Doc. No.: PIPL-QM-01 APPX.

V
Turtle Diagram Rev. No.: 00
PIPL Effective Date: 20/10/2017
Process:

Production Process Control

SUPPORT FUNCTION PERFORMANCE INDICATORS & ITS

1: PPC ANALYSIS :
2: QA
3: Store As per Departmental Objectives -
4: Maintenance Deptt. FMT-14
5: Purchase
6: HR
7:Development

INPUT
1: Production Planning
2: Raw Material and BOP Production OUTPUT
3: Skilled Manpower Process owner: HOD 1: OK Products as per plan
4: M/C in running condition Prod. 2: Rejction
5: Process Parameter & WI 3:Process validation
6: Product spec. * Process Control 4: Maintaining of 5 - S
7: Packing Accessories * Production 5: Improvement / Kaizen
Secheduling
* Process Validation

Training ,Skill & Competency

1: Knowledge Of Production Process
2: Kaizen
3: Safety
REF. DOCUMENTS 4: 5'S'
5: Product Safety Awareness.
Monthly production plan F/PRD/02 6: Knowledge Of Soldering
Daily Production Report F/PRD/01 7: Knowledge Of Wiring , Drilling etc.
Daily Check Sheet of machine F/MNT/13 Operation
Line Inspection Report F/QC/04 8: Knowledge Of Product Inspection
Lab Scope Matrix F/QC/LAB/01
Company Performance Indicator For Month
………….. F/SYS/05
Dispatch schedule cum monitor F/PRD/03
Process Validation Report F/QC/21 Risk
1: Delayed Production
2.: Occurance of Non Conformity
3: Manpower Shortage
4: Process non Validated
5: Less Optimization / utilize of
Resources

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
 Doc. No.: PIPL-QM-01 APPX. V
Turtle Diagram Rev. No.: 00
Effective Date: 20/10/2017
Process:

Human Resource Process

PIPL

SUPPORT FUNCTION PERFORMANCE

1: Manpower Placement INDICATORS & ITS
2: News Paper ANALYSIS :
3: All Department
4: Govt. Department As per Departmental
Objectives - FMT-14

INPUT OUTPUT
1: Recruited Man Power
1: Manpower Requirement 2: Training Plan
2: Training Needs & Resources Human Resources 3: Training Evalueation
3: Legal / Factory Act Requirment Process owner: HR 4: Satisfaction of
* Recruitment Employee
& Training to Employee 5: Full fill of Legal
*Employee Satisfaction Activities/ requirement
Servey 6: Improvement through
* Exit Interview Exit Interview ( In case
employee resigning )

REF. DOCUMENTS
Manpower requirement
Employee Competency Criteria F/16-02 Training ,Skill &
Induction training Schedule cum feed back Competency
form F/HRD/13 1: Knowledge of HR
On Job Training F/HRD/20 activities
Training Need Identification F/HRD/01 2: Kaizen
Annual Training Plan F/HRD/02 3: Safety
Attendence Sheet F/HRD/03 4: 5-S
Training Feed back and effectiveness 5: Knowlwdge of Legal
F/HRD/04 Activity / Factory Act.
Training Record F/HRD/05

Risk
1. Recruitment of Incompetent
person
2.: Insufficient Awareness of
Process importance
3: Manpower Shortage
4: Less Motivation
5: Heigher Manpower Cost

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( Director )
 Doc. No.: PIPL-QM-01 ANNX. V
Turtle Diagram Rev. No.: 00
PIPL Effective Date: 20/10/2017
Process:

Corrective & Preventive Action AND

Quality Assurance
SUPPORT FUNCTION
1: HR PERFORMANCE INDICATORS & ITS
2: Production ANALYSIS :
3: Purchase
4: Maintenance As per Departmental Objectives -
5: Store/despatch FMT-14
6 :customer

INPUT

1:Manufactured/receiving mat.
2: Customer Complaint & return
Quality Assurance OUTPUT
material
Process owner: HOD QA 1: Calibration Plan
3: Customer Requierement &
*Equipment Calibration 2: Calibrated Instrumentt
spec.
* Inspection 3: Mat. Inspection Report
4: Customer's Drg.
(Incoming/Inprocess/Final) 4: Customer Rejection
5: Manpower
* Handaling of customer 5: Handling customer complaint
6. Gauges 7. Instruments
complaint 6: Process/Product Check Sheet
* Control of Non
Conformance
* Customer Complaint
Handling
REF. DOCUMENTS

INSPECTION STANDARDS
MATERIAL RECEIVING INSPECTION REPORT Training ,Skill & Competency
F/QC/29 1: Knowledge of QMS requirment
DAILY INSPECTION REPORT F/QC/04 2: Kaizen
PRE-DISPATCH INSPECTION REPORT F/QC/06 3: Safety
INCOMING INSPECTION REPORT F/QC/54 4: 5-S
SAMPLING INSPECTION PLAN F/QC/57 5: Quality tools like 7 QC Tools
MATERIAL TEST REPORT 6: Knowledge of calibration
CUSTOMER COMPLAINT REGISTER F/MKT/04 process
CUSTOMER RETURN REGISTER F/QC/31 7. Knowlwdge of Quality Control
CAPA F/QC/05 Plan

. Risk
1: Gauges remains non Calibrated
2.: Occurance of Non Conformity
3: Shipment of Non Conformity
4: Customer Complaints not
closed
5: Heigher Degree of non
Conformance

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
 Doc. No.: PIPL-QM-01 APPX. V
Turtle Diagram Rev. No.: 00
PIPL Effective Date: 20/10/2017
Process:

Purchasing

SUPPORT FUNCTION PERFORMANCE INDICATORS & ITS

1: All Deptt. ANALYSIS :
2: Top Management
3 : Suppliers
As per Departmental Objectives -
FMT-14

INPUT OUTPUT
Purchasing
1: Purchase mat. as reqd.
1: Material Specification Process owner: HOD
2: Approved Supplier list
2: Indent / Rurchase Request Purchase
3: Supplier Rating
3: Prod. Plan / Stock Status * Mat. Purchasing
4: Purchase Order
Sheet * New Supplier Devlopment
5: Stock Statement
4: Man Power * Supplier Rating
6.Supplier Quality Audit &
* Supplier Quality Audit &
Improvement
Improvement
* Outsourse Process
Control

REF. DOCUMENTS
LIST OF OUT SOURCE ACTIVITY Training ,Skill & Competency
TRIMMING REGISTER OUTSOURCE 1: Knowledge of Purchase process
2: Kaizen
LIST OF APPROVED SUPPLIERS F/PUR/03 3: Safety
SUPPLIER EVALUATION REQUEST CUM 4: 5-S
REGISTRATION FMT-38 5: Negotiation Skills
PURCHASE ORDER F/PUR/05
SUPPLIER SCHDULE F/PUR/08
SUPPLIER RATING SHEET F/PUR/10
INDENT SLIP
VERBAL ORDER REGISTER FOR SUPPLIERS

Work Instruction For Supplier Rating Risk

1: Incompetent Supplier Developed
2.: Supply of Non Conformity
3: Delayed Receipt of Material
4: Inappropriate Supplier's
Performance
5: Heigher Degree of non Conformance

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
 Doc. No.: PIPL-QM-01 APPX. V
Turtle Diagram Rev. No.: 00
PIPL Effective Date: 20/10/2017
Process:

Management Process & QMS Control

SUPPORT FUNCTION PERFORMANCE INDICATORS & ITS

1: All Deptt. ANALYSIS :
2: Top Management
3: External Agencies As per Departmental Objectives -
FMT-14

INPUT
Management Review
1: Dept. Objective Target vs Process owner: MR
achivement * Internal Audit
2: External / Customer Std * Document Control OUTPUT
3: Products * Record Control 1: Management Review Report
4: Manpower * External Doc. Control 2: Internal Audit Plan and
* Manageent Review Conduction
* Corrective and 3: Controlled Manual, Procedure
Preventive Actions etc.
* Continual Doc. No. 4: Corrective & Preventive Action
* Communication for QMS 5: Internal Audit Results
6: Kaizan Activity
REF. DOCUMENTS
Master List of document cum
Distribution F/SYS/01
Master List Of External Docs F/SYS/03
Document change request F/SYS/07
Engineering Change Notification
F/NPD/11
Engineering Change Note Register
F/NPD/03
Internal Audit Schedule F/SYS/09 Training ,Skill & Competency
Non Conformance Report F/MR/03 1: Knowledge of QMS ISO 9001 &
Audit report summary F/SYS/12 TS 16949 requirments
Internal Quality Audit Checklist 2: Kaizen
F/SYS/13 3: Safety
List Of Trained Internal Auditor F/SYS/23 4: 5-S
Internal EHS Audit Checklist F 5 : Knowledge of Manufacturing
Minutes of Meeting (Meenutes of Process
Management Review Meeting) F/MR/01 6 : Qualified Internal Auditor for
Departmental Objectives F/SYS/05 ISO/ TS 16949 : 2009
CORRECTIVE & PREVENTIVE ACTION
REQUEST (CAPA) F/QC/05
Risk
1: In appropriate Doc. Control
2.: Inappropriate Record Control
. 4: Irregular QMS Audits Conduc
5: Irregualar Management Review
Conduction
6. In appropriate Communication for
QMS

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( Director )
 Doc. No.: PIPL-QM-01 APPX. V
Turtle Diagram Rev. No.: 00

PIPL Effective Date: 20/10/2017

Process:

Sales & Marketing

PERFORMANCE INDICATORS & ITS

SUPPORT FUNCTION ANALYSIS :
1: HR.
2: Acounts As per Departmental Objectives -
3: Development /QA FMT-14
4: PPC/ Prod.
5: Store/ Purchase
6: Customer

INPUT Marketing & Tendering

1: Man power Process
2: Customer Enquairy/ Process owner: Concern
information HOD Marketing
3: Customer Drg./Spec. OUTPUT
4: Cus. Purchase *Business Plan 1: Customer Feed Back
Ordre/Contract * Contract Review 2: List of Customer
5: Customer Feedback * Customer Satsfaction ( Existing &
Servey and Improvement Potential)
REF. DOCUMENTS * Tender Submission and 3: Customer Audit Plan:
Participation Management 4: Customer Audit Feed
MASTER LIST OF REGULAR *Service and Installation Back Report
CUSTOMERS CUM SATISFACTION Management
SURVEY PLAN
CUSTOMERS SATISFACTION SURVEY
F/MKT/02
CUSTOMER ENQUIRY CHECK SHEET
FEASIBILITY STUDY SHEET
F/NPD/04
Training ,Skill & Competency
1: Knowledge of process
2: Kaizen
3: Safety
4: 5-S
5. Knowledge of Service and
Installation

Risk
1: In appropriate Customer
Satisfaction
2.: Inappropriate Order Confirm
3: Inadequate Business Plan
Prepared

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
 Doc. No.: PIPL-QM-01 APPX. V

PIPL
Turtle Diagram Rev. No.: 00
Effective Date: 20/10/2017
Process:

Maintenance

SUPPORT FUNCTION PERFORMANCE INDICATORS & ITS

1:Production ANALYSIS :
2:Quality
3:Purchase As per Departmental Objectives -
4:P.P.C FMT-14
5:HR
6:Account

Maintenance Process
Process woner:
HOD Maintenance
INPUT *M/C Maintenance OUTPUT
( 1: Established or ok m/c
1: Man power Preventive/Predictive / 2: Preventive Maint Plan
2: Purchased M/c & Manual Break Down) 3: List of Criticacal Spare Parts
3: B/D information *New M/c Establishment 4: B/D Hrs Analysis
4: Spare parts * Critical Spare Parts 5: Daily M/c Check Sheet
5: Oil & Management 6: Power Consumption
* Utility Control

REF. DOCUMENTS
MASTER LIST OF MANUFACTURING
EQUIPMENTS F/MNT/07 Training ,Skill & Competency
DAILY MACHINE CHECKLIST F/MNT13 1: Knowledge of Machine inhouse
ANNUAL SCHEDULES OF PREVENTIVE 2: Kaizen
MAINT. F/MNT/04 3: Safety
LIST OF CRITICAL PARTS CUM MIN. 4: 5-S
STOCK STATUS
PREVENTIVE MAINT CHECK LIST
F/MNT/03
MACHINE HISTORY CARD F/MNT/02
WHY WHY ANALYSIS REPORT F/MN/09
BREAKDOWN HOURS ANALYSIS Risk
F/MNT/16 1: In appropriate Prevetive
Maintenance
2.: Inappropriate Predective
Maintenance
3: Heavy Breackdown hours may
occure
4. More Critical Spare Consumed

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
 Doc. No.: PIPL-QM-01 ANNX. V
Turtle Diagram Rev. No.: 00
PIPL
Effective Date: 20/10/2017
Process:

Stores

PERFORMANCE INDICATORS &

ITS ANALYSIS :
SUPPORT FUNCTION
1: All Deptt. As per Departmental Objectives -
2: Suppliers F/SYS/05
3 : Customer

INPUT OUTPUT
1: Purchase Order F/PUR/05 1: Receving of OK (incoming)/ FG /
2: Mat. Issue Slip Store & Dispatch NG material.
3: Incomming / FG / NG Process owners: HOD Store and 2: Identification / Preservation &
Products. Dispatch Incharge desposion of mat.
4: Manpower * Material Storage & Handling 3: Inventry Control
5: Incoming Inspection Report/ * Matterial Issue 4: Mat. despatch to customer
F/QC/29 * Inventory Control 5: FIFO maintening
6: GRN * Daily Dispatch 6: Mat. Issue to production deptt.
7: Supp./ Customer Documents * FIFO Maintenance 7: Document submition record
8: Packed Material updation

REF. DOCUMENTS

Inward Record Register FMT-70 Training ,Skill & Competency

Goods Receipt Note ( GRN ) FMT-71 1: Process Knowledge stores
Raw Material Requistion / Issue Slip and Dispatch
FMT-72 2: Kaizen
Stock Register FMT-74 3: Safety
List of Hazards Material FMT-75 4: 5-S
List of Self Life Control items FMT-76
Daily Dispatch Report FMT-77

Risk :
1: In appropriate Preservation of
Products
2.: Inappropriate Material Handling

3: Material Shortage
4. Irregular Self Life Control &
Hazard Material Control

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )
 Doc. No.: PIPL-QM-01 ANNX. V
Turtle Diagram Rev. No.: 00

PIPL Effective Date: 20/10/2017

Process:
New Product Development

SUPPORT FUNCTION
1: Mkt PERFORMANCE INDICATORS & ITS
2: QA ANALYSIS :
3: Store
4: Maintenance As per Departmental Objectives -
5: Purchase F/SYS/05
6: HR
7: Production
8: Tool Manufacturer

INPUT New Product

1: Customer Enquiry Development
2: Customer specific Owner :HOD Design &
requirement Development OUTPUT
3: Raw Material * Product Design & 1: PFMEA Process Flow
4: Skilled Manpower Proto samples Diagram/Chart
5: M/C must be in running * Validation of Product 2. Quality Control Plan
condition Design 3: Tool dev. And validation As
6: Forging M/C/Tool for trial * Tool/Fixture/Dev. per customer req.
Activity 4: SIR of part
* Tool Control 5: Maintaining of 5 - S
* APQP
* PPAP 6: Improvement / Kaizen
* KAIZEN 7. Tool Trial and Inspection
Report

REF. DOCUMENTS Training ,Skill & Competency

1: Kaizen
TOOL DEVELOPMENT TIMING PLAN 2: Safety
F/NPD/01 3: 5-S
Process Flow Chart F/NPD/05 4. Process Flow Diagram/Chart
Control Plan F/NPD/07 5. Quality Control Plan ,
PACKING STD F/PRD/12 6. PPAP
LIST OF CHECKING AIDS F/QC/10 7. Machining Process
NEW TOOL TRIAL REPORT F/NPD/13

Risk :
1 . More time Consumed for
Development
2. Development / Product
Approval in Multiple hits
3. Cost of Development
Increased

PREPARED BY ( Deptt. HOD) APPROVED BY ISSUED BY ( MR) COPY STATUS

( Director )