PRESENTATION ON DOCUMENTS USED at

RAL
SUBMITTED BY

VISHAL (20L5DMM14106)

COURSE : D.VOC MECHANICAL

MANUFACTURING
SEMESTER : 4TH

SUBMITTED TO
MR SUNIL KUMAR( OJT INSTRUCTOR)

SKILL FACULTY OF ENGINEERING & TECHNOLOGY

SHRI VISHWAKARMA SKILL UNIVERSITY 1

Website : www.svsu.ac.in
 ABOUT UNIVERSITY

• First skill university

• Provide every type of skill in every field.
• Such as manufacturing, healthcare, banking & finance, hospitality,
agriculture, etc.
• Ojt (on the job training) involve in every course
• More than 30+ programs are available in university• university tie
up with many industries.
• Like – roop automotive, jbm, concentric, anand group, hdfc bank,
and hero etc. 2
 ABOUT COURSE

Course duration is 3 year’s.

• Eligibility for D.Voc mechanical manufacturing is 10th /12th pass out with
the any recognised board of india.
• Minimum age limit is 16 year’s old .
• course fees is 24000 only.
• Course coordinator is Mr. ANIL AGGARWAL.
Industry mentor is Mr. SUNIL KUMAR.
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 ABOUT ROOP AUTOMOTIVE LIMITED

Partner is – roop automotives ltd.

Industry type - automotive manufacturing
Industry size – 500 – 1000 employees.
Headquater - GURUGRAM.
Founded in – 18 sep 1991
Customers :
hero honda motors ,bajaj auto,mahindra,maruti suzuki
motors, toyota etc
Global presence : USA , canada and australia 4
 CONTENTS

• 4m change • Daily poka yoke status report

• Wi • Fire action
• Machine breakdown notification slip
• Daily operator checksheet
• Machine history card
• Patrol inspection report
• Monthly material consumption report
• Control plan
• Planned vs actual production data
• Ppe matrix • Production docket
• Insert life record • Process setup sheet
• Skill matrix • Daily maintenance sheet

• Major defect analysis • Daily food wastage monitoring

• Ppm graph chart
• Rejection data sheet
• Line performance board
• Kaizen sheet
• Quality alert
 4 M CHANGE

To record Operator change, machine change, tool change, new operator, operator on leave, New
machine, new gauge & new instrument) and unexpected changes Tool breakage, power failure,
machine breakdown etc.

MACHINE NAME MAN MATERIAL METHOD MACHIINE

CHANGE √
LEGENDS =
NO CHANGE
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 WORK INSTRUCTIONS (WI)

PURPOSE : The purpose of the work instructions is to clearly explain how

a particular work task is performed.

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 DAILY OPERATOR CHECK SHEET

 Regular checks by the operator are a good way of identifying problems as well as

making sure machinery is safe to.

CHECK PARAMETER METHOD SHIFT 1 2 3 4 5 6 7

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 PATROL INSPECTION REPORT

Patrol inspection means that an inspector patrols the manufacturing site and

inspects items on timely basis.

DATE SHIFT TIME SPECIFIED ACTUAL DIM. OK/NOT SIGN.

DIM. OK

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 CONTROL PLAN

 PUROSE : It also provides a written description of the measurements, inspections,

and checks put in place to control production parts and processes.

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 PPE MATRIX

PURPOSE : The matrix directs users to which types of PPE to wear based on
certain work activities.

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 INSERT LIFE RECORD

The purpose of sheet record of a cutting tool life.

INSERT LIFE RECORD

LINE: TOTAL LIFE:

M/C NO. CORNER LIFE:

INSERT NAME
PRODUCTION

DATE SHIFT CORNER 1 CORNER 2 CORNER 3 CORNER 4 TOTAL REMARKS

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 SKILL MATRIX

A skill matrix is important because when it is set up well it can help you organize your
teams easily, identifying any skill sets that you need based on the project requirements

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 MAJOR DEFECT ANALYSIS

Defect analysis focuses on developing solutions to attack root causes of different commonly
occurring defects. The fact that a defect was found is the trigger to an improvement action with
the purpose to prevent such errors from happening again.

MAJOR DEFECT ANALYSIS

S.NO. DEFECT ANALYSIS QTY.

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 REJECTION MONITORING SHEET

REJECTION MONITORING SHEET

DATE PART NO. PROBLEM DESCRIPTION DAILY REJECTION

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KAIZEN SHEET

Kaizen philosophy is
developing a culture for
people engagement in
improving the organization
through small-small
continuous improvement in
daily work rather than one
large improvement at once.

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QUALITY ALERT

A quality alert within the manufacturing

industry is an official notification from
the customer of the defects within a
supplier's delivered parts.

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 DAILY POKA YOKE STATUS REPORT

A poka-yoke is a mechanism that is put in place to prevent human error. Daily

verify the poka yoke status that operator poka yoke used or not.

DAILY POKA YOKE STATUS

LINE NAME SHIFT

MONTH

IDENTIFY 1 2 3 4

PREVENTION OF WRONG LOADING

DETECTION OF NOT PERFORMED OPERATION

SIGN. OF QUALITY INSP.

SIGN OF QUALTY ENGINEER

SIGN OF PROD.
ENGR.
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FIRE ACTION

It helps that how to use of fire extinguisher.

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MACHINE BREAKDOWN NOTIFICATION SLIP

The breakdown
report create
when machine
completely
breaks down
and then
repairing it to
working order.
And write down
the timing of
accepting of
problem by
maintaince
dept.

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 MACHINE HISTORY CARD

To record all history of a machine related to its maintenance, breakdowns in

a single register

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MONTHLY MATERIAL CONSUMPTION REPORT

Keep records how much

material isused monthly

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PLANNED VS ACTUAL PRODUCTION DATA

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 PRODUCTION DOCKET

Production docket records daily process production, breakdowns, etc. it

records daily all machine problems,Reasons, operator allowances etc. it is
used on shop floor

PRODUCTION DOCKET

DATE

SR. NO. MACHINE NO. OPERATION OPERATOR PLAN ACTUAL MACHINE BREAKDOWN reason BREAKDOWN HOURS OTHERS

Sign. Shift
incharge
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 PROCESS SETUP SHEET

It covered all the product parameters & process parameters of various

Operations of the part at the time of Setup. Written in this document
actual and according control plan dimensions

process setup sheet

sr. no. product parameters
product characteristics product specifications
1
2
3

process parameters
machine parameters tools
1
2
3

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Sign.
DAILY MAINTENANCE CHECKSHEET

A preventive maintenance
checklist details the tasks that
your technicians must complete
during a maintenance check. 

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 DAILY WASTAGE FOOD MONITORING

This system helps in reducing the amount of food wastage as well by

the daily report of food wastage.

DAILY WASTAGE FOOD MONITORING DATA

SR NO. DATE UOM QUANTITY

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 PPM GRAPH CHART

PPM – parts per million

1 PPM means one defect in a million -1/1000000

PPM is a measurement used today by many customers to

mesaure quality performace.

REJ. PPM –

REJ. QTY . 1000000 / TOTAL PROD. QTY.

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 LINE PERFORMANCE BOARD

The board show the daily line performance , its include actual production ,
breakdown hours, rejections , reworks quantity, reasons etc

LINE PERFORMANCE BOARD

S.NO. OPERATION SHIFT PLAN ACTUAL REJ. BREAKDOWN HRS.

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