Bumper SCRAP

  • DS&R's are all accounted for?

  • JIT returns are all accounted for?

  • Painted Scrap are all accounted for?

  • Assembly Scrap are all accounted for?

  • Disassembly undercontrol?

ASSEMBLY

General

  • No yellow cards issued to your Department?

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

  • No parts on the floor?

  • BI Data up to date?

  • Dock audit clear?

  • No parts without tow hook covers?

  • 15 bumpers or more supplied out of Hospital?

Top 7

1. Raw Material

  • 1.1 Bumpers Stock levels up

  • 1.2 SS Stock levels up

  • 1.3 Wiltie's Parts above 5 days?

  • 1.4 Buy out Parts above 5 days?

  • 1.5 Scanning Above 90%?

2. O.E.E.

  • 2.1 Above 90%?

  • Parts per Hour

  • Scrap

  • Downtime

3. Finished Goods

  • 3.1 All shifts above 80 sets?

  • 3.2 All D&B stock above 5 days?

  • 3.3 All India commitments met?

4. Quality & Process

  • 4.1 Achieved PPM Target?

  • 4.2 Achieved Process Audit Target?

  • 4.3 JIT returns below 3?

5. Maintenance

  • 5.1 85% PM Schedule Attainment achieved?

  • 5.2 All critical spares in store?

  • 5.3 No outstanding job cards?

6. Internal Logistics

  • 6.1 No forklift or truck issues?

  • 6.2 No packaging or Dunnage issues?

7. Services

  • 7.1 Less than 2% absenteeism?

  • 7.2 Overtime docs done.

  • 7.3 Man Matrix's updated?

7.4 Safety, Health & Environment

  • 7.4.1 Housekeeping is to standard?

  • 7.4.2 No Incidents?

  • 7.4.3 No accidents?

  • 7.4.4 No spills?

  • 7.4.5 6S Above 85%

  • 7.4.6 Safety Meeting Held?

  • Shift A

  • Shift B

  • Shift C

7.5 Commercial

  • 7.5.1 No outstanding commercial issues?

7.6 Purchasing

  • 7.6.1 No outstanding purchasing issues?

7.7 Finance

  • 7.7.1 Scrap is within target?

  • 7.7.2 Overtime is within target?

  • 7.7.3 Maintenance is within target?

PAINT PLANT

General

  • No yellow cards issued to your Department?

  • Parts are being Polished, spot repaired or reworked properly

  • No parts on the floor?

  • Scanning Data working?

  • BI Data up to date?

  • First off process working?

  • No reworks on the floor at loading?

  • All stations at loading are manned appropriately?

Top 7

1. Raw Material

  • 1.1 Bumpers above 3 days?

  • 1.2 Side Skirts above 3 days?

  • 1.3 Paint above 3 days?

  • 1.4 Reworks under target?

2. O.E.E.

  • 2.1 Above 75%?

  • Parts per Hour

  • Scrap

  • Downtime

  • 2.2 Scan Data above 85% ?

  • 2.3 FTB Bumpers above 65% ?

  • 2.4 FTB Side Skirts above 75% ?

3. Finished Goods

  • 3.1 Next 300 vehicles covered?

  • 3.2 All D&B stock above 5 days?

4. Quality & Process

  • 4.1 Achieved PPM Target?

  • 4.2 Achieved Process Audit Target

  • 4.2 Facility Process under Control?

5. Maintenance

  • 5.1 85% PM Schedule Attainment achieved?

  • 5.2 All critical spares in store?

  • 5.3 No outstanding job cards?

6. Internal Logistics

  • 6.1 No forklift or truck issues?

  • 6.2 No packaging or Dunnage issues?

7. Services

  • 7.1 Less than 2% absenteeism?

  • 7.2 Overtime docs done.

  • 7.3 Man Matrix's updated?

7.4 Safety, Health & Environment

  • 7.4.1 Housekeeping is to standard?

  • 7.4.2 No Incidents?

  • 7.4.3 No accidents?

  • 7.4.4 No spills?

  • 7.4.5 6S Above 85%

  • 7.4.6 Safety Meeting Held?

  • Shift A

  • Shift B

  • Shift C

7.5 Commercial

  • 7.5.1 No outstanding commercial issues?

7.6 Purchasing

  • 7.6.1 No outstanding purchasing issues?

7.7 Finance

  • 7.7.1 Scrap is within target?

  • 7.7.2 Overtime is within target?

  • 7.7.3 Maintenance is within target?

MOULDING HALL 1

General

  • No yellow cards issued to your Department?

  • All scrap bins are identified and managed well?

  • All bumper stillages are inside the warehouse?

  • Trimming area well organized with updated production data?

  • Parts and containers identified correctly?

  • Parts are being flamed and cleaned properly?

  • BI Data updated with actions?

  • First off process working?

Top 7

1. Raw Material

  • 1.1 All raw materials above 5 days?

2. O.E.E.

  • 2.1 All machines 90%?

  • Parts per Hour

  • Scrap

  • Downtime

  • 2.2 Large machines 90%?

  • Parts per Hour

  • Scrap

  • Downtime

3. Finished Goods

  • 3.1 No bumper and Side Skirt Red Dots?

  • 3.2 No bulk Red Dots?

  • 3.3 No assembly parts Red Dots?

4. Quality & Process

  • 4.1 Achieved PPM Target?

  • 4.2 Achieved Process Audit Target

5. Maintenance

  • 5.1 85% PM Schedule Attainment achieved?

  • 5.2 All critical spares in store?

  • 5.3 No outstanding job cards?

6. Internal Logistics

  • 6.1 No forklift or truck issues?

  • 6.2 No packaging or Dunnage issues?

7. Services

  • 7.1 Less than 2% absenteeism?

  • 7.2 Overtime docs done.

  • 7.3 Man Matrix's updated?

7.4 Safety, Health & Environment

  • 7.4.1 Housekeeping is to standard?

  • 7.4.2 No Incidents?

  • 7.4.3 No accidents?

  • 7.4.4 No spills?

  • 7.4.5 6S Above 85%

  • 7.4.6 Safety Meeting Held?

  • Shift A

  • Shift B

  • Shift C

7.5 Commercial

  • 7.5.1 No outstanding commercial issues?

7.6 Purchasing

  • 7.6.1 No outstanding purchasing issues?

7.7 Finance

  • 7.7.1 Scrap is within target?

  • 7.7.2 Overtime is within target?

  • 7.7.3 Maintenance is within target?

MOULDING HALL 2

General

  • No yellow cards issued to your Department?

  • Parts and containers identified correctly?

  • BI Data updated with actions?

Top 7

1. Raw Material

  • 1.1 All raw materials above 5 days?

2. O.E.E.

  • 2.1 All machines 90%?

  • Parts per Hour

  • Scrap

  • Downtime

  • 2.2 Large machines 90%?

  • Parts per Hour

  • Scrap

  • Downtime

3. Finished Goods

  • 3.1 No OE Red Dots?

  • 3.2 No non auto red dots?

4. Quality & Process

  • 4.1 Achieved PPM Target?

  • 4.2 Achieved Process Audit Target

5. Maintenance

  • 5.1 85% PM Schedule Attainment achieved?

  • 5.2 All critical spares in store?

  • 5.3 No outstanding job cards?

6. Internal Logistics

  • 6.1 No forklift or truck issues?

  • 6.2 No packaging or Dunnage issues?

7. Services

  • 7.1 Less than 2% absenteeism?

  • 7.2 Overtime docs done.

  • 7.3 Man Matrix's updated?

7.4 Safety, Health & Environment

  • 7.4.1 Housekeeping is to standard?

  • 7.4.2 No Incidents?

  • 7.4.3 No accidents?

  • 7.4.4 No spills?

  • 7.4.5 6S Above 85%

  • 7.4.6 Safety Meeting Held?

7.5 Commercial

  • 7.5.1 No outstanding commercial issues?

7.6 Purchasing

  • 7.6.1 No outstanding purchasing issues?

7.7 Finance

  • 7.7.1 Scrap is within target?

  • 7.7.2 Overtime is within target?

  • 7.7.3 Maintenance is within target?

Closing Instructions

  • There are no closing instructions?

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