Top 7 Management Caravan Rev 06

• Document No.

• Top 7 Management Caravan

• Conducted on

  Date

• Prepared by

General Communication

• There are no general communications?

  Yes

  No

  N/A

Bumper Returns

• DS&R's are all accounted for?<br>

  Yes

  No

  N/A

• JIT returns are all accounted for?<br>

  Yes

  No

  N/A

• Painted Scrap are all accounted for?<br>

  Yes

  No

  N/A

• Assembly Scrap are all accounted for?<br>

  Yes

  No

  N/A

• Disassembly undercontrol?<br>

  Yes

  No

  N/A

INBOUND LOGISTICS

General

• No yellow cards issued to your Department?

  Yes

  No

  N/A

• Regrind is under control?

  Yes

  No

  N/A

• There are no paint "unexplained" items?

  Yes

  No

  N/A

• There are no assembly parts "Unexplained"?

  Yes

  No

  N/A

• There are no general concerns?

  Yes

  No

  N/A

• Process audit achieved 85%+?

  Yes

  No

  N/A

Safety, Health & Environment

• Stores housekeeping is to standard?

  Yes

  No

  N/A

• No Incidents?

  Yes

  No

  N/A

• No accidents?

  Yes

  No

  N/A

• No spills?

  Yes

  No

  N/A

• 6S Above 85%

  Yes

  No

  N/A

• Safety Meeting Held?

  Yes

  No

  N/A

ASSEMBLY

General

• No yellow cards issued to your Department?

  Yes

  No

  N/A

• Parts are properly stored on racks? (No Touch)

  Yes

  No

  N/A

• No parts on the floor?

  Yes

  No

  N/A

• BI Data up to date?

  Yes

  No

  N/A

• Dock audit clear?

  Yes

  No

  N/A

• No parts without tow hook covers?

  Yes

  No

  N/A

• 15 bumpers or more supplied out of Hospital?

  Yes

  No

  N/A

Top 7

1. Raw Material

• 1.1 Bumpers Stock levels up

  Yes

  No

  N/A

• 1.2 SS Stock levels up

  Yes

  No

  N/A

• 1.3 Wiltie's Parts above 5 days?

  Yes

  No

  N/A

• 1.4 Buy out Parts above 5 days?

  Yes

  No

  N/A

• 1.5 Scanning Above 90%?

  Yes

  No

  N/A

2. O.E.E.

• 2.1 Above 90%?

  Yes

  No

  N/A

• Parts per Hour

• Scrap

• Downtime

3. Finished Goods

• 3.1 All shifts above 80 sets?

  Yes

  No

  N/A

• 3.2 All D&B stock above 5 days?

  Yes

  No

  N/A

• 3.3 All India commitments met?

  Yes

  No

  N/A

4. Quality & Process

• 4.1 Achieved PPM Target?

  Yes

  No

  N/A

• 4.2 Achieved Process Audit Target?

  Yes

  No

  N/A

• 4.3 JIT returns below 3?

  Yes

  No

  N/A

5. Maintenance

• 5.1 85% PM Schedule Attainment achieved?

  Yes

  No

  N/A

• 5.2 All critical spares in store?

  Yes

  No

  N/A

• 5.3 No outstanding job cards?

  Yes

  No

  N/A

6. Internal Logistics

• 6.1 No forklift or truck issues?

  Yes

  No

  N/A

• 6.2 No packaging or Dunnage issues?

  Yes

  No

  N/A

7. Services

• 7.1 Less than 2% absenteeism?

  Yes

  No

  N/A

• 7.2 Overtime docs done.

  Yes

  No

  N/A

• 7.3 Man Matrix's updated?

  Yes

  No

  N/A

7.4 Safety, Health & Environment

• 7.4.1 Housekeeping is to standard?

  Yes

  No

  N/A

• 7.4.2 No Incidents?

  Yes

  No

  N/A

• 7.4.3 No accidents?

  Yes

  No

  N/A

• 7.4.4 No spills?

  Yes

  No

  N/A

• 7.4.5 6S Above 85%

  Yes

  No

  N/A

• 7.4.6 Safety Meeting Held?

  Yes

  No

  N/A

• Shift A<br>

  Yes

  No

  N/A

• Shift B<br>

  Yes

  No

  N/A

• Shift C<br>

  Yes

  No

  N/A

7.5 Commercial

• 7.5.1 No outstanding commercial issues?

  Yes

  No

  N/A

7.6 Purchasing

• 7.6.1 No outstanding purchasing issues?

  Yes

  No

  N/A

7.7 Finance

• 7.7.1 Scrap is within target?

  Yes

  No

  N/A

• 7.7.2 Overtime is within target?

  Yes

  No

  N/A

• 7.7.3 Maintenance is within target?

  Yes

  No

  N/A

QUALITY

• No yellow cards issued to your Department?

  Yes

  No

  N/A

BMW

• No PPM?

  Yes

  No

  N/A

• Rework minutes below target.

  Yes

  No

  N/A

• JIT returns downward trend?

  Yes

  No

  N/A

• Final Buy Off downward trend?

  Yes

  No

  N/A

• No audit bay findings?

  Yes

  No

  N/A

• Oven buy off downward trend?

  Yes

  No

  N/A

• No general concerns?

  Yes

  No

  N/A

All other Customers

• No PPM?

  Yes

  No

  N/A

Safety

• No accidents?

  Yes

  No

  N/A

PAINT PLANT

General

• No yellow cards issued to your Department?

  Yes

  No

  N/A

• Parts are being Polished, spot repaired or reworked properly

  Yes

  No

  N/A

• No parts on the floor?

  Yes

  No

  N/A

• Scanning Data working?

  Yes

  No

  N/A

• BI Data up to date?

  Yes

  No

  N/A

• First off process working?

  Yes

  No

  N/A

• No reworks on the floor at loading?

  Yes

  No

  N/A

• All stations at loading are manned appropriately?

  Yes

  No

  N/A

Top 7

1. Raw Material

• 1.1 Bumpers above 3 days?

  Yes

  No

  N/A

• 1.2 Side Skirts above 3 days?

  Yes

  No

  N/A

• 1.3 Paint above 3 days?

  Yes

  No

  N/A

• 1.4 Reworks under target?

  Yes

  No

  N/A

2. O.E.E.

• 2.1 Above 75%?

  Yes

  No

  N/A

• Parts per Hour

• Scrap

• Downtime

• 2.2 Scan Data above 85% ?

  Yes

  No

  N/A

• 2.3 FTB Bumpers above 65% ?

  Yes

  No

  N/A

• 2.4 FTB Side Skirts above 75% ?

  Yes

  No

  N/A

3. Finished Goods

• 3.1 Next 300 vehicles covered?

  Yes

  No

  N/A

• 3.2 All D&B stock above 5 days?

  Yes

  No

  N/A

4. Quality & Process

• 4.1 Achieved PPM Target?

  Yes

  No

  N/A

• 4.2 Achieved Process Audit Target

  Yes

  No

  N/A

• 4.2 Facility Process under Control?

  Yes

  No

  N/A

5. Maintenance

• 5.1 85% PM Schedule Attainment achieved?

  Yes

  No

  N/A

• 5.2 All critical spares in store?

  Yes

  No

  N/A

• 5.3 No outstanding job cards?

  Yes

  No

  N/A

6. Internal Logistics

• 6.1 No forklift or truck issues?

  Yes

  No

  N/A

• 6.2 No packaging or Dunnage issues?

  Yes

  No

  N/A

7. Services

• 7.1 Less than 2% absenteeism?

  Yes

  No

  N/A

• 7.2 Overtime docs done.

  Yes

  No

  N/A

• 7.3 Man Matrix's updated?

  Yes

  No

  N/A

7.4 Safety, Health & Environment

• 7.4.1 Housekeeping is to standard?

  Yes

  No

  N/A

• 7.4.2 No Incidents?

  Yes

  No

  N/A

• 7.4.3 No accidents?

  Yes

  No

  N/A

• 7.4.4 No spills?

  Yes

  No

  N/A

• 7.4.5 6S Above 85%

  Yes

  No

  N/A

• 7.4.6 Safety Meeting Held?

  Yes

  No

  N/A

• Shift A

  Yes

  No

  N/A

• Shift B

  Yes

  No

  N/A

• Shift C

  Yes

  No

  N/A

7.5 Commercial

• 7.5.1 No outstanding commercial issues?

  Yes

  No

  N/A

7.6 Purchasing

• 7.6.1 No outstanding purchasing issues?

  Yes

  No

  N/A

7.7 Finance

• 7.7.1 Scrap is within target?

  Yes

  No

  N/A

• 7.7.2 Overtime is within target?

  Yes

  No

  N/A

• 7.7.3 Maintenance is within target?

  Yes

  No

  N/A

MOULDING HALL 1

General

• No yellow cards issued to your Department?

  Yes

  No

  N/A

• All scrap bins are identified and managed well?

  Yes

  No

  N/A

• All bumper stillages are inside the warehouse?

  Yes

  No

  N/A

• Trimming area well organized with updated production data?

  Yes

  No

  N/A

• Parts and containers identified correctly?

  Yes

  No

  N/A

• Parts are being flamed and cleaned properly?

  Yes

  No

  N/A

• BI Data updated with actions?

  Yes

  No

  N/A

• First off process working?

  Yes

  No

  N/A

Top 7

1. Raw Material

• 1.1 All raw materials above 5 days?

  Yes

  No

  N/A

2. O.E.E.

• 2.1 All machines 90%?

  Yes

  No

  N/A

• Parts per Hour

• Scrap

• Downtime

• 2.2 Large machines 90%?

  Yes

  No

  N/A

• Parts per Hour

• Scrap

• Downtime

3. Finished Goods

• 3.1 No bumper and Side Skirt Red Dots?

  Yes

  No

  N/A

• 3.2 No bulk Red Dots?

  Yes

  No

  N/A

• 3.3 No assembly parts Red Dots?

  Yes

  No

  N/A

4. Quality & Process

• 4.1 Achieved PPM Target?

  Yes

  No

  N/A

• 4.2 Achieved Process Audit Target

  Yes

  No

  N/A

5. Maintenance

• 5.1 85% PM Schedule Attainment achieved?

  Yes

  No

  N/A

• 5.2 All critical spares in store?

  Yes

  No

  N/A

• 5.3 No outstanding job cards?

  Yes

  No

  N/A

6. Internal Logistics

• 6.1 No forklift or truck issues?

  Yes

  No

  N/A

• 6.2 No packaging or Dunnage issues?

  Yes

  No

  N/A

7. Services

• 7.1 Less than 2% absenteeism?

  Yes

  No

  N/A

• 7.2 Overtime docs done.

  Yes

  No

  N/A

• 7.3 Man Matrix's updated?

  Yes

  No

  N/A

7.4 Safety, Health & Environment

• 7.4.1 Housekeeping is to standard?

  Yes

  No

  N/A

• 7.4.2 No Incidents?

  Yes

  No

  N/A

• 7.4.3 No accidents?

  Yes

  No

  N/A

• 7.4.4 No spills?

  Yes

  No

  N/A

• 7.4.5 6S Above 85%

  Yes

  No

  N/A

• 7.4.6 Safety Meeting Held?

  Yes

  No

  N/A

• Shift A

  Yes

  No

  N/A

• Shift B

  Yes

  No

  N/A

• Shift C

  Yes

  No

  N/A

7.5 Commercial

• 7.5.1 No outstanding commercial issues?

  Yes

  No

  N/A

7.6 Purchasing

• 7.6.1 No outstanding purchasing issues?

  Yes

  No

  N/A

7.7 Finance

• 7.7.1 Scrap is within target?

  Yes

  No

  N/A

• 7.7.2 Overtime is within target?

  Yes

  No

  N/A

• 7.7.3 Maintenance is within target?

  Yes

  No

  N/A

MOULDING HALL 2

General

• No yellow cards issued to your Department?

  Yes

  No

  N/A

• Parts and containers identified correctly?

  Yes

  No

  N/A

• BI Data updated with actions?

  Yes

  No

  N/A

Top 7

1. Raw Material

• 1.1 All raw materials above 5 days?

  Yes

  No

  N/A

2. O.E.E.

• 2.1 All machines 90%?

  Yes

  No

  N/A

• Parts per Hour

• Scrap

• Downtime

• 2.2 Large machines 90%?

  Yes

  No

  N/A

• Parts per Hour

• Scrap

• Downtime

3. Finished Goods

• 3.1 No OE Red Dots?

  Yes

  No

  N/A

• 3.2 No non auto red dots?

  Yes

  No

  N/A

4. Quality & Process

• 4.1 Achieved PPM Target?

  Yes

  No

  N/A

• 4.2 Achieved Process Audit Target

  Yes

  No

  N/A

5. Maintenance

• 5.1 85% PM Schedule Attainment achieved?

  Yes

  No

  N/A

• 5.2 All critical spares in store?

  Yes

  No

  N/A

• 5.3 No outstanding job cards?

  Yes

  No

  N/A

6. Internal Logistics

• 6.1 No forklift or truck issues?

  Yes

  No

  N/A

• 6.2 No packaging or Dunnage issues?

  Yes

  No

  N/A

7. Services

• 7.1 Less than 2% absenteeism?

  Yes

  No

  N/A

• 7.2 Overtime docs done.

  Yes

  No

  N/A

• 7.3 Man Matrix's updated?

  Yes

  No

  N/A

7.4 Safety, Health & Environment

• 7.4.1 Housekeeping is to standard?

  Yes

  No

  N/A

• 7.4.2 No Incidents?

  Yes

  No

  N/A

• 7.4.3 No accidents?

  Yes

  No

  N/A

• 7.4.4 No spills?

  Yes

  No

  N/A

• 7.4.5 6S Above 85%

  Yes

  No

  N/A

• 7.4.6 Safety Meeting Held?

  Yes

  No

  N/A

7.5 Commercial

• 7.5.1 No outstanding commercial issues?

  Yes

  No

  N/A

7.6 Purchasing

• 7.6.1 No outstanding purchasing issues?

  Yes

  No

  N/A

7.7 Finance

• 7.7.1 Scrap is within target?

  Yes

  No

  N/A

• 7.7.2 Overtime is within target?

  Yes

  No

  N/A

• 7.7.3 Maintenance is within target?

  Yes

  No

  N/A

Outbound Logistics

• No yellow cards issued to your Department?

  Yes

  No

  N/A

• Is stacking safe?

  Yes

  No

  N/A

• There are no red dots?

  Yes

  No

  N/A

• All parts are identified both location and container

  Yes

  No

  N/A

Safety, Health & Environment

• Stores housekeeping is to standard?

  Yes

  No

  N/A

• No Incidents?

  Yes

  No

  N/A

• No accidents?

  Yes

  No

  N/A

• No spills?

  Yes

  No

  N/A

• 6S Above 85%

  Yes

  No

  N/A

• Safety Meeting Held?

  Yes

  No

  N/A

Closing Instructions

• There are no closing instructions?

  Yes

  No

  N/A