Doc. No.

REPL/QAP/QA/05
Process Mapping Origin Date 14.01.2024
LOGO
Rev. No & Date 0
Documented Process for Suspected & Non -Confirming Material Handling
Page No. 01 OF 02

Purpose :- This documented process defines the method to ensure that Suspected & Non-Conforming Product is Prevented from
unintended use.

Scope:- This documented process is applicable to control the Suspected and Non-Conforming Product, Material & goods in press shop,
Forging shop, Machine shop, Inprocess Insp, PDI and supplier end.

Process Owner :- The overall responsibility for the effectiveness of this documented process lies with:
* Head Quality
* Incharge- Production

Document /
Input Reference Activity Flow Output Formats Resp. Control Point

Identify the non confirmity products / Suspected

Generation of Non - HOD-QA Note:
WI/PR/03 products at Process /Supplies /Customer End. REPL/F/QA/51 Production Incharge
conforming items Write reason for rej. on part with permanent Daily Non Engineer-QA If there is any non
marker. Conforming conformity occurs
reports. on
line/process/pdi/
customer end head
Daily Non HOD-QA
Production Incharge Q/A is authorised
REPL/F/QA/51
Conforming for stop the
Do red bin analysis and reports.
Daily Non take corrective action. shipment. He can
Conforming reports. stop the shipment of
material in transit
also.
Incase of Non
YES Return the conformance due to Debit Given to HOD-QA
Non-confirmity supplier, return the supplier through Engineer-QA
Verification for its material to material to supplier mail & internal
Product due to
prime responsible supplier scrap the material
supplier ?

NO

Situation when non Decision making for

conformity due to reworking, if
NO rework not possible
organization Rework / to rework then for REPL/F/QA/46 HOD-QA
discripency Repair Scrap material scrapping Production Incharge
possible?

YES Decide rework/non rework as per

ANNEXURE-A

Rework allowed for

Situation if Rework is Reworking of Non Production Incharge
possible Rework/ Repair /Segregate the conformity REPL/F/QA/51 Engineer-QA only one times i.e.
material R1.

Ok after rework/repair

Use the material &

Reworking of Non take action on rework
conformity Verify reworked / parts. R marking to be
Repair /
Daily Rework REPL/F/QA/48 Engineer QA
done with permanent Sheet
segregated marker or engraving
material machine & record to
be kept in register
Not OK before send to
customer. Invoice/
Kanban no to be
record Iinitiation of
Do correction for all non conforming Corrective action
Situation if Rework is for major NC REPL/F/QA/04 HOD-QA
not possible parts.

Iinitiation of Take corrective actions with proper 5 why analysis for top 1 rejections
Corrective action for area wise for press, weld, assy, cnc etc. monthly for in-house and CFT (Include
major NC supplier rejection and Supplier Quality , Q/A, Prod./ Tool
Raise In-house QPCR as per criteria give in ANNEXURE-B Inhouse Quality Room/ Maint.) In-house defect,
Action to be decide upto 7th of every month and action to be Problem & REPL/F/QA/04 supplier defect and
C'Measure Report. customer defect data
implement upto 15th of every month for last month rejection. HOD-QA to be shared with
Iinitiation of Development Unit
Corrective action upto Last week of
implementation every month for
Standardize the documents like FMEA, PCS, WIS as per updating of Kakotora
summary sheet and Effectiveness to be check for 3 month. sheet

Horizontal deployment after effectiveness ok with in one Supplier Quality , REPL/F/QA/04 HOD-QA
Inhouse Quality
month Problem &
C'Measure Report. .

Prepared By: Checked By: Approved By:

 Doc. No. REPL/QAP/QA/05
Process Mapping Origin Date 14.01.2024
Rev. No & Date 0
Documented Process for Suspected & Non-Conforming Material Handling Page No. 02 OF 02

ANNEXURE - A

TYPE OF DEFECT ALLOWED / NOT ALLOWED FOR REWORK ANNEXURE - B

CRITERIA FOR RAISING IN-HOUSE 8D report:

Type of Defect Allowed / Not Allowed For Rework
Responsibility S. NO. PROBLEM DESCRIPTION RAISING RAISED BY
S.No. CONDITION
for Records
Defect Rework Allowed Defect Rework Not Allowed Record 1 If quality problem observed in PDI and More than 2 hour Head QA
dispatch delay.

Damages in flank / in Daily Non Conformance If major problem in part and part need
1 Minor damages functional area Report. QA 2 to be scraped More than 3% Head QA

2 Undue burrs near chamfer / Heavy burrs projecting in Daily Non Conformance QA 3 If major problem in part and part need More than 10% Head QA
face / milling location gear flank / Report. to be reworked (Exclude Burr)

Grinding / finish bore U/s

3 Turning / grinding bore U/s more than spec by 50 Daily Non Conformance QA 4 If there is any customer effected due to For Every time Head QA
upto 50 microns microns Report. problem.

Turning / grinding OD O/s Turning / grinding OD O/s Daily Non Conformance For top three rejections at the end of
4 upto 50 microns more than 50 microns Report. QA 5 month Top 3 Head QA

Bore / OD chattering marks / Finish cone dia chattering Daily Non Conformance
5 step upto 50 microns max marks / pattern Report. QA
For every defect have severity 9,10 &
6 For Crack, thining. Every Defect Head Q/A

6 Incomplete operation parts Incomplete operation parts Daily Non Conformance QA

observed in soft stage observed in hard stage Report.

7 Turning / grinding OD R/out Turning / grinding OD R/out Daily Non Conformance QA 7 Any NC observed during process audit Every Non Head Q/A
upto 100 microns more than 100 microns Report. which effect part quality. confirmity

Correcting minor shaving Heavy shaving cutter marks

8 cutter marks observed in soft observed in soft stage by Daily Non Conformance QA
stage by reducing DOP /S reducing DOP /Span size Report.
pan by 50 microns max more than 50 microns

Grinding / turrning process Grinding / turrning process

surface finish improvement surface finish improvement Daily Non Conformance
9 by removing additional 10 by removing more than 10 Report. QA
microns max material microns material

Grinding process cracks

10 -- formed due to abrupt mtl Daily Non Conformance QA
removal from part Report.

HT batch code marking on

11 HT Batch Code not visible / grinding face / functional Daily Non Conformance
QA
legible / not present area
Report.

Child parts which can be Child parts which cannot Daily Non Conformance
12 assembled in soft stage / QA
before fnal processing be assembled at final / FF Report.
stage
Rust traces in tooth flanks /
Parts showing rust traces on grinding / finish surfaces Daily Non Conformance
13 non fiunctional areas like which can lead to poor finish Report. QA
cavity / gear face / OD etc in functional areas

Scratch / dent marks on gear Scratch /dent marks in Daily Non Conformance
14 face / OD in soft stage functional areas / flanks Report. QA

Documents :
Sr. No. Document No. Document Name Prepared By Approved By
-- -- -- -- --

Records :-

Sr. No. Record No. Record Name Retention Period

1 REPL/F/QA/51 Daily Non-Conformance Report 3 Years

2 REPL/F/QA/46 Rework disposal sheet 3 Years

3 REPL/F/QA/48 Daily Rework Sheet 3 Years

4 REPL/F/QA/04 8D Analysis Report 3 Years

Sr No Change history Rev No Rev Date

1 INITIAL RELEASE 0 14.01.2024

Prepared By :- Checked By :- Approved By :-