Warehouse Business Flow

BPFCH-QAD-04
BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE

Purpose: To ensure deviation approval
Scope: All customers
Responsibility/Inte
Input Activities Control Document / Checkpoint Output
raction
NONO YES
YES
YES YESYES
Visit to customer (if reqd )
Defect glass from Final Collection
arrange of claimed Glass
for segregation at FG ware house &
inspection / Inprocess / at customer end( if req) and replace with good
customer claim glass as a contingency measure Production 1.E-MAIL, 2.VOC, 3.MCM report/ deviation request Detailed report of the glass
QA
Detailed report /Standards
fitment trials report at
customer end / function
test report in house Analyise the reports CFT Minutes of meeting deviation request
Claimed glass from Display of claim glass / information on 1.Flow of message to the process personal & QA
QA inspector Employees signature against
the shop floor & information to all
recd. customer concern On the same day of the claim witnessing the defective
glass
Filled QACR for all the relevent

Raise the QACR in customer QA 1.QACR provisions
Customer requireme- specific format / Asahi format 1.Target Date of Action Plan from the Customer
nts,
1.Varify from PPC/FG w/h that all the existing stock is

Type of defect 100 % Re- Inspection of the existing WIP, QA, PPC, FG W/H AND covered Remove any defective glass
QCFG & FG & Review in MCM 2.Segregation to be completed within 48 HRS from the
PROD. receipt of claim detail.
Result of segregation Confirm the short term containment action to QA, SECTION HEAD-
Trigger off the C/M, FMEA
1.Ensuring that OK glasses are fed to customer line revision
the customer
PROD, MKTG
QA, PROD-(CFT) 1.C/M plan is complete within 7 days. Revised FMEA, Review of
Problem analysis & drive counter-
Type of defect measure plan & review FMEA 2.Any PPAP or similar activities involved, Masterlist, Deep Analysis
Type of Claim 1.Any special testing required and source identification.

Report
Deep Analysis report QA-MKTG 1.Analysis is done jointly, Deep Analysis/DOE reqd. Completed CA-PA form
Initiate CA- PA
2.Discussion with the Technical Advisor,
3.Short term corrctive actions are completed prior to
sending
4.CA-PA within 7 days/as specified by customer.
Action completed NO QA-PROD 1.Planned action , 2.Commited date

as per target
YES
Completed CA-PA form Verify Effectiveness of QA-Mkg 1.Customer claim for the same problem Product Audit Resut
counter-measure 2.Product Audit results
YES Repetition of the

Results of five problem QA-Mkg 1.History of problem
consecutive product
audit
NO
Close QACR QA 1.QACR format
1.Monthly/ Quarterly data is recd from customer or RO

Weekly Reports from Monthly customerwise PPM
PPM analysis against regularly
R.O. targets MKG-RO-QA- PROD 2.PPM matching with finacial data Trend graphs
3.Defect trend is catagorized in terms of bkg
& process defect
1.Monthly/ Quaterly data is recd from customer or RO

YES
Achievement of 2.Reporting to MCM
Target or claim re- MKG-RO-QA- PROD 3.Target V/s actual PPM
occurence 4.PPM matching with finacial data
NO
1.Collect the model wise, defect wise and location wise

QACR submitted, Product Review of counter measurement & check the MKG-RO-QA- PROD data to pin point the problem
Trigger off FMEA and/Control
product audit result for the same model & for the 2.Collection of more detailed data model having the major
audit Result same problem . Plan updation, Review of Job
rejection from RO
BPFCH-QAD-04
Purpose: To ensure deviation approval
Review of counter measurement & check the
product audit result for the same model & for the Responsibility/Inte
same problem . raction
3.Product Audit result Standard
4.Review the CA/ PA
Review the Control QA- CFT 1. Amendment plan, 2. FMEA, 3. Control Plan
plan , FMEA , Job 4. Information to customer on amended plan
Std
Review & Update the FMEA, CP , PPAP , QA- CFT 1.FMEA, CP , PPAP , Job Std. If PPAP, submit it to customer.
Job Std.
Sending of PDI, Monthly Inspection, QA 1.PDI, 2.Monthly InspectionReports.

Revalidation reports to customers as per
their requirements
Process Efficiency : Zero customer complaints & Objectives and Accountabilities. Distributed to :1,2,3,15,22,23,29
Process Effectiveness Measure : Customer Satisfaction analysis
A New Release 1/1/2005

Modification Status Modification details Checked By Approved by Date
BPFCH-QAD-03
Business Process Flow (Final Inspection)
Purpose: To ensure 100 % right quality of the product as per specifications to customer.
Scope: All products manufactured.
Input Process / Activity Resp / Interaction Control doc / Checkpoint Output

Products 1)QA Inspector / 1) Model Specific Inspection Standard Final Inspection
offered for 1) Production shift 2) Control Plans Result
inspection as supervisor/ In-charge 3) Appearance standard /
Final inspection
per process 2) Section Head - Prod 1) Proper identification of offered glass
flow chart & QAPCH-QAD-01 2) Qty mentioned in the process card
Completion of (Procedure for 3) Thickness of glass
all previous Calibration) 4) Colour of Glass
processes in 5) Use of Calibrated Instruments
process 6) MSA Qualified Inspectors
quality checks.
Final 1)QA Inspector / 1) Model Specific Inspection Standard If OK : Pallet Card

Inspection 1) Production shift 2) Appearance Standard / If on HOLD : Isolate
Result supervisor/ In-charge 1) Proper identification of offered glass Card
NO 2) Section Head - Prod 2) Qty mentioned in the process card If Reject : Place it on
Decision QAPCH-QAD-03 3) Thickness of glass red cart and reject
(Procedure for Handling 4) Colour of Glass card
Treat As per Non conforming Product)
non-conforming QAPCH-QAD-04
product (Procedure for CA/PA)
YES
OK Glass 1) Production shift Filled & Signed Pallet

Reports supervisor/ In-charge Card
2) QA Inspector
Hand over OK Glass to FG
Warehouse
-
OK Glass 1) Section Head - In Control Plan Product audit result

Stored in FG Process (Quality) / sheet ( QA/XX/CK-
warehouse 1) In-charge FG 07)
with pallet warehouse
card. Pick on random basis OK glass from FG
warehouse for product audit/ functional testing
Product audit 1) Section Head - In Control Plan Signed Off pallet card
result sheet Process (Quality) / & FG Warehouse slip
( QA/XX/CK- 1) FG warehouse in- if OK
07) NOT OK charge If Not OK quarantine
Status of product audit/ 2) Shift supervisor to isolate/ lot-out area
functional testing QAPCH-QAD-03
(Procedure for Handling
of NC Product)
QAPCH-QAD-
04(Procedure for CA/PA)
OK
FG 1) QA Inspector / Movement of OK
Warehouse 1) FG warehouse in- Glass to FG
slip charge Warehouse.
-
Pass the lot for despatch
Distributed to : 1,2,3,22,23,30
Process Efficiency : As per Objectives & Accountabilities.
Process Effectiveness Measure : Monitoring through In Process PPM Score.

Modification
Status Modification details Checked By Approved By Date
BPFCH-QAD-02
Business Process Flow (In Process)
Purpose: To ensure quality of the product during manufacturing processes as per specifications.

Products 1) QA Inspector / 1) Model Specific Inspection Standard In Process
offered for 2) Production shift 2) Appearance standard Inspection reports
inspection as supervisor/ In-charge 1) Proper identification of offered glass
per process Periodical Patrolling 3) Section Head/ In- 2) Qty mentioned in the process card
flow chart -Inprocess Inspection charge - Prod 3) Thickness of glass
QAPCH-QAD-01 4) Colour of Glass
(Procedure for 5) Use of Calibrated Instruments
Calibration) 6) MSA Qualified Inspectors
In Process 1) QA Inspector 1) Model Specific Inspection Standard If OK : Process Card

Inspection 1) Production shift 2) Appearance Std If on HOLD : Isolate
reports supervisor 1) Proper identification of offered glass Card
NO 2) Section Head - Prod 2) Qty mentioned in the process card If Reject : Place it on
Decision QAPCH-QAD-03 3) Thickness of glass red cart and reject
(Procedure for Handling 4) Colour of Glass card
Treat As per Non conforming Product)
non-conforming QAPCH-QAD-04
product (Procedure for CA/PA)
YES
Inspection and 1) Production personnel / Filled & Signed

Test Status of 1) Production shift Process Card
previuos supervisor/ In-charge
process & Pass to Next Operation
offering of
product to
next process
-
Process Efficiency : As per Objectives & Accountabilities.
Process Effectiveness Measure : Monitoring through In Process PPM Score.

Modification
BPFCH-QAD-01
Business process Flow ( Incoming Quality Assurance)
Purpose: Ensure all Quality Assurance during receipt of Product Related parts.
Scope: Direct BOM items
Resp /
Input Process / Activity Control doc / checkpoint Output
Interaction
Information from stores Incoming Inspector / AVL / Lot no. / MRN No. on the material Verification of material at Incoming
through phone (Lot No., Qty, Reject & Back to Stores Officer/ inspection location
MRN No., ) stores Receipt of MRN from Stores QAPCH-STR-01
Regular Production / sample
BPF-MAT-01
NO Did stores Is it from AVL

informed about NO
the status -
Yes
Supplier report Incoming Inspector AOI/ PPAP with supplier
Inform stores/
Purchase for getting Check for the receipt of supplier
report report
Yes
Availability of MRN/ Lot No. Incoming Inspector Control Plan (QA/IN/CP-01) & Sampling Incoming Inspection report
identified material at incoming Plan (QA/IN/FM-03)
inspection location. Carry out Incoming Calibrated instrument
Inspection
Incoming inspection report's Incoming Inspector / Signature of Inspector by permanent Signed boxes having OK material.
status QAPCH-QAD-03 marker with date of inspection.
Assign Inspection status

on the material
Completion / after sign off on Incoming Inspector / Incoming Inspector Report (QA/IN/FM- Get OK material shifted to identified
the material. Stores Officer 01) location and get not OK material shifted
Inform to stores about the status to red marked area.
of material OK material is issued to the concerned
deptt upon request.
1) Consolidation of Incoming Inspector / Acceptance criteria for Quality rating Vendor Rating & suggestion for
Supplierwise Quality Materials department improvements / corrective action.
performance Review of supplier performance QAP-MAT-01
2) Incoming Inspection
Reports
Process Efficiency : Clearance of Material - No stoppage due to Incoming Inspection & Objectives accountabilities Distributed to : 1,2,3,7,23,28,30
Process Effectiveness Measure : Lotwise report and report about to the supplier for corrective actions.

Modification Status Modification details Checked By Approved By Date
BPFCH-TPS-01
BUSINESS PROCESS FLOW FOR PRODUCT REALISATION
Purpose: To establish a procedure for a structured system of upfront product quality planning.
Scope: Applicable for all products developed & manufactured by the company.
INPUT TIME PERIOD ACTIVITY RESPONSIBILITY INTERACTION CHECK POINT CONTROL DOC. OUT PUT
1.) Review and making of 1.) Inspection / Job Standard

Finalised Time Line Chart Process Instruction.
1.) TPS
2.) Inspection & Release of 2.) Std. Tooling & Gauges Status.
STAGE - III (PROCESS DESIGN &
Customer Main Events Tooling & Gauges.

Initial Preparation PPC 3.) Allocated Raw-material & 3.) Technical Specs. Sheet
Contract Review / LOI for Trial consumable .
DEVELOPMENT )
4 WEEKS
PRODUCTION 4.) Trial Dates. 4.) Standard reporting format

2.) QA
5.) Review of Packaging 5.) Product / process quality review.
standards.
6.) Product / process quality 6.) Review of Process Flow Chart .
requirements
7.) Process Flow Chart . 7.)Review of Floor plan layout .
8.) Floor plan layout . 8.)Review of PFMEA.
9.) PFMEA. 9.)Review of Control plan. (Prototype)
10.) Control plan. 10) Review of MSA & SPC.
11.) Homologation 11) Review of Packaging
requirement Standards
1.) Specifications.
1.) TPS 2.) Critical & Specific Sample Data Sheet / Report
Prototype Control Plan characteristics control.
Sampling & Testing
PPC 3.) Qty. of Samples to
Inspection / Job Standards 2.) QA produced.
PRODUCTION 4.) Type of Testing Required &
Tooling & Gages Std. specs.
5.) Required recording of
data.
SAMPLE EVALUATION TEAM Standard Specs. Vs Actual Acknowledgement sign off by TPS, QA,
Data Concerned on Sample data sheet
Sample Data Sheet
1. Technical Advisor(If reqd)
N.G Sample
Evaluation
OK 1.) TPS Concerned Section
Head.(If reqd)
2.) QA
Sign Off Approval

Purchase Order Submission of 1) Mode of Packing. Qty. of Samples to be send
Packing Std. Samples to 1.) TPS MKTG. 2) Types of Documents to be
Standard Formats Customer
Attached / sent.
Customer Report of fitment Dept. Head Prdn. Discussion over difficult case. 1.)Modification requirement(if any).
trial 1 TPS
Fitment Results
Technical Dir. and Adv. 2.)Discussion over difficult case.
Concerned process Section 3.)Toolings and gauges modification plan.
Person(Prod.)
Concerned process 4.)Raw Material and consumable status.
Section Person(Q.A) 5.)Any other quality related issues.

PPC
Production Prepa- Materials
ration Meeting
Marketing
Customer Report of fitment Test and Trial Schedule

STAGE - IV (TRIAL
Requirement TPS
trial YES (PPC format)
PRODUCTION )
of Trial
Repeat PPC Production Trial date
4 WEEKS
NO
Customer Report for Relevant Documents submission & Sign Off.
Fitment Results 1.) TPS
Initial Product
Validation & 2.)Q.A
Approval
1) RM & consumable Requirement.

'Preparation For PPAP for any new item
Pilot Lots Prod'n.
Customer Report for QA 2) Information to Prod'n /PPC for Prod'n. Dates.
fitment results Homologation certificates
TPS
MATERIALS 3) Required Modifications / New Tooling.
1.) Implementation of Improvement Points.

Technical Sheet Pilot Lot Production 2.) Qty. of Prod'n.
TPS Production deptt. 3.) Variation of Actual vs Planned Process yield
N.G.
STAGE - V (PILOT
Sample 1. Technical Advisor(If reqd)

Sample Data Sheet Evaluation
PRODUCTION )
1) TPS
2 Concerned Section Head(If reqd)
4 WEEKS
2) QA
Sign Off Approval Q.A 1) Mode of Packing. Qty. of Samples to be send

Purchase Order OK
Packing Std. TPS Mktg. 2) Types of Documents to be
Standard Formats Attached / sent.
Submission of lot to
customer
Customer Report of fitment

trial N.G 1.) TPS
Results of Pilot Lot
2.) MKTG.
1) Modification requirement if 1) Effectiveness of earlier modifications

any.
Dept. Head Prdn. 2) Raw material & 2) Toolings & Gauges modification plan.
Consumables status
Technical Dir. and Adv. 3) Any other quality related 3) Minutes of Meeting
issue
TPS Concerned process
Production Prepa- Section Person(Prod.)
ration Meeting Concerned process
Section Person(Q.A)
PPC
Materials
Marketing
Minutes of Meeting Q.A PPAP Documents ( QAP-TPS-01)

Production Trial Run Prod. Customer Specific Submission of PPAP documents to customer and
TPS Requirements their approval
PPC
Customer
( If customer wants)
1) PPAP approval file from 1) PPAP for each part and Raw Material & Consumables Availability
customer 1.) TPS child parts.
2) Raw Material to be QA 2) Prep'n. for Transfer
included in the stocks meeting.
( PD/TP/FM-06) Initial Preparation
3) Specific format for for 1st Mass 3) Freezing of all
defining consumables in Production Toolings/gauges.
the system 4) Process yield.
1) PPAP approval file from QA - 1) Transfer of Documents.

customer Transfer Meeting TPS
2) APQP file Prod'n 2) Quality Planning
3) Customer
Correspondance
1) PPAP approval file from 1) RM & Consumable 1.) Process std., Job std.,
STAGE - VI (MASS
customer availability.
PRODUCTION )
2) APQP file Prod'n 2) Specific requirement 2) Inspection std. Preparation.

3) Customer application.
Correspondance
4) Quality Planning Sign Off Final Preparation of Q.A. 3) Relevant Testing & 3) Review of process yield.
First Mass TPS documentation.
Sheet
Production Mktg. 4) Packing & Transportation.
4 WEEKS
Distributed to : 1,2,3,15,22,23,28,29,30,31
Process Efficiency :
Process Effectiveness Measure :
01/01/2005 A New Release as per TS
Date Mod. Status Modification details Reviewed by Checked by Approved by

BPFCH-QAD-04
Purpose: To ensure smooth switchover in case of enghineering changes and to clearly understand and minimise customer concerns.
Responsibility/Inte
raction
Doc. From TPS Reciept of approved PPAP along with the list of QA/TPS 1.PSW signed off, Update Masterlist of
wavier wrt drawing, wrt material specs , w.r.t 2.Waivers and Correspondances in writing and documents
Performance specs , if any customer signed.
Doc. From TPS, Review the documents as per List received QA 1. PPAP Manual Physical verification of
Updated Masterlist from TPS 1. All documentation are complete documents as per PPAP
2. Any model/part pending for approval
3. PPAP/PSW for Child Parts Completeed.
1. VOC Report/ MCM Report/E-Mail etc.

VOC Report, MCM Customer Concern received through Mkg, QA 1.Review of the details on the concern/information Log in ECN/Customer
Report, E-Mail etc. VOC, MCM, E- MAIL , RO , CSA, Directly 2.Desired Lead time from customer concern
from customer. 3.Acknowledgement sent to customer.
Draft of customer 1. Review the details of concern, 2. Requirement Customer concern/ECN/

concern NO Any Engineering QA of change in the quality system, 3. Desired Lead- drawing
Change reqd. by Mktg/TPS time from customer, 4. Forward to TPS in case
customer ? of any new enquiry
Yes
Customer's ECN,
Check the
QA-PROD 1. Customer supplied ECN,
NO YES
Drawing feasibility of 1. Check for the Material availability,
change 2. Feasibility of Tooling development,
3. Part Submission date.
4. Review to be completed within two weeks of
receipt of the concern.
Verbal consensus Feed back to custmer & all QA/MKTG

concerned Feedback to customer within 14 business days Through E--Mail with mentioning
taken from concern the reason why the required
change is not feasible
departments.
YES QA/MKTG Through E--Mail, Telephone, Fax

Alternative
Suggested
NO
Customer communi- Close the concern QA

cation
1. Issue the inspection Std, Job
1. Commitment from PPC, Std.
Issue the ECN along
Customer's ECN & with updated QA 2. Review of FMEAs and to issue the ECN, 2. Sample Inspection report
feasibility consensus documents and follow 3. To inform the customer regarding the part shipment
date,
up of ECN
4. Dispatch the material as per the target date,
5. Sending of Inspection report to customer.
New sample Submit the samples to

Inspection Report customer QA 1. Changed Inspection Std. And the Job Std. Inspection report
1. Samples quantity, 2. Packing Condition,
3. Date of shipment as per the comittment.
Customer Communi- Feed Back on the changed item received QA 1. VOC/MCM report, E-Mail (from Mktg/Customer), Triggering of New ECN
cation. through Mkg, VOC, MCM, E- MAIL , RO , 2. Fitment result
Directly from customer.
QA/MKTG 1.Approval received for the sample parts submitted,

NO
Implementation 1.Availibity of Material, 2.Tooling, M/C,
reqd in mass 3.Lead time , 4.Custmer Specific requirement for
production identification, 5.Cost impact approval through mkg.
YES
1.Distribution of ECN to the reqd. area, 2.Updated

-DO- Issue a new ECN for QA Inspection Standard, Updation of ECN Log ,
mass production along 1.Commitment from Material Dept, PPC and TPS for
with committed date tooling development Distribution of ECN copies.
.
1.Inspection Std, 2.Job Std. Inspection Reports, Cpk

Carry out PPAP
-DO- QA 1.Change is affecting the Process Capability, Study reports, Performance
2.Change in the Customer suppplied Dwg, Reports
3.Inspection and Test reports, 4.Functional Testing,
1.PSW, 2.Cpk Analysis and update the relevant
document.
NO
Is PPAP 3.Inspection Report, 4.Cpk analysis, 5.Performance
successful ?
Testing Report
YES
Product validation 1. PPAP manual Send PPAP file to customer

Submit updated PPAP
reports for changed file for PSW sign off QA 1. Changed documents.
specification
Signed off PSW QA Updated PPAP file,

Update PPAP file
Release to Mass Production
1.Glass Model, 2.Lot Detail,

PRODUCT
CLAIM
BPFCH-QAD-04
Responsibility/Inte
raction
PRODUCT
3.Defect Type, 4.Defective Qty,
CLAIM
YES
Information from R.O./ Collection of claimed Glass QA-MKTG 1.E-MAIL, 2.VOC, 3.MCM report Mangement Decision of
Directly from customer vising customer
Customer communi- Visit to customer (if reqd ) QA Visitting customer,

cation, Management arrange for segregation at FG ware house & 1.Arrange man power for segregation Displatch of the Contingency
decision
at customer end( if req) and replace with good glass to customer
glass as a contingency measure
1.Flow of message to the process personal & QA

Claimed glass from Display of claim glass / information on QA inspector Employees signature against
recd. customer
On the same day of the claim witnessing the defective
concern
glass

nts,


the customer PROD, MKTG
Type of defect 2.Any PPAP or similar activities involved, Masterlist, Deep Analysis
measure plan & review FMEA
Report
Initiate CA- PA
sending

as per target
YES
Completed CA-PA form

Verify Effectiveness of QA-Mkg 1.Customer claim for the same problem Product Audit Resut

Results of five QA-Mkg 1.History of problem
problem
consecutive product
audit
NO
QA 1.QACR format
Close QACR

Weekly Reports from regularly Monthly customerwise PPM
PPM analysis against
& process defect

YES
NO

QACR submitted, Product Review of counter measurement & check the MKG-RO-QA- PROD data to pin point the problem Trigger off FMEA and/Control
audit Result same problem . rejection from RO Plan updation, Review of Job

4.Review the CA/ PA
Std
Job Std.

their requirements
Process Efficiency : Zero customer complaints & Objectives and Accountabilities. Distributed to :1,2,3,15,22,23,29

BPFBL-QAD-04
Responsibility/Inte
raction


Yes
Customer's ECN,
Check the
QA-PROD 1. Customer supplied ECN,
NO YES
Verbal consensus
Feed back to custmer & all QA/MKTG
concerned Through E--Mail with mentioning
departments.

Alternative
Suggested
NO

cation
Issue the ECN along
date,
up of ECN

cation. through Mkg, VOC, MCM, E- MAIL , Directly 2. Fitment result
from customer.

NO
YES

.

Carry out PPAP
1.PSW, 2.Cpk Analysis and update the relevant document.

NO
successful ?
Testing Report
YES

Submit updated PPAP
specification

Update PPAP file

PRODUCT
3.Defect Type, 4.Defective Qty,
CLAIM
YES
BPFBL-QAD-04
Responsibility/Inte
raction

decision
at customer end( if req) and replace with good glass to customer

recd. customer
On the same day of the claim witnessing the defective
concern
glass

nts,


the customer PROD, MKTG
Report
Initiate CA- PA
sending

as per target
YES
Completed CA-PA form

Verify Effectiveness of QA-Mkg 1.Customer claim for the same problem Product Audit Resut

problem
consecutive product
audit
NO
QA 1.QACR format
Close QACR

Weekly Reports from regularly
Monthly customerwise PPM

& process defect

YES
NO

rejection from RO
4.Review the CA/ PA
Std
Job Std.

their requirements
Process Efficiency : Zero customer complaints & Objectives and Accountabilities. Distributed to : 1,2,3,15,30,31

BPF-MKT-02
Business process Flow (Customer Satisfaction Analysis)
Purpose: To measure Customer Satisfaction Index
Scope: All OEM's and After Market Distributor's
Input Activity Resp / Interaction Control Doc / Checkpoint Output
1) Delivery Problem CRM's / Customer - Compiled List of Customer Concerns

2) Quality Problem Prepare List of customers & Collection Support Executive (Customer Wise)
3) New Model Development of Input data
Problem
4) Packaging Problem
Customer wise data Head - Marketing Customer Satisfaction Analysis plan

Preparation of CSA Plan
Customer Satisfaction Analysis As decided - Internal or Audit on Supply, Quality, Packing, CSA format dispatch / CSA Visit
plan External Development issues
Conduct Customer Satisfaction Survey Format CSA No……..MK/XX/FM-11 &
Document used by external agency
CSA Visit reports / Surveys Internal - Customer Analysis Report

Support executive/
Compilation of Customer feedback & External agency
Analysis
Analysis Report Head - Marketing Action Plan Report
Action Plan preparation on dis-

satisfaction points & improvement plan
on good points
Action Plan Report Head - Marketing Status of Completion of Action Plan

Report
Implementation of Action Plan
Status of Completion of Action Head - Marketing Management Review Reports

Plan Report
Review of results during MCM
Management Review Reports Head - Marketing / Annual Consolidated Report to evaluate

CRM's Repetition.
Monitoring of Customer feedback for
the elimination of dis-satisfaction
Process Efficiency : Zero customer concerns &Objectives and accountabilities Distributed to : 1,2,3,4,5,6,7,8,9,10,11,29,31
Process Effectiveness Measure : Customer Satisfaction Anaylsis Score.
B Review 1/1/2005
A New Release as per TS 1/2/2003

PJ/XX/FM-03
BPF-TPS-01
BUSINESS PROCESS FLOW FOR PRODUCT REALISATION
Purpose: To establish a procedure for a structured system of upfront product quality planning.
Scope: Applicable for all products developed & manufactured by the company.
PRE-CONTRACT PHASE
TPS
Inform customer through mktg.

Information from
customer /mktg for new QA, PRODUCTION - (Discussed in VOC,Design Review meting)
model launch and (PROCESS),PPC,MATERIALS,
Development plan MAINTENANCE, TOP MGMT(If reqd)
NO Possibility of
Development
YES
Inform to mktg
1.) 3D- Data/Master sample. 1) Update masterlist of drawings, 3D's

Initial Information
2.)Drawing. Receiving from MKTG 2) Customer Manuals
3.)Specification. MKT. 3) New Model Enquiry login sheet
4.)Customer System.
5) NMD Card
Technical Sheet
All relevant informations TPS
available from drawing Initial Preparation
/master sample /specs. of Technical sheet
1.)Data Provided Vs Requirement.(Deviation from

NOT FEASIBLE
Technical Sheet specs.)

Q.A. 2.)Equipment , Process & Capacity Study
(Forecast/Plan).
Mktg. 3.)Process capability.
Feasibility Study 1 TPS
Materials 4.)Review of material specs. &
Identification of SC & CC's
PPC 5.) Difficulty level Evaluation.
CFT
All Production-Section Head 6.)Review of customers specific requirements, if
any.
Top mgmt. (If reqd) 7) VA / VE Proposals.
8.)Review of past problems in the similar model
related to design and specs.
STAGE - I (FEASIBILITY REVIEW )
QA 1.)Review of clarification items with customer.

Design Review Meeting
Technical Sheet MARKETING 2) VA / VE Proposals (If any)
with Customer(if reqd.)
TPS 3) Technical sheet
4) Clarification items
MOM with Customer

2 WEEKS
FEASIBLE
MOM with Customer 1.)Consideration of all finalised points during

feasibility study
Finalised Technical
TPS 2) VA / VE Proposals (If any)
Sheet
3) Customer feedback
4) Minutes of meeting
1.)Review of final specs., Customer feedback and
yields
Approval of
Finalised Technical 2) Technical sheet
Technical Sheet Dept. Head Prod.
Sheet
POST-CONTRACT PHASE
Customer Main Events 1.)Scope of supply. 1) Time line Chart
2.)Lead Time for in-House 2) Scope of Supply (BOM)
Contract Review Jobs.
Letter of Indent Prepare "Time TPS CFT 3.) Lead Time for Material & 3)Production & Test
Line Chart" Consumable Procurement for Equipment Review
samples & mass production.
4.) Lead Time for Process &

Product Validations.
5.)* Customer specific
requirement.
STAGE - II (PLANNING/TOOL,GAUGES DEVELOPMENT)
6.) Sub assy items.

7.) Various Supply
Dates.
1.)Customer main events Vs 1) Time Line Chart Sign Off / MOM
Actual status.
Dept. Head Prdn. 2.)Sampling plan for new
Time Line Chart Production models.
Preparation Meeting Technical Dir. and Adv. 3.)Toolings and gauges plan. 2) Standard Tool Design & Actual gauge Curve
12 WEEKS
TPS Concerned process 4.)Raw Material and

consumable status.
Section Person(Prod.) 5.)Design changes in new
Inform customer ,if delay
models.
Concerned process 6.)Discussion over difficult
case.
Section Person(Q.A) 7.)Any other quality related
issues.
PPC 8.) Feedback for tool design
(Complexity of Model and the
existing tool design)
Materials
Marketing 9.) General issues.
1.) Status of Tooling
Development.
2.)Status of raw-material &
Time Line Chart consumable receiving.
Review of
development TPS Dept.Head Prod.. 3.) Sub assy status (if any). Time Line Chart (Finalised)
Customer Main Events schedule
4.) Any other changed

requirement.
5.) Homologation and other
testing requirements.
6.)Customer Project Plan.
PJ/XX/FM-03
1.) Review and making of 1.) Inspection / Job Standard

Finalised Time Line Chart Process Instruction.
1.) TPS
2.) Inspection & Release of 2.) Std. Tooling & Gauges Status.
STAGE - III (PROCESS DESIGN &

Customer Main Events Tooling & Gauges.
Initial Preparation PPC 3.) Allocated Raw-material & 3.) Technical Specs. Sheet
Contract Review / LOI for Trial consumable .
DEVELOPMENT )
4 WEEKS
PRODUCTION 4.) Trial Dates. 4.) Standard reporting format
2.) QA
5.) Review of Packaging 5.) Product / process quality review.
standards.
6.) Product / process quality 6.) Review of Process Flow Chart .
requirements
7.) Process Flow Chart . 7.)Review of Floor plan layout .
8.) Floor plan layout . 8.)Review of PFMEA.
9.) PFMEA. 9.)Review of Control plan. (Prototype)
10.) Control plan. 10) Review of MSA & SPC.
11.) Homologation 11) Review of Packaging
requirement Standards
1.) Specifications.
1.) TPS 2.) Critical & Specific Sample Data Sheet / Report
Prototype Control Plan characteristics control.
Sampling & Testing
PPC 3.) Qty. of Samples to
Inspection / Job Standards 2.) QA produced.
PRODUCTION 4.) Type of Testing Required &
Tooling & Gages Std. specs.
5.) Required recording of
data.
Sample Data Sheet
1. Technical Advisor(If reqd)
N.G Sample
Evaluation
OK 1.) TPS Concerned Section
Head.(If reqd)
2.) QA
Sign Off Approval

Purchase Order Submission of 1) Mode of Packing. Qty. of Samples to be send
Packing Std. Samples to 1.) TPS MKTG. 2) Types of Documents to be
Standard Formats Customer
Attached / sent.
Customer Report of fitment Dept. Head Prdn. Discussion over difficult case. 1.)Modification requirement(if any).
trial 1 TPS
Fitment Results
Technical Dir. and Adv. 2.)Discussion over difficult case.
Concerned process Section 3.)Toolings and gauges modification plan.
Person(Prod.)
Concerned process 4.)Raw Material and consumable status.
Section Person(Q.A) 5.)Any other quality related issues.

PPC
Production Prepa- Materials
ration Meeting
Marketing
Customer Report of fitment Test and Trial Schedule

STAGE - IV (TRIAL
Requirement TPS
trial YES (PPC format)
PRODUCTION )
of Trial
Repeat PPC Production Trial date
4 WEEKS
NO
Customer Report for Relevant Documents submission & Sign Off.
Fitment Results 1.) TPS
Initial Product
Validation & 2.)Q.A
Approval
1) RM & consumable Requirement.

'Preparation For PPAP for any new item
Pilot Lots Prod'n.
Customer Report for QA 2) Information to Prod'n /PPC for Prod'n. Dates.
fitment results Homologation certificates
TPS
MATERIALS 3) Required Modifications / New Tooling.
1.) Implementation of Improvement Points.

Technical Sheet Pilot Lot Production 2.) Qty. of Prod'n.
TPS Production deptt. 3.) Variation of Actual vs Planned Process yield
N.G.
STAGE - V (PILOT
Sample 1. Technical Advisor(If reqd)

Sample Data Sheet
PRODUCTION )
Evaluation 1) TPS
2 Concerned Section Head(If reqd)
4 WEEKS
2) QA
Sign Off Approval Q.A 1) Mode of Packing. Qty. of Samples to be send

Purchase Order OK
Packing Std. TPS Mktg. 2) Types of Documents to be
Standard Formats Attached / sent.
Submission of lot to
customer
Customer Report of fitment

trial N.G 1.) TPS
Results of Pilot Lot
2.) MKTG.
1) Modification requirement if 1) Effectiveness of earlier modifications

any.
Dept. Head Prdn. 2) Raw material & 2) Toolings & Gauges modification plan.
Consumables status
Technical Dir. and Adv. 3) Any other quality related 3) Minutes of Meeting
issue
TPS Concerned process
Production Prepa- Section Person(Prod.)
ration Meeting Concerned process
Section Person(Q.A)
PPC
Materials
Marketing
Minutes of Meeting Q.A PPAP Documents ( QAP-TPS-01)

Prod. Customer Specific Submission of PPAP documents to customer and
Production Trial Run TPS Requirements their approval
PPC
Customer
( If customer wants)
PJ/XX/FM-03
1) PPAP approval file from 1) PPAP for each part and Raw Material & Consumables Availability
1.) TPS
customer child parts.
2) Raw Material to be QA 2) Prep'n. for Transfer
included in the stocks meeting.
( PD/TP/FM-06) Initial Preparation
3) Specific format for for 1st Mass 3) Freezing of all
defining consumables in Production Toolings/gauges.
the system 4) Process yield.
1) PPAP approval file from QA - 1) Transfer of Documents.

customer Transfer Meeting TPS
2) APQP file Prod'n 2) Quality Planning
3) Customer
Correspondance
1) PPAP approval file from 1) RM & Consumable 1.) Process std., Job std.,
STAGE - VI (MASS
customer availability.
PRODUCTION )
2) APQP file Prod'n 2) Specific requirement 2) Inspection std. Preparation.

3) Customer application.
Correspondance
4) Quality Planning Sign Off Final Preparation of Q.A. 3) Relevant Testing & 3) Review of process yield.
First Mass TPS documentation.
Sheet
Production Mktg. 4) Packing & Transportation.
4 WEEKS
Distributed to : 1,2,3,4,5,7,12,13,14,15,16
Process Efficiency :
Process Effectiveness Measure :
1-Feb-03 A New Release as per TS
Date Mod. Status Modification details Reviewed by Checked by Approved by

BPF-MKT-01
Business Process Flow for Customer Related Process - ( New Model development / Existing Model modification)
Purpose: To understand customer requirements during enquiry handling & Contract Review.
Scope: All Products - OE
Input Process/Activity Resp/Interaction Control Doc/Check Output
Points
Customer Letter/mail HOD-Marketing Customer - new model Acknowledgement to customer
Receipt of customer enquiry CRM Customer credibility
Product type
Volume
No Checking
Regret Letter to against AIGL CRM Regret Letter to Customer
Customer capability
Yes
Drawings/CAD/Samples CRM Customer plan NMD Card,Drawings/CAD/
Customer Plan Executive - Marketing Samples
Forward drawings/CAD data/
samples to TPS with NMD
card.
Feasibility Study-CFT CRM Customer specs. Technical study sheet

Section Head-TPS AIGL Process capability
Technical study sheet Head Marketing Technical study sheet Commercial proposal to customer
Preparation of Quotation &
Section Head-Mktg Printing/Drilling
Submission to customer Planning / Technical Study
Sheet for intended
requirements Yields
Difficulty level
Customer target COO AIS price policy

Price negotiation with customer
Competitor price HOD - Mktg. AIS cost
CRM Voulume
No HOD-Marketing AIG quotation Revised Commercial proposal

Revised quotation Customer CRM AIG price policy
acceptance AIG cost
Yes
Letter of Intent HOD-Mktg. Price

Receipt of LOI and customer
CRM's Payment terms
plan Development schedule
General terms and conditions
No HOD-Mktg. Price Letter to customer

Acceptable/not
Inform customer acceptable
CRM's Payment terms Contract review to TPS
Yes
Section Head-TPS Customer Trial Plan Development Schedule

Submision of development CRM's
schedule to customer
Purchase Order CRM's Price Purchase Order

Receipt of purchase order Payment terms AIG quotation
General terms and conditions Contract Review
No HOD-Marketing Price Purchase Order

Inform Customer Acceptable/not
Payment terms AIG quotation
acceptable
Yes
TPS/QA Customer development plan Samples
Samples submission Section Head - Despatch Sample requirement
if not ok TPS/QA Customer specs. Customer standards

Resubmission of Fitment
CRM's
samples Approval
ok
TPS/QA/Despatch Customer plan Pilot lot

Pilot lot submission Customer schedule
TPS Modification/specific application Customer report

requirement
Result of pilot lot Production
submission & reveiw QA
PPC
Marketing
Customer Approval Production Process/Job Standards Final Contract Review

Commercial Production Inspection standards
Raw material/consumable
availability
BPF-MKT-01
Business Process Flow for Customer Related Process - ( New Model development / Existing Model modification)
Purpose: To understand customer requirements during enquiry handling & Contract Review.
Scope: All Products - OE
Input Process/Activity Resp/Interaction Control Doc/Check Output
Points
Process Efficiency : 100% execution of customer requirements ,Objectives & accountabilities. Distributed to :1, 2 , 3, 4, 5, 6
Process Effectiveness Measure : Customer Satisfaction Analysis

BPF-MKT-01
Business Process Flow - Customer Related Process( After Market)
Purpose: To understand customer requirements during enquiry handling & contract reviews.
Scope : All products - After Market.

Resp /
Input Activity Check Points Document Output
Interaction
Distributorship Review the customer contract - S.H. (AFM) All the contract terms Distributorship Agreement Contract review format
Agreement - Distributor agreement
for intended use.
Excel sheet of sales S&OP sales plan

performance - Make projections for next eight months by - S.H. (AFM) - Customer schedule - S&OP procedure
20th of previous month; - S.H. (PPC) - Past schedule v/s despatch
- Firm plan by 6th of every month performance
- Model
- Qty.
Order through e-mail Transfer data in excel

Order receipt at AIGL and acknowledgement of - S.H. (AFM) - Customer schedule sheet and list of orders
order to customer - Customer to Notice Board
- S.H. (Packing)
Customer
Order received - S.H. (AFM) Decide on the acceptance - Customer schedule E - mail message to
through e-mail of order based on: - AIGL price list customer/ packing
section
NoOrder acceptance - Models - Overdue statement
- Quantity
- Delivery requirement
- Rates/discount
- Vehicle load
Yes - Overdue payment
Order v/s despatch Change in sales plan

status format
- S.H. (AFM) Comparison of sales plan v/s - Sales plan
Check for any change Yes actual orders received
in sales plan
- Customer schedule
Information to
PPC
No
Stock status at FG requisition slip
packing Daily requirement to PPC - S.H. (Packing) Check FG availability - Warehouse issue slip
BPF-DES-01 based on FG stocks - Stock ratio
Stock ratios FG requisition slip

Issue of FG by PPC - S.H. (Packing) Requirement received - Warehouse issue slip
- S.H. (PPC) from Packing - Stock ratio
Movement of glass to
Packing shed.
- S.H. (Packing) - Availability of forklift - Job standard for forklift

- FG to be transferred movement
- Warehouse issue slip
Excel sheet 1. Loading plan

containing stock of Packing and preparation of - S.H. (Packing) Compliance to: - Packing job standards 2. Vehicle requisition
consumables slip
loading plan and intimation to - Packing specifications
truck/lcv union for vehicle. - Type of vehicle required
(lcv,lp,T407)
- Availability of road permit
Vehicle requisition
slip Vehicle arrangement - S.H. (Packing) - Type of vehicle ordered - Vehicle requisition slip
- Condition of vehicle:
a) Tarpaulin with vehicle
b) Date/time at which
required
Loading plan Loading plan
Loading of the vehicle - S.H. (Packing) - Compliance to loading plan - Loading plan
- Sealing of material
Loading plan Invoice

Road permit Despatch of vehicle after Invoicing - S.H.(Despatch) 1. Loading plan details - Rate list Material gate pass
GR copy
2. Compliance to Govt. rules and Road permit
regulations:
- CST/LST applicable
- Form 38 requirement
- Road permit
2. Rates as per rate list
Movement of
vehicle to - S.H. (Despatch) - Point of delivery - GR copy
destination.
- Transporter - Transit time - Transit time standard
Excel sheet of daily E-mail to customer

despatch details Send despatch details to customer and HO - S.H. (Packing) Collection of following - Schedule v/s despatch statement
- S.H. (AFM) information:
- Model
- Quantity
- Vehicle no.
- Date of despatch
Despatch details Updation of GR record
Receipt confirmation of vehicle - Customer - Condition of glass on - GR copy of transporter in excel sheet
delivery at customer end
on GR copy by customer - S.H. (Despatch) - Breakage/rejection report
Business Process Flow - Customer Related Process( After Market)
Purpose: To understand customer requirements during enquiry handling & contract reviews.
Scope : All products - After Market.

Resp /
Input Activity Check Points Document Output
Interaction
Survey report
- Customer - No. of broken pcs. - GR copy of transporter

Yes - S.H. (AFM) - Reason for breakage - Breakage/rejection report
Check for breakage
- Insurance surveyor
- Survey report
- Insurance claim procedure
Insurance survey to be
conducted
No
Generate monthly/weekly reports - S.H. (AFM) - Models - Order Vs Despatch

(MCM,VOC,MD) - S.H. (Packing) - Quantity statement
- Gross Value - Order turnaround report
- Order turnaround time - Regional sales report
- % Execution - VOC agenda
- FG not available
- Rejections data
Billing history Overdue statement
Collection of payment - S.H. (AFM) - Contract terms - Distributorship Agreement
- Overdue factor - Statement of accounts
- Breakage/rejections
END
Distributed to : 1, 2, 3, 4, 5, 6, 20
Process Efficiency : 100 % execution of customer requirements & Objectives & accountabilities.
Process Effectiveness Measure : Customer Satisfaction Analysis.
A New release as per TS 1/2/2003

Business Process Flow for Customer Related Process - ( Sales Planning and Execution) BPF-MKT-01
Purpose: To understand customer requirements for production volumes
Scope: OEM Sales Planning, After Market Sales Planning & Exports
Input Process / Activity Resp / Interaction Control Doc / Checkpoint Output
Annual Planning
1) Customer Plan, Department Head -Marketing 1) Customer Plan / Report on Market Study
2) Production and Sales Trend Market Study 1) New Model Launch,
Report, 2) New Customer,
3) NURC Report, 3) Competitor Position, Replacement rate v/s car
4) SIAM/ACMA reports, parc.
5)Market Research Report
1) Report on Market Study, 2) 1) Department Head 1) Customer Plan / Annual Sales Plan
Customer Annual Plan, 3) Annual Sales Plan -Marketing / 1) New Model Launch,
Sales plan by CRM, Section 1) Section Head - Planning, 2) Market Scenario,
Head 2) CRM (North, West & 3) AIGL Share of Business,
South), 4) Govt. Regulations/Tariff's
3) Section Head - After-
market,
4) Section Head - Exports
1) Mid Term Plan, Steering Committee Future Strategy, Profitability, Strategic Implication Annual Sales Plan
2) Annual Sales Plan
Not OK Review by Top
Revise Plan Management
OK
Deptt Head (Mktg) , Steering
Committee / BPF-MKT-01 (OE
Finalise Annual Sales Plan & AFM)
Monthly Planning
1) Annual Sales Plan, CRM, North, West & 1) AIGL Share of Business, Monthly Sales Plan
2) Customer orders South,Steering Committee / 2) Vehicle Stock at customer end,
Submission of Monthly Sales Plan by CRM's, BPF-MKT-01 (OE & AFM) 3) F.G. stock at regional warehouse and customer,
Section Head - After-Market and Exports
4) Material in transit
Section Head - After Market 1) Competitor activity (domestic and imports), Monthly Sales Plan
2) Past trend (order v/s despatch),
3) AIGL price v/s competitor price
Section Head -Exports 1) Past trend (order v/s despatch), Monthly Sales Plan
2) AIGL price v/s customer target,
1) Monthly Sales Plan from Section Head - Planning 1) Industry trend (actual prodn. v/s projection), Monthly Sales Plan
CRM's, 2) Vehicle Sales Trend,
2) SIAM/ACMA reports, 3) Annual Projection v/s Actual
Finalise Monthly Sales Plan
3) Sales Report
1) Annual Sales Plan, 2)Monthly 1) Department Head - 1) Annual Sales Plan,

Sales Plan Marketing / 2) Sales Trend,
1) Section Head - Planning, 3) Industry Trend (Projection v/s actual prodn.)
Sales Planning Meeting
2) CRM's,
3) Section Head - After-Market
1) Department Head - 1) Annual Sales Plan, Industry Scenario Report

Marketing / 2) Sales Trend,
2) Section Head - Planning, 3) Industry Trend (Projection v/s actual prodn.)
Not OK Review of Industry 3) CRM's,
Revise Monthly Sales Plan Scenario 4) Section Head - After-Market
OK
1) Customer schedule, Section Head - Planning 1) Customer orders, Monthly Sales Plan (as per planning horizon)
2) Sales report, 2) Stock at customer/ regional warehouse,
3) Share of business report, 3) Material in transit,
Submit Sales Plan to PPC
4) Inventory norms at regional warehouse,
5) New model introduction
Regret to customer
1) Monthly Sales Plan (as per No Section Head-PPC 1) Capacity availability (BPF-PPC--01) Production Plan
planning horizon), 2) Raw material availability, (BPF-STR-01)
2) Capacity Planning Sheet No Acceptance of 3) Consumables availability, (BPF-STR-01)
Review by steering committee Sales Plan by PPC 4)Pallets availability,
5) F.G.+WIP stocks
Yes
Weekly Planning
1) Monthly Sales Plan v/s Executive - Demand 1) Stock at customer and regional warehouse, Weekly Despatch Plan
Actual Despatch Report, Fulfillment 2) Material in transit,
2) Stock report, 3) Lead time for delivery
3) Customer orders,
Weekly despatch plan (2 weeks rolling)
1) Monthly Sales Plan v/s 1) CRM's, 1) Increase/decrease in production at customer Change in Sales Plan
Actual despatch report, 2) Section Head-After-market, end,
2) revised customer order, Yes Change in 3) Exports / 2) AIGL share of business
Submit Change in Sales Plan customer 1) Section Head-Planning
requirement
No
Weekly Planning
BPF-MKT-01 SOP Page 20

Business Process Flow for Customer Related Process - ( Sales Planning and Execution) BPF-MKT-01
Purpose: To understand customer requirements for production volumes
Scope: OEM Sales Planning, After Market Sales Planning & Exports
1) Weekly Despatch Plan, Executive - Demand 1) Daily despatch report Daily Despatch Plan
2)Customer orders Fulfillment 2) Stocks at regional warehouse/customer end,
Daily Despatch Plan 3) Material in transit,
4) Lead time for delivery
Daily Despatch Plan 1) Section Head - Despatch 1) F.G. availability, Despatch from plant, Daily despatch report
(BPF-DES-01) 2) Transportation availability,
Execution of despatch plan 2)Section Head - Packing
Process Efficiency : 100% execution of customer orders, Objectives & accountabilities. Distributed to : 1, 2, 3, 4, 5, 6
Process Effectiveness Measure : No premium freighting, no loss in share of business/customer orders, no raw material allocation, optimum inventory (raw material+f.g.)

BPF-MKT-01 SOP Page 21

Page : 22 of 55
Business process Flow ( Purchasing)
Purpose: To establish a procedure for the procurement of material and services and monitoring of performance on pereodic basis
Scope: All material procured against MPC schedules and requistions
Resp Control Doc ( * ) /

Input Process / Activity
/ Interaction Checkpoint ( - )
Annual Activities
1) Company guidelines and target S&C 1) Major categories of items
2) Annual localization plan Prod. 2) Major suppliers
3) Annual alternate sourcing plan Prepare annual savings plan MPC 3) Share of business ( value wise)
4) Last year procurement value item Stores
wise
5) Annual Material requirement plan
for next FY
1) Annual MRP Sheet S&C 1) Major categories of items

2) Last year average procurement MPC 2) Major suppliers
cost Prepare annual procurement budget for BOM Stores 3) Share of business ( value wise)
3) Annual Localization plan items for next FY.
4) Annual new product devlopment
plan
5) Annual savings plan
6) Issues with suppliers
1) Annual procurement budget S&C 1) Travelling budget

2) Annual savings plan C-Planning 2) General Budget
3) Last year overall rating of supplier Prepare Overheads budget for S&C section.
4) Other isuues and reasons
5) Travelling plan and schedule
6) Cost / Trip ,expected savings / trip
and issues to be discussed
7) Other expenses / section
8) Training schedule and budget
Quaterly Activities
Monthly results of performance of S&C 1) Procedure for vendor rating
suppliers Prod.
To conduct run periodic vendor rating for Stores 1) Compare with results of last year ,quarter
suppliers in AVL and expectations
1) Shortlisting of suppliers for S&C 1) Procedure for vendor rating

upgradation plan as per TS-16949 2) Format - MT/PU/FM-07
Feedback report to suppliers and counter
action reports 1) Clearly identify areas for improvement
and action plans
1) Countercation report on areas for S&C 1) Compliance of schedules with plan

improvement
2) Plan for upgradation of quality Monitor results of countercation plans and
system as per TS-16949 schedules
Monthly Activities
1) Annual procurement budget for S&C 1) Cost reduction targets
BOM. Stores 2) Other Issues with supplier
2) Annual Overheads budget for S&C Visit suppliers in line with schedules of Prod
Section. Overheads and procurement budget. MPC
3) Variation in procurement cost as
compaired to last year average price.
4) Issues to be discussed with
suppliers
Vist Report S&C 1) Change of lead time / Supply cycle

MPC 2) Change in price / agreement / SOB
Inform concerns sections / Dept's about the QA 3) Change in Inventory norm
outcomes of meeting Prod. 4) Certification plans
Stores 5) Other Issues
Mktg.
C-Planing
Page : 23 of 55

Approved MRP orders ( MT/ RW / FM- Clarifications from S&C MRP ( MT / RW/ FM-30)
30) / Requisitions MPC / Stores / Users MPC 1) Need by Date as per lead time
Capex Approval and Joint agreement QA 2) Budgeted requirement
Prod. 3) Information of new Items and suppliers
Stores 4) Other Issues
NO TPS Requistions
Is MRP/
Reuqitsions 1) Approval from concern section heads
adequate ? 2) Need by Date as per lead time
3) Unit of measure
4) Charge Account
5) Specifications
YES
Adequate MRP / requisition S&C 1) Agreements / Contracts with suppliers
Approved vendor list for BOM Prod. 2) Industrial directories / Internet
(MT/PU/FM-09) Mech. 3) Valid ISO Certifications
List of suppliers in oracle base Arrangemen Elect. 4) Plan for certification
t of quotes if Stores
required NO
1) Identification of sources YES S&C 1) Last procurement price

2) Comparative quotes 2) Standard rates in the market
3) Comparitive quoates
4) Budget for procurement
5) Need by date
Negotiation 6) Other terms and condition
7) Details to be shared & approved by
concern authorities as per lmit.
8) Regulatory concerns w.r.t EMS
1) Agreement / Contract S&C 1) Qty

2) Approved MRP / requisition 2) Need by date
Creation of Orcale Order 3) specification
4) Negotiated prices
5) Negotiated terms and condition
6) Requirement of inspection reports
7) Regluatory concerns , Statutory
requirements , Storage Requirement
8) Issues related to shelf life
Oracle Order S&C 1) Remarks of approver

NO
Approval of Order
YES
Approved Oracle purchase Order S&C Reconcilation with purchase orders
Release of Orders to suppliers and get
acknowledgements from suppliers
Confirmed schedules from supplier S&C 1) Check payment terms

Accounts 2) Check expected time of arrival
3)Check Invoice date
Release of payment as per agreed terms and
condition
Release of payment S&C 1) Orcale Order sheet

2) Incomming status sheet
Co-ordinate dispatches and track shipments
1) Need by date / Promise date
2) Shipment documents
Page : 24 of 55

Shipment documents from supplier S&C 1) All documents shall be delivered to plant.
MPC 2) Correctness of invoice and availibility of
Stores all other related docs.
Inform Stores / MPC about expected time of
Prod.
arrival of material
Shipment documents from supplier S&C 1) Availibility of all documents required for
clearance
Clearance of shipment ( shipment from 2) Clearance with in free period
Overseas suppliers)
Clearance of shipment S&C 1) Orcale Order sheet

Stores
Receiving of material at plant MPC 1) Item ,qty and schedule verification
against P.O
2) Physical Inspection
3) Documents with shipment
Material ready for inspection and bill S&C 1) Quality

posting in sytem QA 2) Quantity
Is there any discrepancies NO Stores 3) schedule
User 4) Other information / document
YES
Discrepancy report 1) Information to supplier. S&C 1) Complete information about the
2) Arrangement of repalcement ( if required) QA discrepancy.
3) Arrangement of documents ( if required) 2) Arrangement of countermeasure report
Information to supplier and clear the S&C 1) Compare invoice with P.O
discrepancy. Bill posting in system Stores
Receiving of material and ready for S&C 1) Payment Terms

issue Release of payment to suppliers as per Accounts
agreement.
Data for monitoring and control of S&C 1) Change in basic cost

procurement cost variation. To evaluate variation in procurement cost as Accounts 2) Premium freighting
compaired to last year procurement cost. 3) Change in other factor
Distributed to : 1,2,3,4,5,7,8,10,11,17
Process Efficiency : No stoppage of production line.
Process Effectiveness Measure : Accountabilities & Objectives
A New release as per TS

Modification Status Modification details Checked By Approved By
Page : 25 of 55
BPF-MAT-01
ess Flow ( Purchasing)
Output
Annual Savings plan
Annual procurement
budget for BOM.
Annual Overheads
budget for S&C
Section.
1) Shortlisting of
suppliers for
upgrading quality
system as per TS-
16949
1) Countercation
report on areas for
improvement
2) Plan for
upgradation of
quality system as
per TS-16949
1) Upgradation of
supplier
Visit Report
Inclusion of change
points in MRP / Min.-
Max. Norms
Page : 26 of 55
BPF-MAT-01
Output
Adequate MRP /
Requistion
1) Identification of
sources
2) Comparative
quoates
Agreement /
Contarct
Oracle Order
Approved Oracle
purchase Order
Confirmed
schedules from
supplier
Release of payment
Shipment
documents from
supplier
Page : 27 of 55
BPF-MAT-01
Output
Clearance of
shipment
Material ready for

inspection and bill
posting in sytem
Discrepancy report
Information to
supplier and clear
the discrepancy.
Receiving of material
and ready for issue
Data for generating

periodic vendor
rating.
Data for monitoring
and control of
procurement cost
variation.
Actual variation in
procurement cost as
compaired to last
year average buying
price.
1/2/2003
Date
BPF-PPC-01
Business process Flow ( Production Planning & Control)
Purpose: To plan and control production & materials planning
Scope: For all OEM, Spares and Export Order.
Annual Planning
* ACTUAL VEHICLES SALES
MKTG * CUSTOMERS PROJECTED SCHEDULE.
CATEGORY WISE TRENDS. RECEIVING OF
* VEHICLE POPULATION CATERGORY ANNUAL SALES - EXPORTS/AFTER MARKET REQUIREMENT. ANNUAL SALES PLAN BUCKETTED
WISE PLAN. MONTHLY
FOR OEMS' AND SPARES
* NEW MODELS
SEPARATELY.
1.PPC
* MODEL WISE ALLOCATION ON * MODEL ALLOCATION TO BE DONE
I/C PLANNING TEMPERING &
VARIOUS RESOURCES MAKING OF CONSIDERING VARIOUS SPECIFICATIONS
LAMINATED
ANNUAL
PRODUCTION TENTATIVE ANNUAL PRODUCITON
* TARGET APS,YIELDS MODEL WISE 2. SECTION HEAD - ELECTRICAL./ PLAN WORKCENTREWISE.
AT EACH PROCESSES. PLAN MECHANICAL.
*ANNUAL MAINTENANCE PLAN FOR 3. SECTION HEAD - TRIAL

ALL EQUIPMENTS PRODUCITON SECTION.
1.PPC PROVISIONAL CAPACITY

* TARGET APS,YIELDS MODEL WISE * MAINTENANCE REQUIREMENT MUST BE
CAPACITY I/C PLANNING TEMPERING & UTILISATION SUMMARY SHEET
AT EACH PROCESSES. INCORPORATED IN PLAN
UTILISATION WORK LAMINATED WORK CENTREWISE.
CENTREWISE
* MODEL WISE ALLOCATION ON * CAPACITY UTILISATION MUST NOT BE > =
VARIOUS RESOURCES 2.SECTION HEAD LAMINATING./ 100% FOR ANY WORKCENTRE.
TEMPERING.
* TARGET TIME YIELD / TACT
3.SECTION HEAD SUB-ASSEMBLY.
MODELWISE FOR EACH PROCESS.
* MODEL SPECIFICATIONS 4.SECTION HEAD -TPS.
*SPECIAL PROCESSES IF ANY

5.SECTION HEAD -PPC.
*NEW MODELS
FINALISATION OF ANNUAL
- TENTATIVE CAPACITY UTILISATION PRODUCTION PLAN. 1.PPC FINAL CAPACITY UTILISATION
* CONSIDERATION OF ALL FINALIZED POINTS
SUMMARY SHEET WORK I/C PLANNING TEMPERING & SUMMARY SHEET WORK
DURING FEASIBILITY STUDY.
CENTREWISE. LAMINATED CENTREWISE.
FINAL CAPACITY UTILISATION - APPROVED PRODUCITON PLAN

SUMMARY SHEET WORK DEPTT. HEAD PRODUCTION
CENTREWISE.
APPROVAL OF
PLAN
IF NO
FINAL CAPACITY UTILISATION PREPARATION OF ANNUAL 1.PPC YIELDS TARGETS

SUMMARY SHEET WORK PRODUCTION BUDGET I/C PLANNING TEMPERING & AVERAGE PER SHIFTS TARGET
CENTREWISE. /TARGETS FOR LAMINATED
PALLETS /MANPOWER
- TARGET CONSUMABLE AND POWER CONSUMPTION BUDGETS:
CONSUMPTION AND PROCESS PALLETS
YIELDS.PROJECTED CONSUMABLES.
BUDGET:
- MODELS SPECIFICATION SHEETS. 3.SECTION HEAD - ELECTRICAL
CAPACITY UTILISATION COST / SQUARE METER
WORKCENTREWISE. BUDGET:
* TARGET APS,YIELDS MODEL WISE 4.SECTION HEADS -LAM./TEMPERING.
AT EACH PROCESSES. KWH / SQUARE METER
* TARGET POWER CONSUMPTION

MODEL WISE.
* NEW MODELS
- TARGET CONSUMABLE APPROVED PRODUCITON

* REVIEW OF MODEL ALLOC.
CONSUMPTION BUDGET TARGETS/BUDGETS.
APPROVAL * REVIEW OF MANPOWER STATUS I.e.
- MODELS SPECIFICATION SHEETS. DEPTT. HEAD PRODUCTION
REQUIREMENT Vs AVAILABILITY.
- NEW MODELS DEVLOPMENT
IF NO AVAILABILITY
SCHEDULE
* CONSIDERATION OF ALL FINALIZED

POINTS DISCUSSED DURING BUDGET
FINALISATION OF PREPARATION
PRODUCTION TARGETS FOR :
PROCESS YIELDS 1.PPC APPROVED PRODUCITON
PALLETS. I/C PLANNING TEMPERING & TARGETS/BUDGETS.
MANPOWER. LAMINATED
POWER CONSUMPTION. 2.SECTION HEAD -PPC.
Monthly Planning
* CUSTOMER REQUIREMENT.
* CUSTOMER SCHEDULES. MKTG SALES PLAN SUBMISSION
RECEIVING OF MONTHLY
* STOCKS AT CUSTOMER. SALES PLAN FOR PLANNING DATES: 21st OF MONTH N0-1 SALES PLAN FOR PLANNING
HORIZON BY 6th & 21st OF HORIZON
EVERY MONTH AND
* ANNUAL SALES PROJECTIONS.
6th OF MONTH N0
*SALES PLAN FOR PLANNING

PRODUCTION PLAN SUBMISSION DATES :
HORIZON
MAKING OF PRODUCTION
PLAN FOR MONTH M0 AND PPC * MONTHLY CAPACITY UTILIZATION
* ANNUAL MAINTENANCE SCHEDULE. PLANNING HOROZON I/C PLANNING TEMPERING & DATES: 26TH OF MONTH N0-1 TEMPERING/LAMINATING
LAMINATED WORKCENTRE WISE.
* MODEL RUNS AND ALLOCATION AND * TENTATIVE PRODUCITON PLAN
PROJECTED STOCKS RATION 10th OF MONTH N0 FOR MONTH M0 + HORIZON
STOCK RATION MODELWISE HORIZON
*NEW MODELS
* TENTATIVE PRODUCITON PLAN

* PROJECTED STOCKS RATIO * FINAL PRODUCITON PLAN
FOR MONTH M0 + HORIZON
HORIZON APPROVAL OF SECTION HEAD -PPC MUST BE WITH IN NORMS FOR MONTH M0 + HORIZON
PLAN FOR MO
MONTH
FINAL CAPACITY UTILISATION
IF NO
SUMMARY SHEET WORK
CENTREWISE.
FINAL CAPACITY UTILISATION

SUMMARY SHEET WORK
CENTREWISE.
*TENTATIVE PRODUCITON
- TARGET CONSUMABLE TARGETS/BUDGETS FOR THE
CONSUMPTION MONTH
PREPARATION OF TARGET * TENTATIVE CAPACITY UTILISATION

- MODELS SPECIFICATION SHEETS.
FOR M0 MONTH SUMMARY SHEET PROCESS WISE
FOR :
POWER CONSUMPTION. PPC
* TARGET APS,YIELDS MODEL WISE PROCESS YIEDLS I/C PLANNING TEMPERING &
AT EACH PROCESSES. PROJECTED CAPACITY LAMINATED
UTILISATION
* TARGET POWER CONSUMPTION
MODEL WISE.
* NEW MODELS
BPF-PPC-01
* CAPACITY UTILISATION SUMMARY APPROVAL OF -MANPOWER REQUIEMENT Vs. AVAILABILTY * FINAL PRODUCITON
SHEET MONTHLY TO BE CHEKCED BASED ON CU FOR EACH TARGETS/BUDGETS FOR THE
* NEW MODELS SCHEDULE.
TARGETS.
SECTION HEAD -PPC PROCESSWISE MONTH
MONTH.
IF NO
* FIANLISED CAPACITY UTILISATION
* MAINTENANCE SCHEDULE
SUMMARY SHEET PROCESS WISE.
* FINAL PRODUCITON - BUDGET SHEET CONSUMABLE

TARGETS/BUDGETS FOR THE MONTH 1.SECTION HEAD -PPC WISE.
FINALISATION OF
MONTH. PRODUCTION 2.PPC
TARGETS FOR M0 I/C PLANNING TEMPERING &
MONTH LAMINATED
3.SECTION HEADS - TEMPERE 1,2
* FIANLISED CAPACITY UTILISATION
TEMPERED 3,4
SUMMARY SHEET PROCESS WISE.
LAMINATED
- SUMMARY SHEET FOR VARIANCE

* VARIANCE /ANALYSIS BETWEEN OF PLANNED Vs.ACTUAL
PLANNED Vs.ACTUAL DISPATCHES 1.PPC. PRODUCTION .
FOR MONTH M0-2.
* SALES PLAN SUBMITTED ON 22nd - SUMMARY SHEET FOR VARIANCE

SALES AND OPERATIONAL 2.SECTION HEADS -LAM./TEMPERING. OF PLANNED Vs.ACTUAL
OF MONTH M0-1 FOR PLANNING
HORIZON. PLANNING MEETING DISPATCHES.
* VARIANCE/ANALYSIS BETWEEN
PLANNED Vs.ACTUAL PRODUCTION 3. SECTION HEAD -MPC
FOR MONTH M0-2.
* PROJECTED RM STOCKS AND

CRITICALITY'S IF ANY. 4. SECTION HEAD- MATERIALS.
5.SECTION HEAD- MKTG.
6. SECTION HEAD - DISPATCH.
Weekly Planning
1.PPC - ROLLING DESPATCH PLAN FOR 15 DAYS

* FG STOCKS RATIO . MAKING OF LINEAR I/C PLANNING TEMPERING & FOR OEMS'S
*WEEKLY DESPATCH PLAN PRODUCTION PLAN FOR LAMINATED
THE CURRENT WEEK
* MAINTENANCE REQUIREMENT 2. SECTION HEAD- - FIRMED UP S&OP PRODUCTION PLAN FOR * LINEAR WEEKLY PLAN FOR
ACCOMODATING
*NEW MODELS SAMPLING DATES LAMINATING/TEMPERING MONTH M0. TEMPERING
VARIANCE OF PREVIOUS
WEEK. - TEST & TRIAL SCHEDULE. FURNACE WISE AND FOR CRITICAL
3. SECTION HEAD - RM WAREHOUSE.
PROCESS IF ANY.
*MONTHLY PRODN PLAN - RM STOCK STATEMENT LAMINATING:
Vs.ACTUALS. 4. SECTION HEAD - TPS. BENDING FURNACES ONLY.
5. SECTION HEAD - DISPATCH. - WEEKLY STOCK RATIO SHEET.
*MODEL ALLOCATION 6. ACCOUNT EXECUTIVES- MKTG.
1.SECTION HEAD - PPC - PREVIOUS WEEK's PRODUCTION RESULTS.

* CRITICAL MODELS SCHEDULING.
APPROVAL OF
* SAMPLING DATES AND TIME WEEKLY PLAN 2.SECTION HEAD - - TIME LINING CHART FOR NEW MODELS.
ALLOCATED FOR SAMPLING. TEMP12,TEMP3,LAMINATED
*LAMINATED : WEDNBESDAY OF EVERY
IF NO
WEEK
*TEMPERED : SATURDAY OF EVERY WEEK
1.PPC
FINALISATION OF WEEKLY
LAMINATED
PRODUCTION PLAN.
2.SECTION HEAD -PPC
* TO BE HELD ON WEDNESDAY OF EVERY

WEEK.
1.PPC - CHANGE IN SALES PLAN FORMAT.
* WEEKLY PRODUCTION PLAN
LAMINATED
PLANNING CELL
MEETING -ROLLING DESPATCH PLAN.
* ROLLING DESPATCH PLAN 2. SECTION HEAD -MPC
*CRITICAL FINSIHED GOODS -FEEDBACK SHEET FOR DESPATCH PLAN

REQUIREMENT. 3.SECTION HEAD- MKTG.
*RAW MATERIAL AVAILABILITY -WEEKLY PRODUCITON PLAN -TEMPERED
4. SECTION HEAD - DISPATCH.
STATUS FOR HORIZON BASED AND LAMINATED.
-STOCKS RATIO SHEET TEMPERED AND
5.SECTION HEAD -PPC
S&OP PRODUCITON PLAN LAMIANTED.
* FG STOCKS AT AIS - CHANGE IN SALES PLAN FORMAT.

WAREHOUSE/CUSTOMER's
END/ADVANCE WAREHOUSE MONITORING OF WEEKLY
PLANNED Vs.ACTUAL - DAILY PRODUCTION RESULTS. * CHANGE IN PRODUCITON PLAN
PPC
PRODUCTION BASED ON ALL THESE INPUTS TO
* CHANGE IN SALES PLAN. I/C PLANNING TEMPERING &
LAMINATED MEET CUSTOMER
* DYNAMIC PROCESS YIELD/TIME - DAILY PDCA SHEET FOR EACH SECTION. DEMAND.
YIELDS
* NEW MODELS SAMPLING - MONTHLY PLAN Vs. ACTUAL SHEEET.
SCHEDULED DATES.
- DAILY DESPATCH PLANS.
- PRODUCTION RESULTS PROCESS

Results Preparation YIELDS,TIME YIELDS.
*CONTROL FILES FOR EACH PROCESS IN - TIME YIELD REPORT.
SOFT.
1.PPC - IRA'S REPORT.
*PROCESS OPERATION RECORDS FOR EACH - RM CONSUMPTION Vs ISSUE
PROCESSES. TALLYING .
* DAILY SHIFTWISE DATA ENTRY LAMINATED
INTO VARIOUS SOFT CONTROL 2.SECTION HEAD -PPC *RE-WORK INSPECTION CARDS. -TARGET Vs.ACTUAL C.U.
SHEETS , PRODUCITON SECTION - SUMMARY SHEET FOR TARGET Vs
WISE RESOURCE WISE. PREPARATION OF 3.SECTION HEAD- MKTG. ACTUAL SAVINGS IN
PERIODICAL PRODUCTION CONSUMABLES.
REPORTS
- SUMMARY SHEET FOR TARGET Vs
2. SECTION HEAD -MPC 4. SECTION HEAD - DISPATCH. ACTUAL POWER CONSUMPTION.
- SUMMARY SHEET FOR TARGET VS

ACTUAL PRODUCTION
5. SECTION HEAD -MPC COST/SQUARE/METER.
FG Warehouse
*Pallets ID Number writted on Transfer
slips.
* Date and Shift of Production VERIFICATION & FG in lot-out not to be transferred to FG W/h.
TRANSFER OF FG FG W/H SHIFT SUPERVISOR
PALLETS FROM VARIOUS
* Quantity mentioned on transfer slips. PRODUCTION SECTIONS Physical quantity of pallets must match Finsihed Goods pallets can be
with the quantity mentioned in transfer transferred to warehouse.
* FG models to be transferred to W/h. slips.
* Pallets in QCFG area matching with Each pallets card affixed on OK FG pallets
that mentioned in Transfer slips. must be countersigned by QA Shift I/C.
*Type of pallets to be stacked Warehouse Layout and location plan
*Model location. Stacking of Pallets at Standard for Material handling/Stacking of FG Finsihed Goods pallets can be
FG Shift Supervisor. Pallets. transferred and stacked properly at
defined location in Forklift driver
warehouse their location in warehouse.
* Qty of pallets to be stacked in a
column.
Complete transactions Finished Goods trnasfer slips.

a) Receiving Finished Goods stocks Daily despatch plan from Despatch Section. Daily FG Stock Statement
reporting considering receipts FG Shift Supervisor.
and issues
BPF-PPC-01

Finished Goods stocks
Resp / Interaction Control Doc / Checkpoint Output
reporting considering receipts
b) Issuing and issues FG Warehouse I/c.
c) Sale-return
*Despatch Quantity. Receipt of Despatch Despatch Sec *Despatch Quantity.

* FG material transfer slip from W/h to Plan from despatch Pallets No.'s of palltes to be isuued to be * Schedule for FG issue from W/h.
Despatch. section & isuue of FG FG Warehouse I/c. mentioned on transfer slips only.
pallets to PDI area.
*Daily FG Stock Statement FG Shift Supervisor *Quantity requested for issue from W/h.
*Quantity requested for issue from Warehouse Layout and location plan
W/h.
FG transfer slip form Wh to despatch. *FG pallets number and location of pallets.
Pallet wise tracking file of FG.

Checking of stocks working files for FG
received & issued in models where FIFO system to be followed pallet Number
differences found. wise.
FG transfer slip form Wh to despatch.
*Defined location of models stacked Physical Stock take Physcial Fg stocks, Invoices and Transfer slips Complied model wise physical stocks
Model wise and statement.
* Models Code/name. compilation. FG Warehouse I/c. Warehouse layout and location plan
* No of pallets stacked FG Shift Supervisor Format for stock tacking
* Qty in pallets
*Net physical stocks IF NG FG Warehouse I/c.

Comparison of
*System stocks files system and *Final Finished Goods Stocks
physical stocks Statement for Planning only
Monhtly & Bi - Monthly. AND
Interim FG stocks report
statement for EXCISE
reconcilation.
IF OK
*Final Finished Goods Stocks
Statement for Planning only Interim FG
Monhtly & Bi - Monthly. Stocks report FG Warehouse I/c.
statement
Checking of stocks working files for
FG received & issued in models
where difference found
IF OK
*Physcial stocks statement FG Warehouse I/c. *Physcial stocks take format
*Excise records. Reconcillation with * RG1 register
Excise Stocks
* Documents related for receiving and * Fg transfer slips
Concerned person from
Issuing of material excise deptt * Fg material issue books
* Pre-despatch check sheet
IF OK
*Entries in excise records Variations in finsihed goods stocks

Results FG Warehouse I/c. modelwise.
Model Wise
Section head-excise * Finished goods Invoices
IF NG * Receiving and issuing documents
* Finished Goods Gate pass
IF OK
Finilisation of FG Stock FG Warehouse I/c.

report Reconcilled stock statement Finalised FG stock statement
Distributed to :
LEGENDS: 1,2,3,4,5,6,7,10,11,12,13,14,15,16
RM===> RAW MATERIAL.

FG===> FINISHED GOODS.
C.U.===> CAPACITY UTILIZATION.
kWh/Sq.Mtr.==> KILO WATT HOUR/SQUARE METER.
M0===> CURRENT MONTH UNDER PLANNING CONSIDERATION.
M0+1==> REFERS TO MONTH AFTER CURRENT MONTH I.e. IF CURRENT MONTH IS SEPTEMBER THAN M0+1 MONTH
WILL BE OCTOBER.
M0-2==> REFERS TO MONTH BEFORE CURRENT MONTH I.e. IF CURRENT MONTH IS SEPTEMBER THAN M0-1 MONTH
WILL BE JULY.
S&OP===>SALES & OPERATIONAL PLANNING.
Process Efficiency : 100% execution of customer orders, Objectives & accountabilities.
Process Effectiveness Measure : No premium freighting, no loss in share of business/customer orders, no raw material allocation, optimum inventory (raw material+f.g.)

BPF-TPS-02
Business Process Flow ( Tooling Management)
Purpose: To establish flow for Tool Management & to ensure proper maintenance and manufacturing methodology
for all the tools / gauges.
Scope :For all process tools / gauges developed & manufactured in tooling section.
Resp / Interaction Control Doc / Checkpoint

Input Process / Activity Output
APQP Time line Trial Production Section APQP Time line chart Tool development
chart Receipt of Tool Development Request
BPF-TPS-01 Schedule
(PD/TP/FM-05)
Tool Trial Production Section Tool Development Timeline Plan Tool development
development Develop Gauge / Tool development
Schedule
Schedule Time line plan
Trial Production Section Masterlist of designs / Tool Final Gauge

Review of Develop Gauge Design & Finalise Design Design( PD/TP/CK-
Resources 15)
Gauge Design TPS / MAT / STORES Material Indent in System Oracle P.O. Approval
Raise Indent for Procurement of
Gauge / Tool RM
P.O. Approval TPS / MAT / STORES Incoming Inspection report / Inspection report
Tool Design & Material Specs
NA Insp. Of
Gauge /
Return to vendor
Tool RM
Accepted
Inspection Trial Production Section Work Instructions / Job Gauge /Tool

Start Mfg of Gauge / Tool
report standards
Gauge / Tool Trial Production Section Gauge & Tool Inspection report / Gauge /Tool
Gage R&R Studies Checksheet Inspection Report
Fail Insp. Of ( PD/TP/FM-21)
Gauge / (PD / TP / CK-10)
Corrective Action
Tool
Gauge /Tool Pass TPS / QA / PPC / Component Inspection Report / Product as per
Inspection Concerned Sec Head Check Sheet Drawing / CAD
Report (Prod) (PD / TP/ FM-21)
( PD/TP/FM- Fail Trial of Is PPAP to trigger here?
21) Tool
Corrective Action
(PD / TP / CK-
10)
Pass
Gauge / Tool TPS / Concerned Section 1) Masterlist of Tools Masterilst of Gauges

with Head (Prod) 2) Identification list (PD/TP/FM-18)
Identification & Update master list of Gauges
identification 3) Tool history card
TPS / QA / Concerned Component Inspection Report & Component

Sec Head (Prod) Sign Off Inspection Report
Tool Handover to Manufacturing
( PD/TP/FM-21)
TPS / Concerned Tool Maintenance Charter / Tool Annual gauge

Section Head ( Prod) Checklist Revalidation
Gauge / Tool Gauge / Tool Maintenance Charter PPAP trigger for major change Schedule
Break down ( PD/TP/FM-23)
Process Efficiency : 100% OK Tool, Gage & Objectives & Accountablities Distributed to : 1,2,4,5,12,13,14,15,17
Process Effectiveness Measure :Number of tools made OK first time.

Modification
BPF-DES-01
Business Process Flow - Customer Related Process ( Dispatch)
Purpose: Ensure dispatch of Finished Goods to the customers
Scope: Dispatches made to OEM's and After Market
Resp /
Input Process / Activity Control Doc / Checkpoint Output
Interaction
1) Dispatch Plan through e- Section Head - Dispatch Masterlist of Parts Masterlist of Parts / Transfer data to
mail. Receipt of Dispatch Plan from Mktg Notice Board
H.O.
Section Head - Dispatch / - FG stock statement from Warehouse

Officer - FG Warehouse
Verification of
NO finished part
Meeting with PPC availability at
W/H
Yes
Officer Dispatch / Trailer Movement Board Trailer Movement Record

Marketing Deptt. - HO
Availability of
NO trailer
Inform Marketing
Transfer data of notice board Officer-dispatch Despatch plan of H.O. for model parts. Excel sheet of daily dispatch plan.
Yes
Preparation of daily despatch plan
Excel sheet of daily dispatch Officer-dispatch / Forwarded Excel sheet

plan. Marketing H.O.
Inform to H.O. confirmed dispatch plan
-
Excel sheet of daily dispatch Officer - Dispatch / Dispatch Plan FG Requisition Slip
plan. Officer - FG Warehouse
Requisition to FG Warehouse
Requisition slip Officer - Dispatch / Physical verification of shifting of

acknowldegement from FG Officer - FG Warehouse material.
warehouse Receipt of Information about allocation
of FG Material -
Allocation of Material Officer - Dispatch / Loading Plan

Officer - FG Warehouse
Preparation of loading plan
-
Loading Plan PDI Inspector PDI Checksheet
Hold the NO
Offer for
material Pre -
dispatch
PDI Checksheet Yes PDI Inspector Quantity & Model Physical verification of material
Checking of material against loading

plan
Trailer Maintenance PDI Inspector Physical Condition of Trailer Status of trailers on the checksheet.
Checksheet BPF-QAD-03
NOT OK Check
Trailer not loaded condition
of trailer
OK
Pallet checksheet PDI Inspector Physical Condition of Pallet Status of pallets on the checksheet.
BPF-QAD-03
Not OK Check
Inform Pallet Section condition
of pallets
Daily Dispatch Plan OK Shift Supervisor- Dispatch Plan from Marketing H.O. Material Gate Pass
Dispatch PDI reports as per Customer
Dispatch of Material Requirements
Excel sheet of daily dispatch Section Head (Dispatch) Gate Pass Daily Dispatch Details status sheet
details. Glass Model
Information to H O Quantity
Vehicle No.
Swipe Card Section Head (Dispatch) Location of trailer Swipe Machine Print Output
Tracking of Trailer Movement
GR document Section Head (Dispatch) Any information on GR Copy GR Record
Receipt of GR
Transportation Bill Section Head (Dispatch) Time taken (w.r.t the norms) Trailer
GR Record Movement board
Submission of Bill -
GR Record Section Head (Dispatch) Amount by Section Head (dispatch) Release of Payment.
Transporter Bill based on Customer and Warehouse
Reports
Payment to Transportation
Process Efficiency : No stoppage of customer line and Objectives & accountabilities. Distributed to : 1,2,3,4,5,6, 20
Process Effectiveness Measure : Delivery Rating from the customer on monthly basis & Delivery Performance Monitoring

BUSINESS PROCESS FLOW FOR UPKEEP OF PLANT & MACHINERY.
Responsibility /
Activities Control Doc / Checkpoint Output
Interaction
Maintenance
Maint. Of Prod Unplanned

Equipments & Maintenance
Predictive Maint
B
A
A
Preperation of Section Head Maint. Break Down Trend of m/c. Annual maint. Plan :-
Annual maint. plan Section Head PPC MN/ME/FM-06
Monthly maintenance Section Head Maint Monthly Maint. Plan :-

Plan MN/ME/FM -22
Take dates & shifts for Section Head Maint Weekly production plan Up dation of Monthly maint. plan
maint. from PPC Dept. Section Head PPC MN/ME/FM - 22
Pre preperation of Periodical

Maintenance Execution plan Section Head Maint a)Replacement,Repair,Checking freq. a)Updation of Periodical Maintenance
b)M/C. History Card Execution Plan :-MN/ME/FM-07
c)Prod. Maint. Req. slip items
d)Adequate manpower availability
e)Required material availability in store
f)Arrangement of fabricated items
g)Patrol Check sheet of machine
h) Improvement plans
Execution of maint. plan Process Incharge a) Time taken for execution. Updation of Periodical Maintenance
(E & M) b) Adherence to Periodical maint. plan Execution Plan :-MN/ME/FM-07
c) Time taken for execution.
Are all
points Section Head Maint All Critical Items should covered Updation of Periodical Maintenance
executed Execution Plan :-MN/ME/FM-07
No
Carry
YES Section Head Prod.
Forward to
next NO
maint. Section Head maint.
Process Incharge / Updation of Periodical Maintenance

Driving Test
Shift Incharge Execution Plan :-MN/ME/FM-07
(E+M+P)
Removal of
abnormality
Process Incharge / Running M/C checking Updation of Periodical Maintenance
Shift Incharge parameters like noise Execution Plan :-MN/ME/FM-07
Is driving (E+M+P) vibration & movement
test is
NO normal
YES
Process Incharge /
Start Production
Shift Incharge
Removal of (E+M+P)
abnormality
Process Incharge / Size ,Curvature,Fragmentaion Updation of Periodical Maintenance
Is product Shift Incharge Grinding & washing quality, Execution Plan :-MN/ME/FM-07
quality (E+M+P+Q)
parameter are
NO within
Standards
YES
Hand over to Prod. Shift Incharge (E+M) Updation of Periodical Maintenance

Deptt. Execution Plan :-MN/ME/FM-07
Updating of Maintenance
Charter Process Incharge Periodical Maint. Execution plan Up dation of Annual Maintenance plan &
(E+M) Improvement plan execution details: MN/ME/FM-18 &
Production request slip Periodical Maint. Execution Plan :
End MN/ME/FM-07
BPF-MNT-01
Business Process Flow ( Mechanical Maintenance)
Purpose: Business process flow for quality, predictive & preventive maintenance of equipments to ensure health of equipment and safety of operation.
Scope : All manufacturing & production equipments.
Cont.Doc/Checking
Input Activities Responsibility / Interactions Point
Output
(1) Verbal Information of Information of equip.B/D to Prod. Shift I/C Update Machine
Break down or by pressing maint. Deptt. Prod.worker History card(for time & m/c.)
alram by production worker
(1) Fault tree diagram Section Head

Take Corrective Action
Process Incharge
Shift Incharge
Section Head M/c Manual

Testing Of
Process Incharge
M/c
Shift Incharge
Section Head
Hand Over to Process Incharge
Concerned Dept. Shift Incharge
Shift Incharge Time Consumed, Updation of M/C History

Problem discription in
(1) Machine History card Spare Used Card : MN/ME/FM-01
History Card
Dept. Head a) Freq. Of problem M/C History Card updation for

(1) Machine history card Weekly Analysis Section Head b) Time consumed countermeasure:MN/ME/FM-01
of Break Down Process Incharge
(1) Machine history card Section Head (a) MRA schedule Signature in M/C History Card
Implement Process Incharge (b) Job change MN/ME/FM-01
Countermeasure
schedule
(1) Countermeasure effec- Check effectiveness of Dept. Head MachineHistory Updation ofCountermeasure
-tiveness sheet countermeasure Section Head card effectiveness sheet :MN/ME/FM-23
Countermeasure Process Incharge
Problem Yes
Again
Repeat
No
(1) Master list of machinery Implement Same Countermeasure Section Head MachineHistory Updation of history card for
on similar M/C. Process Incharge card countermaesure implementation
End
Process Efficiency : Zero Breadown and Objectives & Accountabilities

Distributed to : 1, 2, 4, 5, 11, 16
Process Effectiveness Measure : Graphical trend of breakdown time.

Modification Modification details Checked By Approved By Date
Status
Update history
card
Weekly Analysis
Implement
Counter Measure
BPF-MNT-02
Business Process Flow ( Electrical Maintenance)
RESP./INTERACTI CHECKING POINT /

INPUT ACTIVITIES OUTPUT
ON. CONTROL DOC
Section Head Pending Jobs From Previous day Trouble shooting reports :- MN/EL/FL-51
Meeting
Process I/C Previous day B/D's Monthly maintenance plan :- MN/EL/FM-06
Shift I/C Routine jobs
Maint. Of
Maint. Of Prod Equipments which PM meeting
Section Head Frequency Annual maint. Plan :- MN/EL/FM-08
Equipments & require power shut Monthly Maint. Plan :- MN/EL/FM -06
Predictive down
Maint. PM meeting Record :- MN/EL/FM -01
B C
A
( 1 ) Master list of Machine Preperation of Annual Section Head (E & M) M/C maint. Frequency Annual maint. Plan :- MN/EL/FM-08
( 2 ) Manufacturer manuals maint. plan Section Head PPC
Monthly Maint. Plan :- MN/EL/FM -06 Taking tentative Maint. Section Head Monthly Maint. Plan :- MN/EL/FM -06
Date from PPC.
Annual maint. Plan :- MN/EL/FM-08 Display of monthly Section Head a) Monthly maint. Plan
maintenance Plan Ref :- MN/EL/FM - 06
Pre preperation of Periodical

Monthly Maint. Plan :- MN/EL/FM -06 Maintenance Execution plan Section Head a)Preventive maintenance items. a) P.M Meeting Record :- MN/EL/FL - 01
b)Pending items from previous b)Maint. check sheet :- MN/EL/CK-40
maintenance.
c)Prod. Maint. Req. slip items
d)Adequate manpower availability
e)Required material availability in
store
f)Arrangement of material req.to be
fabricated.
Weekly prod. Plan :- PD/PP/FM-08 Confirmation of dates & shifts in
weekly prod. plan by PPC Section Head Weekly production plan Weekly prod. Plan :- PD/PP/FM-08
Periodical maint. Execution plan Execution of maint. plan Process Incharge a) Time taken for execution.
(E & M) b) Adherance to maint. plan
as per check sheet. b)Maint. check sheet :- MN/EL/CK-40
c) Time taken for execution.
d)Job Standards,
NO Are all
points Section Head a) Maint. check sheet :- MN/EL/CK-40
executed b) Prod. request slip
Carry
Forward to
next maint. YES
Process Incharge /
Driving Test Shift Incharge
(E+M+P)
Is driving
YES Process Incharge / Running M/C checking parameters Maint. Check sheet :- MN/EL/CK-40
test is
normal Shift Incharge like noise, viberation & mpovement Job standard
(E+M+P) Inspection check sheet :- MN/EL/FL-55
NO
Removal of
abnormality
Process Incharge /
Hand over to Prod. Deptt. Shift Incharge
(E+M+P)
Hand over to Prod.Deptt.

Day / Shift Incharge
Maint. Check sheet :- MN/EL/CK-40 Process Incharge / Maint. Check sheet :- MN/EL/CK-40
Updating of history card
Inspection check sheet :- MN/EL/FL-55 (E+M+P) Job standard

Inspection check sheet :- MN/EL/FL-55
End
Making of list of activities

& schedule in month of Section head Dates of holidays Annual maint. Plan :- MN/EL/FM-08
April
a)Adequate manpower availability List of activities

Pre preperation of b)Required material availability in
activities Section head store
c)Arrangement of material req.to
be fabricated.
Information of personnel Section head

& security deptt.
BPF-MNT-02
Business Process Flow ( Electrical Maintenance)
Information of personnel RESP./INTERACTI CHECKING POINT /

INPUT ACTIVITIES
& security deptt. OUTPUT
ON. CONTROL DOC
Execution plan. Section head Annual maint. Plan :- MN/EL/FM-08
All jobs
completed
Section head
Add to next
maint.
OK
END
Section head
Collection of Data
Process Incharge /
Shift Incharge
Analysis of problem Section head & Review of trouble shooting record. Trouble shooting record file.
Shift Incharge MN/EL/FL - 51
Section head Setting up of resp. & target dates PM meeting file :- MN/EL/FL - 01
Setting up counter
measure plan Process Head
Execution plan. Section head 5S, safety, job standards 5S Manual

Safety Mannual
Job Standard
NOT Section head

All jobs
completed Equipment
failure data
OK
Record Update
END
Process Efficiency : Zero Breadown & Objectives & Accountabilities Distributed to : 1, 2, 4, 5, 10, 16
Process Effectiveness Measure : Graphical trend of breakdown time.

BPF-QAD-04
Purpose: To ensure customer requirements are clearly understood and to minimize customer concerns.
Responsibility/Inte
raction
Doc. From TPS Reciept of approved PPAP along with the list of QA/TPS 1.PSW signed off, Update Masterlist of
wavier wrt drawing, wrt material specs , w.r.t 2.Waivers and Correspondances in writing and documents
Performance specs customer signed.
Doc. From TPS, Review the documents as per List received QA 1. PPAP Manual Physical verification of
Updated Masterlist from TPS 1. All documentation are complete documents as per PPAP
2. Any model/part pending for approval
3. PPAP/PSW for Child Parts Completeed.


Customer's ECN, Check the QA-PROD 1. Customer supplied ECN,

NO YES
Verbal consensus
Feed back to custmer & all QA/MKTG
concerned Through E--Mail with mentioning
departments.

Alternative
Suggested
NO

cation
Issue the ECN along
date,
up of ECN

cation. through Mkg, VOC, MCM, E- MAIL , RO , 2. Fitment result
Directly from customer.

NO
YES

.

Carry out PPAP
1.PSW, 2.Cpk Analysis and update the relevant
document.
NO
successful ?
Testing Report
YES

Submit updated PPAP
specification

Update PPAP file

PRODUCT 3.Defect Type, 4.Defective Qty,
CLAIM
YES

decision at customer end( if req) and replace with good glass to customer

recd. customer
the shop floor & information to all On the same day of the claim witnessing the defective
concern
glass
BPF-QAD-04
Purpose: To ensure customer requirements are clearly understood and to minimize customer concerns.
Responsibility/Inte
raction
nts,

Confirm the short term containment action to Trigger off the C/M, FMEA
Result of segregation QA, SECTION HEAD-
the customer
PROD, MKTG
Report
Initiate CA- PA
sending

as per target
YES
Completed CA-PA form Verify Effectiveness of QA-Mkg 1.Customer claim for the same problem Product Audit Resut

problem
consecutive product
audit
NO
Close QACR QA 1.QACR format

Weekly Reports from regularly
Monthly customerwise PPM

& process defect

YES Achievement of 2.Reporting to MCM
NO

rejection from RO
4.Review the CA/ PA
NO
Std
YES
Job Std.

Revalidation reports to customers.
Process Efficiency : Zero customer complaints & Objectives and Accountabilities. Distributed to :1,2,3,4,5,6

BPF-STR-01
Business Process Flow ( Material Planning & Control)

Purpose: To establish a procedure for planning & managing Raw material, BOM items,Spare Parts and other consumable inventories so as to ensure that stock levels are optimum.
Scope: Raw material, BOM items, Spare parts and other consumables.
Resp /
Interaction
Annual Planning
1) MTP for the Year MPC/SIC 1) Supply Cycle with major vendors 1) Annual MRP sheet
2) TPS Sheet for New Items 2) Production schedule at Suppliers
3) BOM consumables allocations, yield. Prepare Annual Material Requirement 3) Last year budget
4) RM Yields (MT/RW/FM-23) Plan for RM and BOM items.
5) Model allocations on suppliers
6) Lead time of supplies
7) Share of business
1) Annual MRP sheet MPC/SIC 1) Inventory norms - RM, BOM & Spares 1) Inventory budget for RM,BOM items,
2) Supply cycles and lead times for last year (MT/RW/FM-19). Spare parts and other consumables.
3) Updated min-max norms 2) Inventory holding in days for last year
Prepare Inventory Budget for next fiscal (MT/RW/FM-19).
year for RM, BOM items , Spare parts 3) Share of business for last year & current
and other consumables. year
4) Inventory ageing (MT/RW/FM-26)for
last year
5) Slow moving trend (MT/RW/FM-27)for
last year
6) RM allocations (MT/RW/FM-28)for last
year
7) Capacity assesment for Warehouse
Quarterly Planning
1) Change of lead time / supply cycle MPC / SIC 1) Planned vs actual production. 1) Revised annual MRPs.
2) Change in price agreement/share of 2) Planned vs actual allocations. 2) Revised inventory budgets.
business 3) Warehouse/ storage assessment.
Not Achieved Review of Annual
3) Change in product mix 4) Planned inventory holdings vs actual
Requirements and
4) Change in customer plans Inventory Budgets. inventories.
5) Change in sources of supply 4) Planned inventory turnover vs actual
6) Change of Min - Max norms inventory turnover.
Update and amend annual

requirements and inventory
budgets.
Achieved
Monthly Planning
1) Monthly sales plan and production MPC/SIC 1) Shortages and allocations. 1) MRP Sheet - RM & BOM
plan (PP/PP/FM-08). 2) Material requirement dates. (MT/RW/FM-20 for Imported
2) Annual Requirement Plan. Working out material requirement: MRP 3) Lot size per supplier RGL,MT/RW/FM-21 for Domestic RGL,
3) RM defect %age. for RM, BOM items. 4) Production constarints and supplier MT/RW/Fm-22 for PVB & MT/RW/FM-
4) BOM items yields/ life. Requistions for Spare parts and other prefrences. 30 for BOM)
5) AIG stocks(MT/RW/FM-16) consumables. 5) Shipment schedules. 2) Oracle requisitions for Spare parts
6)BOM stocks (MT/ST/FM-25) and other consumables
7) Supplier stocks (MT/PU/FM-24)
8) Production/dispatch schedule
9) Oracle database(Min-Max reports)
10) Production Yields (MT/RW/FM-23)
1) MRP Sheet - RM & BOM (MT/RW/FM- MPC/SIC 1) Procurement Budget 1) MRP workings (MT/RW/FM-20 for
20 for Imported RGL,MT/RW/FM-21 for 2) Share of business Imported RGL,MT/RW/FM-21 for
Domestic RGL, MT/RW/Fm-22 for PVB & Approval of material 3) Default organisations Domestic RGL, MT/RW/Fm-22 for PVB
MT/RW/FM-30 for BOM) 4) Item Category & MT/RW/FM-30 for BOM)
requirement output
2) Oracle requisitions for Spare parts 5) Vendor Checks 2) Prodcution Oder / dispatch Order
and requisitions.
Imported RGL Orders: MT/PU/FM-21
and other consumables Not OK 6) Minimum Ordering Qty
Domestic RGL Orders:MT/PU/FM-22
7) Ordering Schedules PVB Orders :MT/PU/FM-23
3) Approved requistions.
OK
1) Approved MRP Order / Oracle S&C/ RMP 1) MRP Sheet for RM & BOM (MT/RW/FM- 1) Production Orders /Forecasts
requisitions 20 for Imported RGL,MT/RW/FM-21 for Imported RGL Orders: MT/PU/FM-21
Domestic RGL, MT/RW/Fm-22 for PVB & Domestic RGL Orders:MT/PU/FM-22
MT/RW/FM-30 for BOM) PVB Orders :MT/PU/FM-23
Initiation of procurement process 2) Shipping schedules. 2) Dispatch orders
3) Indenting guidelines to buyer. 3) Purchase orders/releases
Weekly Planning
1) MRP workings (MT/RW/FM-20 for MPC 1) Customer Wise Despatch Schedules 1) Corrections in MRP workings
Imported RGL,MT/RW/FM-21 for 2) Material Availability against requirement 2) Plan Allocations
Domestic RGL, MT/RW/Fm-22 for PVB & Planning Cell Meeting 3) Minutes of meeting
MT/RW/FM-30 for BOM)
2) Prodcution oder / dispatch order
Imported RGL Orders: MT/PU/FM-21
Domestic RGL Orders:MT/PU/FM-22
PVB Orders :MT/PU/FM-23
3) Min-Max
1) Oracle inventory MIS MPC/SIC 1) Action plan for Slow Moving &
1) Inventory Turnover (MT/RW/FM-03) Ageing Inventory (MT/RW/FM-27)
2) Slow moving inventories (MT/RW/FM-
No Is Inventory inline 27)
with the targets? 3) Age of inventories (MT/RW/FM-26)
4) Allocation loss in sqmtr/value
(MT/RW/FM-28)
Action plan for Slow Moving & 5) RM turnover consumption
Ageing stocks 6) RM, BOM & Spares inventory trend
Yes 7) Inventory record accuracy
1) Consumption Statement (MT/RW/FM- MPC/SIC/RMP/S 1) Pending points Minutes of Meeting

13) &C 2) Agenda
2) Statement of slow moving,dead 3) Accuracy of reports
stocks (MT/RW/FM-27) Department meeting, 4) Critical issues
3) Allocation Loss (MT/RW/FM-28) MCM , TG Meeting
4) Age of Inventory (MT/RW/FM-26)
5) Inventory turnover reports
(MT/RW/FM-03)
6) Critical item list
1) Minutes of Meeting MPC/SIC/RMP/S 1) Oracle std reports Diversion of Material

2) Suppliers instructions Sale of rejected /Scrap Stocks &C 2) ED records and manual
3) Sales quotations 3) Books value and market value of stocks
4) Excise impact on the sale of stocks
Daily Planning Sale of rejected / Scrap stocks

1) Dispatch order MPC/SIC 1) Approved PO 1) Allocation of facilities and manpower
2) Incoming material status reports: 2) Job std for receiving (MT/RW/JS-05)
Imported shipment status : MT/PU/FM- Planning for Receipts
26
Domestic shipment status : MT/PU/ FM-
27
Model Wise Delay Status (Domestic) :
MT/PU/FM-28
3) Advance set of shipment docs
BPF-STR-01
Business Process Flow ( Material Planning & Control)

Purpose: To establish a procedure for planning & managing Raw material, BOM items,Spare Parts and other consumable inventories so as to ensure that stock levels are optimum.
Scope: Raw material, BOM items, Spare parts and other consumables.
Resp /
Interaction
1) Bill / Invoices from Suppliers MPC/SIC 1) Approved PO 1) Gate Entry
2) Completeness of documents - Invoice/ 2) Material receipt Note
GRN/Challans
Gate entry - Generation of MRN Nos.
1) Material Receipt Note MPC/SIC 1) PO number. 1) Incoming inspection Report

Not OK 2) Technical specification sheet
Physical Inspection &
receipt of Material 3) Job standard for receiving (MT/RW/JS-
05)
4) Not returnable gate pass.
Store in reject Area
Return to Vendor
1) OK Material MPC/SIC 1) Type of Material 1) Updated location on locator grid
2)Incoming Inspection Report 2) Area of utilisation / Cost Centre 2) Updated FIFO boards
Storage of Material. 3) Location grid 3) Updated stocks statement
4) FIFO boards
1) Requisition slip from Plant MPC/SIC 1) Availability as per stock statement 1) Updated Stock Statement
(MT/RW/FM-09) 2) Requisition slip (MT/RW/FM-09) work (MT/RW/FM-16 & MT/ST/FM-25)
order number. 2) Updated Bin Cards, FIFO Boards,
Issue of Material 3) Issues as per allocated stocks statement Locator Grids
4) Issues as per FIFO 3) Updated location file
5)Correct Lot nos.
1) Return Slip (MT/RW/FM-10) Production/MPC 1) Physical condition of the material 1) Updated Stock Statement
Return of material from Production /SIC 2) Quantity on Return Slip (MT/RW/FM-10) (MT/RW/FM-16 & MT/ST/FM-25)
2) Updated Bin Cards, FIFO Boards,
Locator Grids
3) Updated location file
1) Updated stocks net of returns Take corrective MPC 1) Shortages and allocations. 1) MRP Sheet - RM & BOM
(MT/RW/FM-16 & MT/ST/FM-25) action Review MRPs for RM, Bom items and 2) Material requirement dates. (MT/RW/FM-20 for Imported
2) Revised Sales & Production Plan Min-max for Spare parts and other 3) Lot size per supplier RGL,MT/RW/FM-21 for Domestic RGL,
consumables. 4) Production constarints and supplier MT/RW/Fm-22 for PVB & MT/RW/FM-
prefrences. 30 for BOM)
5) Shipment schedules. 2) Oracle requisitions for Spare parts
and other consumables
Process Efficiency : No stoppage of production line. Distributed to : 1,2,4,5,7,16,18
Process Effectiveness Measure :Accountabilities and Objectives of MPC, SIC.
MPC= Material planning and control

SIC= Stores inventory control
RMP= Raw material procurement
S&C= Spares and consumables procurement
Raw Material: At AIG there are two raw materials i.e. Float Glass and PVB.
Bill of material: specifies all subcomponent items required to manufacture an end product.
For the purpose of planning and control BOM is categorised into following categories:
Direct BOM Items: All material that becomes a part of final product Eg. Mirror Buttons,Terminals, Inks etc.
Indirect BOM Items: Consumables the requirement of which can be determined from the production plans using input/output
ratios. Eg. Bevelling wheel, Core- drill seamers etc.
Spare Parts: Parts used to support maintenance, repair and operation of fleets and facilities.
Other consuambles: Consumables the requirement of which can not be ascertained directly from the end product to be
produced.

BPF-MAT-01
Business Process Flow ( Raw Material Procurement)
Purpose: To establish a procedure for procurement of Raw Glass and PVB as per required quality and delivery standards at optimal cost.
Scope: Raw Glass and PVB
Resp /
Interaction
Annual Planning
1) Prepare annual budget (Procurement - Sales Plan / Production Plan

RMP Annual Budget Sheet
& Overheads) for next F.Y for RGL and (PP/PP/FM-08)
PVB
- Annual MRP from MPC
2) Define annual defect targets and Annual improvement plans agreed
MT/RW/FM-20, MT/RW/FM- - New Models requirement (PD/TP/FM-06)
prepare improvement plan with with Suppliers
21 suppliers to reduce gap between
current and target.
- Supplier Contracts 3) New source identification & - Result of current F.Y (Budgets V/s Actuals)
development
- Model Allocation on - Process flow for Budgeting and Review
suppliers from Production (Annexure I)
-Supply Cycle agreed with

Suppliers
(production and dispatch
schedules)
-Defect Targets from Suppliers
- Previous audit sheets Supplier audit report

RMP / QA - Audit check sheet
- Defect Trend 1) Plan Quality audits of vendors

QAP-MAT-01 - Approved Vendor List
Monthly Planning
- Sales Plan / Production Plan

RMP / QA Budget review and revised projections
Not Ok (PP/PP/FM-08)
- Change in Supplier - Plan for new Models
agreements (PD/TP/FM-06)
- Change in Model Allocation 1) Make contingency plan to meet
1) Review annual budget against
requirement and maintain cost - Results of last F.Y
on suppliers 2) Review annual countermeasure
actual procurement and latest
MRP
plan
- Change in Supply Cycle with 2) Review defect target v/s actual
defect
Suppliers 3) Reviee status and effectiveness -Annual budget sheet for current F.Y
(production and dispatch of countermeasure plan
schedules)
- Process flow for Budgeting and Review

-Defect Targets, Actual Trend
(Annexure I)
- Annual Countermeasure Plan

Ok
- Exceptional rejection / QACR
- Defect Report from QA RMP Defect Claim report
(QA/XX/FM-23)
- Supplier agreements Defect claim to supplier / Exceptional - Factor for landed cost Calculation
reporting
- Inspection reports
- Defect trend
- Defect Claim Report RMP Reconcialiation of Claime with supplier Defect claim status sheet
- Supplier agreements Settle defect claims with supplier. Credit note
Vendor Evaluation Sheet Vendor Rating

Delivery history
Vendor Rating as per system to
suppliers
Comparative cost Vendor feed back on the rating
Management system RMP
Improvement Activities /
Techinal Support
Defect Trend & Settlement
Fortnightly /
Monthly Planning
- Stock statements Send production schedules, Stock

Overseas supplier: details, RM defect % to MPC
MT/PU/FM/24 Ageing stocks at supplier end Campaign Plan sheet
Domestic Supplier:
MT/PU/FM/25
Stocks net of previous dispatches (MIP) Supplier stock status sheet

- Defect report Overseas supplier: MT/PU/FM/24 1) Overseas supplier: MT/PU/FM/24
Domestic Supplier: MT/PU/FM/25 2) Domestic Supplier: MT/PU/FM/25
Incomming Material Status

report
Shipment Status (Imported):
MT/PU/FM/26, Shipment RMP Incoming Material Status report
Status (Domestic): Shipment Status (Imported): MT/PU/FM/26,
T/PU/FM/27, Model wise Shipment Status (Domestic): T/PU/FM/27,
Incomming Material Status Model wise Incoming Material Status
(Domestic): MT/PU/FM/28 (Domestic): MT/PU/FM/28
Pending production
Order Sheets
- Fortnightly MRP
1) Imported RGL: MT/PU/FM/21
MT/RW/FM-20, MT/RW/FM- RMP - Model Allocation on suppliers
2) Domestic RGL: MT/PU/FM/22
21
3) PVB: MT/PU/FM/23
Check fortnightly
Not Ok MRP received - Defect percentage considered for MRP
- Supplier agreements Return to MPC for review from MPC calculations
- Supply Cycle with Suppliers

(production and dispatch - Revision in RM sizes
schedules)
N
o - Supply cycle with supplier
t
O
k
BPF-MAT-01
Business Process Flow ( Raw Material Procurement)
Purpose: To establish a procedure for procurement of Raw Glass and PVB as per required quality and delivery standards at optimal cost.
Scope: Raw Glass and PVB N

o
t
Resp /
Input Process / Activity O Control Doc / Checkpoint Output
Interaction
k
Production / Despatch Order Ok
RMP - Order Sheet Format Purchase Order
Sheet
Send order to supplier/s - Process Flow for Order Processing
- Approved Vendor List
- Suppliers agreement
- Terms & Conditions of PO as appropraite.

- Supply Cycle with Suppliers ( MSDS, AOI, QMS, Process Qualification)
Communication to supplier if required

Receive acknowledgement and dispatch RMP - Need by date for the material on change in delivery schedule
schedule from supplier
- Order sheet sent to the supplier
- Shippling line schedules Imported RGL: MT/PU/FM/21
Domestic RGL: MT/PU/FM/22
PVB: MT/PU/FM/23
- Process Flow for Order Processing
- Order sheet sent to the Creation & Approval of system Standard Oracle Procedure for
Compensation shipments / Hold System Releases and Agreements
supplier agreement / Order / Release RMP Purchasing
release
Incoming material Status report

1) Shipment Status (Imported):
MT/PU/FM/26,
- Dispatch Statement by 2) Shipment Status (Domestic):
supplier MT/PU/FM/27,
3) Model wise Incoming Material Status
(Domestic): MT/PU/FM/28
RMP - Need by date for the material
Co-ordinate Dispatches /Track
shipments - Order sheet sent to the supplier
- Process Flow for Import Clearance
- Order sheet sent to the

supplier
Imported RGL:
MT/PU/FM/21 Landing Charges Report
Domestic RGL:
MT/PU/FM/22
PVB: MT/PU/FM/23
RMP - Process Flow for Order Processing
- Dispatch Statement by Receiving advance documents & DEPB consumption sheet
supplier arranging for clearance (For - Process Flow for Import Clearance
Imports/Documents through bank
shipments only)
- Supplier agreements - Payment track sheet

RMP - Payment terms with Suppliers
Take corrective
- Material invoice action Tracking vendor payments,
Reconcilation of accounts & statutory - Status of any pending claims
documents
- Statement of accounts
- Monitoring of premium frieghts.
Quality rating Sheet QAP-MAT-01 (Procedure for Vendor Selection

Delivery performance sheet or & evaluation) Vendor Evaluation report
any customer disruptions Periodical Vendor Evaluation RMP
QA
QAP-MAT-01 (Procedure for Vendor Selection

& evaluation)
Vendor
evaluation
within NO 1st 2nd 3rd DELETE
acceptance
criteria
RMP
Vendor Evaluation report
OK
Continue in Approved Vendor List
Process Efficiency : On time availability of Raw Material for Production & Accountabilities and Objectives
Distributed to : 1,2,3,4,5,7,8,10,11,17
Process Effectiveness Measure :Vendor rating

Process Flow for Budgeting and Review : Raw Material Procurement
Annexure I
Activity Responsibility / Interaction Check Points Standards

Annual Production Plans (PP/PP/FM-08)
Preparation of Gross New Model (PD/TP/FM-06)
Annual requirement Plan RM Preferences / Model allocation
Defect Trends
Section Head - RMP Previous contracts

Market Trends
Inviting Quotations from Need for development of a new
existing source
suppliers
Identification of New Raw Section Head - RMP Product Portfolio of Supplier Government Regulations
Material Source / New
Suppier Constraint
Product
- Volumes
- Price Customer specific
- Quality requirements
Logistics
Regulatory requirements
[Statutatory requirements]
Section Head - Incomming Material Samples from Suppliers

Comparasion of Technical
NOT OK Section Head - RMP specification RM Specifications
Initial
assessement of
New supplier
OK
Section Head - RMP Size / Thickness RM Specifications
Plan Trials of a Large Sample Section Head - Incomming Material Trial Lot
QA Head
Production Head
Deptt Head Materials
Inform supplier for Section Head - RMP Inspection reports RM Specification
correctives Customer specific
Section Head - Incomming Material Actual v/s Inspection reports requirement
Evaluate Trial
resullts & Rejection Trend of existing
compare with QA Head Rejection Levels suppliers
existing Production Head
NOT OK suppliers Depart Head Materials
Section Head - RMP Market Trends Existing contracts

Comparative price
OK Rejection Targets
Initiate process for PPAPs
Check QS / ISO certification / Plan
Plan Commercial trials with new
supplier & invite initial Quotation
from New Supplier
Market trends
Not Okay (Demand Supply situation) Contracts
Vendor Agreements
RM Preferences / Model allocation
Approval of plan Section Head - RMP Supply Cycle with Vendors
Plan and cost / sourcing
options for Raw Material by HOD
Okay Section Head - MPC RM Preferences / Model Allocation

Production Schedules at Supplier
Supply Cycle with Vendors
Create monthly MRP based on
palnned sourcing options for RM
Not Okay
Section Head - RMP Production Schedules at Supplier
Lead Times
Supplier Constrains
Check
Monthly
MRP
Okay
Prepare detailed cost benefit for Section Head - RMP Review of current Year's Budget Budget Sheet
planned sourcing options for RM
Historical Data Vendor agreements
Projections from Supplier Approved Vendor List
DEPB Premium / Adv. Licence
Import Cost
Projected SOB
Supply Cycle
Not Okay Section Head - RMP Supply Cycle

Discuss & validate Section Head Incomming Material Vendor Agreements
the sourcing Production Head Defect Trends & Claims settlement
options with QA Head
Production & QA HOD Materials
Ok
Section Head - RMP Last Contracts Contract Sheet

Finalize contract with RM HOD Materials Payment term
Suppliers Supply Cycle / Delivery term
Comparative price
Rejection Targets
Annual Countermeasure Plans
Agreement of Inspection (AOI)
Section Head - RMP Raw Material requirement

Prepare RM procurement HOD Materials Exchange Rates
Prepare Travel & overhead
budget budget Vendor Contracts
Last FY Budget
Not Okay Approval

HOD
-Materials
Section Head - RMP Supplier wise details

Tint wise / Thickness wise details
Send Share of business Send Overhead budget to

details to corporate Corporate Planning
planning, MPC, QA,
Prodn
Section Head - RMP CIF Per Sq Mtrs Contracts

Buyer - RMP Duty Structure Customs Tariff / Notification
Purchase Assistant DEPB Premium / Discount Rate
Create Oracle
Agreements Import cost (Landing Charges)
Oracle Agreements
Section Head - RMP Market Trends

Prices, Product Mix & SOB
Review budgeted v/s
actual Change in Pdn Plans / Sales Plan
procurement and DEPB Premium
overhead Import Cost (Landing Charges)
cost on a monthly basis Exchange Rate
Order Processing
(Annexure II)
Not Okay
Contracts / Agreements
Section Head - RMP Market trends with Supplier
Section Head - MPC Supplier Constrains Approved Vendor list
Discuss counter action Production Head Supply Cycles
with MPC, Production and QA Head RM Preferences
QA Comparative price
Order Processing
(Annexure II)
Order Processing
Annexure II
Responsibility /
Activities Interaction Check Points Standards
1.MRP from MPC

Buyer Price MT/RW/FM-20, MT/RW/FM-21
Release PO / DO on the basis of Supplier stocks
MRP received from MPC Overseas supplier: MT/PU/FM/24
Planner Domestic Supplier: MT/PU/FM/25 2.Contracts
3.Order Sheets
Imported RGL: MT/PU/FM/21
Supply cycle PVB: MT/PU/FM/23
Lead times
Need by date
OVERSEAS RGL SUPPLIERS

Receive confirmation of order from
supplier
Material requirement
Send ammended
Buyer MT/RW/FM-20, MT/RW/FM-21 1.Purchase order
FCL to supplier
2.Material requirement sheet from MPC
MT/RW/FM-20, MT/RW/FM-21
Not Recieved 3.Order Sheets

PVB: MT/PU/FM/23
Not OK
Receive &
Check FCL
details
OK Purchaes Co-ordinator Check size, price, Quantity & total invoice value 1.Agreement with supplier
Inform supplier about 2.Purchase order
any discrepancy 3.FCL
PVB S/ment Get PI / Order

confirmation from the
Not OK
supplier & Check the
same
Purchase Co-ordinator Check if any item needs to be added or defined 1.Oracle Purchasing Module
Initiate process to make oracle Check Sq Mtrs calculations in PI & Purchase
releases OK Order
Check the Division
1. Receive shipment schedule from ETD (From point of origin & point of trans
the supplier & follow up for advance Domestic S/ment Buyer shipment Supply Cycle as per Norm
set of documents
Shipping Line Purchase order
2. Receive despatch status from
domestic suppliers
Stock statements (MIP)

Overseas supplier: MT/PU/FM/24
Buyer / Purchase Co-ordinator Domestic Supplier: MT/PU/FM/25 Supply Cycle with suppliers
Incomming Material Status report

Shipment Status (Imported): MT/PU/FM/26,
Shipment Status (Domestic): T/PU/FM/27,
Model wise Incomming Material Status
Lead times
Provide Stocks net off Despatch

orderes to Planners (MIP)
Provide weekly Incoming material

status report
Imported S/ment
Inform supplier about any
discrepancies & follow up
Buyer / Purchase Co-ordinator Check Size & quqntity Agreements with supplier
Price & invoice value PI
Purchase order / FCL confirmation
Check Check if invoice against Claims PVB: MT/PU/FM/23
advance set of Check the B/L terms as per agreements
Documents Check B/L date
Not OK
OK
Purchase Co-ordinator Update Landing Charges Landing Charges track sheet
Send advance set of Docs to CHA
& W/H
Advance Licence / Drawback Lead Buyer / Buyer Balance in Advance Licence Advance Licence
Balance for Duty Drawback Drawback request sheet from Mktg.
Check whether the DEPB availability & Premium
s/ment is to be cleared
against DEPB, Advance, DEPB usage status at Customs
Licence or Duty
Drawback
DEPB
Lead Buyer / Buyer Check for balance DEPB with CHA Standard DEPB File
Ascertain DEPB requirment Standard Imported S/ment tracking format
Customs tarrif
Followup with supplier for

the original set of
documents
Buyer / Purchase Co-ordinator Check size, Qty Agreements

Check the status of Price & Invoice value Purchase order / FCL
Original docs. from Invoice against Claims Advance set of documents
supplier / Bank when Is B/L terms as per agreements Documents set - Standard
S/ment reaches Not Recieved Standard docs. Set
Mumbai
Page 47 of 55
Order Processing
Check the status of
Original docs. from Annexure II
supplier / Bank when
S/ment reaches Responsibility /
Mumbai
Activities Interaction Check Points Standards
Recieved
Send original set of documents to Send Inspection report to QA Purchase Co-ordinator Endorsement by bank F-38 record register
CHA along with f-38 Balance f-38 with CHA Purchase order / FCL confirmation
Division
Buyer Check status of PO in Oracle Customs Tarrif

Give duty request to the accounts ETA at ICD Agreement with CHA
along with S/line charges when Check list received from CHA Agreement with S/Line
s/ment reaches M'bai Shipping Line Duty & S/Line request format
Usage of DEPB or Duty Drawback or Advance
Licence
Buyer / Purchase Co-ordinator Check ETD as in PO Supply Cycle as per Norms

Follow up with CHA & Congesation at Nava Sheva Purchase order
S/Line for s/ment No Railment
Usage Period Shipment track format
Status
Railment
Give the DEPBs A/L to CHA Buyer Railment of s/ment from Mumbai
Check the status of Local IGM with CHA
Purchase Co-ordinator Check the status of the S/ment

Pass duty to CHA Check the debiting of DEPB
Original documents & f-38 with CHA
Not Cleared
Followup the reasons Check the reasons for non clearance / delay if
Follow up for for delay in clearance Purchase Co-ordinator any Demurrage free Period
clearance with & confirm the exact Check Demurrage free days Supply Cycle as per Norm
CHA date of clearance Check Ussage / ETA as per Supply
Cleared
Purchase Co-ordinator Check arrival of s/ment at W/H
Provide clearance / despatch details
Incomming Material Status report
to Warehouse / Planners
Shipment Status (Imported): MT/PU/FM/26,
(Inci\omming material status report)
Shipment Status (Domestic): MT/PU/FM/27,
Model wise Incomming Material Status
Recipt of the Exchange control copy , Send Modvat copy & TR6 to Excise & Exchange control copy to
Modvat copy & TR6 Challan the Bank Purchase Co-ordinator Check the details of the B/E & TR6 Challan Agreement with supplier
Payment request from Bank Agreement with CHA
Payment terms with supplier
Variation in Clearance & reciept of Statutory
Docs.
Reciept of material in oracle system. MPC Oracle Release Number Oracle Purchasing Module
Generation of MRN Check received Sq Mtrs V/s Released
Initiate process to make oracle
releases MRN Pending List
Receiving bills from service provider

Buyer Checking Bills Agreement with CHA
Check for variance in Clearance & reciept of
Bills
Check docs (Copy) - Invoice, BE
All charges as per Agreement with service

Buyer / Purchase Co-ordinator provider 1.Agreement with CHA
Any extra charges levied 2. Agreement with S/Line
Check Bills & make entry Demurrage paid
Toll tax recipt
Original Bill of S/line
Buyer Check Demurrage on the s/ment Standard demurrage free period

Check Detention charged by S/Line Agreements with S/Line
Check for Demurrage & Detention
Reasons
Analyse the reasons for Demurrage

& detention & take corrective actions Buyer Check Oracle Po for approval Agreement with CHA
for future s/ments Delay (if any) in clearance of Bills
Pass bills to accounts & follow up for

Excess received / MRN Pending
payments
Page 48 of 55
BPF-QAD-03
Business Process Flow (Process control)
Purpose: To manufacture the product as per customer requirements under controlled conditions

Monthly Plan Section Head (Prod) / 1) PPC Plan Formats / Weekly Plan
Section Head PPC 1) Stock ratio
BPF-PPC-01 (Procedure 2) Maintenance Plan
Receipt of Monthly PPC Plan and for Production Planning
review of WIP & control)
BPF-MNT-01, 02
(Procedure for Mech &
Elect respectively)
Weekly Plan Section Head (Prod) / 1) PPC Plan Formats / Daily Plan
Section Head (PPC) 1) Stock ratio
Section Head (Elect / 2) Maintenance Plan
Weekly Plan
Mech)
BPF-MNT-01, 02 (Mech
& Elect respectively)
Requisition 1) Section Head - Prod RM Requisition slip / Issued physical RG &

Slip 2) Process Engineer / 1) Thickness of Glass BOM item
1) Section Head (Stores) 2) Colour of Glass
Requisition for RM (BOM items) 2) Officer (RG 3) Size of glass
Warehouse)
Daily Plan Section Head (Prod) / 1) Daily Production Shift Plan

Process Engineers 2) Scheduling Board
Daily Plan
Shift Plan Shift Supervisor Hourly plan format / Hourly Plan

1) Manpower Requirement
Shift Plan 2) tooling Requirement & Maintenance
Hourly Plan 1) Supervisor 1) BPF-QAD-02 Operation

Processing & Appropraite 2) Machine Operator 2) PPAP file / Checksheets ..
Inprocess inspection at respective 3) Process Shift Incharge 1) Operation record formats
stages QAP-QAD-01 (Procedure 2) Machine checksheets
for Calibration) 3) Inspection Standards
QAP-QAD-02, 03 & 04 4) Job Set up verifications
( Procedure for Statistical 5) Job standards
Techniques, NC & CAPA) 6) Appearance Standards
QAP-PRD-01 7) Limit samples
( Procedure for 8) Process Qualification records
Identification & 9) Skill Matrix
Traceability) 10) Safety precautions
QAP-PRD-02 (Procedure
for Inspection & Test
Status)
Operation 1) Machine Operator Defects analysis

records 2) Process Shift Incharge sheet
Report Time Yield Analysis
- Daily IRA Sheet
RM Reconciliation
sheet
Defects 1) Section Head ( Prod) / 1)Production Quantity Updated Plan vs

analysis sheet 1) Process Engineer 2) Rejection rate Actual sheet
Time Yield 3) Rework percentage
Analysis Review of Plan 4) Down time
Daily IRA vs actual 5) Job Change Time
Sheet 6) Cpk
RM 7) Design Yield
Reconciliation 8) IRA Checking
sheet 9) Absenteeism.
Distributed to : 1,2,4,5,12,13,14,
Process Efficiency : Targeted Yield As per Objectives & Accountabilities.
Process Effectiveness Measure : Monitoring through APS, .

Modification
BPF-DES-01
Business process Flow
Purpose:Annual Planning
Scope: Jet Airway Indian Airli Sahara
7025 6725
Resp /
Interaction
1) Comapny's Vision 2) Comapny's Planning dept 1. Last updated MTP 2. Vehicle 1. Five year plans highlighting Cost
Mission 3)Goals of company 4)Themes production trend for different segments Rs / Sqm of different cost elements,
of MD annual policy 5) Enviornmental 3. Govt Budget for fiscal year 4 Customer financial parameters 2. Equipment
factors - Growth in national and projections 5. MD Annual policy 6. deployment - utlisation and
international economy 7) Fiscal Work out sales plan based on inputs Foreign currency trend 7. Previous year improvement 3. Manpower status and
enviornment - interest and exchange
financial results and analysis 8. Annual release plan 4. Funds requirment 5.
rates 8) Growth trend of Automobile
sector 8) Previous year reuslts - plan Share of business
operational and financials 9) Targets in
annual plan - operational and financials
BPF-MRO-01
Purpose: Resource Planning
Scope: Planning for Machines - Production Equipments
Resp /
Interaction
1) Demand forecast as in annual plan and PPC Model wise sales plan Capacity utilisation of machines
MTP Capacilty Utilisation Study
No Gap between
requirement vs
availability
Review if demand rises by 10% more

than budget
Yes
1) Technology update CFT 1. Latest technology available at global 1) Cost caparison of production
2) Product profile level equiment
3) Operations Update - cost comaprison 2 Cost of operation of production 2) Proposals for selection of machine
of different production equipment Assessment of production equipment equipments and vendor comaprison stating
4) Cost of prodcution equipment , and selection 3. Specifications of glass requirement negotiated capital and running cost
technical specifications and scope of work
4. Quotations from vendors and services to be rendered
from different vendors
5) plant Layout 3) Revised Plant Layout
Capex approval form with negotiated cost MD / COO

and cost benifit analysis
Capex approval authority - upto Rs 25
Approval form MD /COO Lacs by COO and more than Rs 25 Lacs
by MD & CEO
If queries raised
OK
1) Approved purchase order, Materials Time schedule for procurement and

2) Delivery schedule form vendor, installation of schedule
Procurement of machinery
3)Plant layout
-
Mechanical, Installation of Mahine

Electrical ,Project Dept
Installation of machinery
Specification sheet
Installation of Mahine Mechanical, Supplier's Agreement

Electrical ,Project Dept
Trial runs on machine
If not ok
OK
1 Projects dept /
1 Vendor,
Training to operators and engineers 2 Production head ,
3 Concerned Section
head
1 Production head / Technical sheet

Concerned Section
head
Mass production on machine
1 Production head / Cost benefit document Budget Vs Actuals

Concerned Section
Montoring of KPIs head
Process Efficiency : Optimum utilisation of resources.
Process Effectiveness Measure : Review reports.

Modification Status Modification details Approved By Checked Date
BPF-MRO-01
Business Process Flow
Purpose: Resource Planning
Scope: Planning for Machines - Infra Structure Equipments/ capex items
Resp /
Interaction
1) Budgeted capex items in annual plan COO, / 1) Purpose of capex item - currently how Cost benefit of a capex item whereever
2) improvement plans Concerned dept head operations are carried out without item it is available
Discussion on cost benefit of capex
suggested
additions proposed
1)Cost of capex item , technical 1 Materials/ 1 Quotations from vendors 1) Vendor selection based on
specifications and scope of work from Assessment of capex item required and 1 Concerned dept negotiated rates and services to be
different vendors 2 Project dept rendered
selection
Capex approval form with negotiated cost MD / COO Capex approval authority - upto Rs 25
and cost benifit analysis Lacs by COO and more than Rs 25 Lacs
Approval form MD /COO by MD & CEO
If queries suggested
OK
Approved purchase order, Delivery Material dept Time schedule for procurement and
schedule installation of schedule
Procurement of capex item
Concerned dept ,
Electrical, Mech ( if
Item is put to use required)
Concerned dept Budget vs Actual as in Cost benefit

sheet
KPIs are monitored
Process Efficiency : Optimum utilisation of resources. Distributed to : 1,2,3,4,5,8


BPF-MRO-01
Purpose: To identify and plan resources and their deployment and its review mechanism for effectiveness
Scope: Annual Planning of Capex items, infrastructure and production equipments.
Resp /
Interaction
1) Themes of MD annual policy Planning dept 1. MD Annual policy 2. Budgets from 1. Annual plan highlighting Cost Rs /
2) Projection of vehicle production and departments Sqm of different cost elements,
SOB Compile and Value qunatitative data capacity utilisation of machines ,
3) Targets at model level for Raw to work out KPI parameters manpower productivity, funds
material procurement ,Production Profit & loss statement and Balance requirement
Yield, Customer rejections in PPM, sheet 2. Customer profitability
Power usage
4) Budgets on Repairs &
maintenance, overheads by all
departments.
5) Manpower requirement
6) Expneses on capital additions and
improvement plans
1) Previous year data of KPI , cost, Planning dept 1. Previous year financial results 2 1) Variance of Budget vs Last year
Proft &loss and Balance sheet , Actual KPI trend of previous year Actuals, 2) Savings or loss as
Variance analysis Comapre budgeted KPIs and finacial compared to last year achievements.
results of previous year 3) Highlights on cost factors where
budgeted cost rate is higher than
previous year
All departments / Annual plan summary of cost and KPIs 1) Cost benefit of new equipment
Contingency Plan required to meet production
requirement and reduce cost
2) New equipment required for
technology upgradation
Discuss budgets with departments 1. budgeted cost is
3) Alternate source plan for
higher than actuals and work out alternate solutions to bring
procurement of inputs
down cost where ever possible 2. KPIs of machines -
4) Revised Profit & Loss statement and
deployments of equipments
balance Sheet
1) Budget summary and targets of Planning dept 1 Plans to incoporate changes suggested Suggestions from top mangement for
departments by depts. changes to be done in plan
2 Revised Annual plan presentation
document
Submit annual plan to top mangement

for approval
Steering Commettee
Top management
suggest changes
OK
Original budget plan with monthly

breakup
Feed back of approved budgets
1) Actual vehicle production and SOB 1. Vehicle production report based on Revised proft & Loss account and
for period. SIAM data reconciliation statement of orignal
2) S&OP plan from marketing dept 2. S&OP report budget vs revised rolling budget
3) Significant change is any input 3. Exchange rate report
which impacts profits Workout rolling budget based actual 4. Fuel rates trend
sales and changes in P&L for rest of
the period
1) Profit & Loss statement and Variance analysis report for all cost
Balance sheet of the period under elements
review
2) Actual KPIs achieved by
departments.
comaprison of Actual results with
revised budgets
MIS reports from departments Contents of monthly MIS folder Monthly MIS folder.
Reports to top mangement and

feedback to departments in MCM
and TG for actual performance and
its financial impact
Minutes of meeting of review meeting by 1. List of corrective actions to be taken.

top mangement 2) Improvement/countermeasure plan
Feedback from top management

for monthly performance and "area
of concern " as discussed in review
meeting by steering committee
Minutes of meeting of review meeting

by top mangement
Information passed on to concerned

dept for countermeasure /correction
plans or specific report requirements
Improvement / Countermeasure plan
Countermeasure plans for "area of

concern" gets incorporated in next
month MIS folder or at at next
review meeting and close
monitoring is done
Process Efficiency : Optimum utilisation of resources.

Modification Status Modification details Checked by Approved By Date
Jet Airway Indian Airli Sahara
7025 6725
BPF-MRO-01
Business Process Flow (Product Homologation)
Purpose: To get product homologated as per ECE regulations
Scope: All safety Glasses manufactured.
Resp /
Interaction
Information from TPS / QA (Customer Section Head (Product 1. Customer Name E mail to homologation agency.
Service Section) through E mail. Homologation) / 2. Glass model name
Receipt of information from TPS / QA
1. Section Head (TPS) 3. FG Size of Glass
(Customer Service)
2. Section Head 4. Height of Segment
( Customer Service - 5. Minimum Radius
QA) 6. Installation Angle
7. Seat Back Angle
8. R point Co-ordinates
E mail to Homologation agency External Agency / 1) Grouping of windscreens Feedback from homologation agency
Scrutiny of data by the homologation Section Head (Product 2) R point Coordinates through fax / e mail.
agency Homologation) 3) Adequacy of documents
Feedback to
TPS/customer and NOT OK
OK
asking for clarification
Feedback from homologation agency External Agency / Type of test as per grouping of E Mail stating the type of tests from
through fax / e mail. Section Head (Product windscreens homologation agency.
Confirmation on the tests required to Homologation)
be done
E Mail stating the type of tests from Section Head (Product ECE reference standard latest version / Approval documents as per
homologation agency. Homologation) / 1. Number of test pieces required requirements.
On site testing of glass External agency 2. Acceptance criteria as per laid down
standards.
Approval documents as per requirements. Section Head (Product 1. Confirmation Approval documents as per
Homologation) 2. List of windscreens requirements.
Preparation of documents 3. Technical Specifications
4. Annexure
Approval documents as per requirements. Section Head (Product

Homologation) /
Send documents to homologation Administration
agency department
- -
Section Head (Product 1. Approval stamp on the certificates and Homologation Certificates.
Homologation) / or papers
External agency 2. Contents mentioned on the
Receipt of homologation certificates certification vis a vis documentation sent
Process Efficiency : Distributed to : 1,2,3,4,5,8

Process Effectiveness Measure : First time through

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BPFCH-QAD-04

BUSINESS PROCESS FLOW FOR CUSTOMER SERVICE

Filled QACR for all the relevent

1.Varify from PPC/FG w/h that all the existing stock is

Type of Claim 1.Any special testing required and source identification.

Action completed NO QA-PROD 1.Planned action , 2.Commited date

counter-measure 2.Product Audit results

YES Repetition of the

Close QACR QA 1.QACR format

1.Monthly/ Quarterly data is recd from customer or RO

1.Monthly/ Quaterly data is recd from customer or RO

1.Collect the model wise, defect wise and location wise

Sending of PDI, Monthly Inspection, QA 1.PDI, 2.Monthly InspectionReports.

Process Effectiveness Measure : Customer Satisfaction analysis

A New Release 1/1/2005

Input Process / Activity Resp / Interaction Control doc / Checkpoint Output

Final 1)QA Inspector / 1) Model Specific Inspection Standard If OK : Pallet Card

OK Glass 1) Production shift Filled & Signed Pallet

OK Glass 1) Section Head - In Control Plan Product audit result

Process Effectiveness Measure : Monitoring through In Process PPM Score.

A New Release 1/1/2005

Input Process / Activity Resp / Interaction Control doc / Checkpoint Output

In Process 1) QA Inspector 1) Model Specific Inspection Standard If OK : Process Card

Inspection and 1) Production personnel / Filled & Signed

Process Effectiveness Measure : Monitoring through In Process PPM Score.

A New Release 1/1/2005

Scope: Direct BOM items

NO Did stores Is it from AVL

Assign Inspection status

A New Release 1/1/2005

1.) Review and making of 1.) Inspection / Job Standard

Customer Main Events Tooling & Gauges.

PRODUCTION 4.) Trial Dates. 4.) Standard reporting format

Sign Off Approval

Section Person(Q.A) 5.)Any other quality related issues.

Customer Report of fitment Test and Trial Schedule

1) RM & consumable Requirement.

1.) Implementation of Improvement Points.

Sample 1. Technical Advisor(If reqd)

Sign Off Approval Q.A 1) Mode of Packing. Qty. of Samples to be send

Customer Report of fitment

1) Modification requirement if 1) Effectiveness of earlier modifications

Minutes of Meeting Q.A PPAP Documents ( QAP-TPS-01)

1) PPAP approval file from QA - 1) Transfer of Documents.

2) APQP file Prod'n 2) Specific requirement 2) Inspection std. Preparation.

Process Effectiveness Measure :

01/01/2005 A New Release as per TS

Date Mod. Status Modification details Reviewed by Checked by Approved by

1. VOC Report/ MCM Report/E-Mail etc.

Draft of customer 1. Review the details of concern, 2. Requirement Customer concern/ECN/

Verbal consensus Feed back to custmer & all QA/MKTG

YES QA/MKTG Through E--Mail, Telephone, Fax

Customer communi- Close the concern QA

New sample Submit the samples to

QA/MKTG 1.Approval received for the sample parts submitted,

1.Distribution of ECN to the reqd. area, 2.Updated

1.Inspection Std, 2.Job Std. Inspection Reports, Cpk

Product validation 1. PPAP manual Send PPAP file to customer

Signed off PSW QA Updated PPAP file,