties

Occurrence 0-25% 1
25-50% 2
50-75% 3
75-100% 4