PFD, Pfmea & CP

Part Number / Latest Change Level:
Part Name/Description:
Supplier / Plant:
Supplier's Approving Authority / Date:
Origin Date/No.
Machine / Process Description

Op. No. Facility (Operation/Inspection/
Type Transportation/Storage)
Painting of parts
130 Trolley Moulded material Movement to paint shop
140 Lux meter, stand Incoming Inspection of molded parts

Supplier / Plant:
Origin Date/No.

Masking table, diecuts ,

140.1 tape& Sisccor& Lux Masking
meter
Conveyor Dolley,
150 Loading of part on painting hanger
Painting Hanger
160 air gun Air blowing

Supplier / Plant:
Origin Date/No.

IPA,Lint free cloth,Lux

170 IPA Application
meter
180 Tag-Rag cloth Tag-Rag Application
Antistatic air
190 blow,Static charge Antistatic air blow
meter
Supplier / Plant:
Origin Date/No.

200 Flaming Flaming

Supplier / Plant:
Origin Date/No.

Ford cup (B4) ,Filter

cloth, measuring
cylinder or measuring
210 Primer Mixing
beakaer,stop watch,
Mixing pot,
Thermometer
Supplier / Plant:
Origin Date/No.

Painting Spray gun,

Jigs, ,measuring
beakaer,stop
watch,Pressure
220 Primer application
gauge,Anemometer,
thermo
hydrometer,lux
meter , Dust count
meter .
Supplier / Plant:
Origin Date/No.

230 Air velocity meter Flash off
B4 cup,Filter
cloth,measuring
240 cylinder or measuring Base-Coat Mixing
beakaer,stop
watch,Mixing pot
Supplier / Plant:
Origin Date/No.

Painting Spray gun,

Jigs,B4 cup,Filter
cloth ,measuring
beakaer,stop watch,
Pressure
250 Base coat application
gauge,Anemometer,T
emp.
controller,thermo
hydrometer,lux
meter,shrink
wrape,air,brush,duster
Supplier / Plant:
Origin Date/No.


Supplier / Plant:
Origin Date/No.

B4 cup,Filter
cloth,measuring
270 cylinder or measuring Clear-Coat Mixing
beakaer,stop
watch,Mixing pot
Supplier / Plant:
Origin Date/No.

Painting Spray gun,

Jigs,B4 cup,Filter
cloth ,measuring
beakaer,stop
watch,Pressure
280 Clear coat application
gauge,Anemometer,T
emp.
controller,thermo
hydrometer,lux
meter,shrink
wrape,air,brush,duster
Supplier / Plant:
Origin Date/No.

300 Oven Baking

Supplier / Plant:
Origin Date/No.

310 Cooling zone Cooling

Supplier / Plant:
Origin Date/No.

Glass marking
320 Pre checking
pencil,Lux level
Supplier / Plant:
Origin Date/No.

Emery paper
330 2500,grade, water, Sanding defect on part
cloth, Lux meter
Polishing Tool,
Polishing Pad, back
340 Polishing of sanding part
up pad, polish cream,
Air,Colth,Lux level
Supplier / Plant:
Origin Date/No.

Light lab equipment,

350 DFT Meter,Cross Inspection
cutter,
360 Empty trolley Unloading

Supplier / Plant:
Origin Date/No.

360.'1 LIGHT &CLOTH Demasking
370 Empty trolley Loading on Trolley
PREPARED BY:
APPROVED BY:
Process Flow Diagram
TRANSPORTATION
Vendor Code:
OPN & INSP. TOGETHER
Core Team:
Incoming source of Symbol

Product Characteristics
variation On Line / Off line
1) Moulded Defects
2) Part mix up 1)No Damage,
2) No Scratch,
3) Dust on Part 3) No Part mix up
4) Part Damage 4) No Warpage on Part
5) Warpage on Part 5) No Dust/Lint on Part
6) Damage Trolley
7) Cover Damage
1) Part mix up
2) Damage during handling, &
storage at trolley 1)No Damage,
3) Standard packaging not used 2) No Scratch,
4) Punching Defect 3) No Molding Defect
5) Storage location is not define for 4)No Punching Defect
molded part. 5) No Mixup
6) Moulding Defect
TRANSPORTATION
Vendor Code:
Core Team:

1) No Under masking (masking problem),

1)Damage,
2) No Over masking (masking problem),
2)Scratch,
3) No Shade variation,
3)Molding Defect
4) No Over spray,
4)Punching Defect
5) No Uncover,
5)Mixup
6) No Dust
SC
SC
Scratch
Scratch
SC
SC
SC
Water
Damage
1) Part damage during handling Water
Spot
SC
Spot
2) Part scratch during handling Scratch
3) Molding Defect on parts. 1) No Warpage / Bend/Dent
4) Dust on hanger 2) No Damage,
5) Wrong hanger 3) No Dust
SC
SC
6) Damage Hanger Blister
Scratch
4)
SC No Scratch
7) Bend hanger SC5) No wrong part loading
Blister
Water
8) Undermasking Spot
9) Over Masking SC
Damage
SC
Water
SC
Spot
SC
SC
Damage
Blister
Scratch
SC
SCSC
1) Part Warpage / Bend Blister
Scratch
Damage
2) Part Damage due to loading SC
1) No Dust/Lint
Water
3 Dust on part
2) No Damage
Spot
4) Scratch on part SC
3) No Scratch
5) Wrong part loading Damage
SC
Water
Spot
SC
Blister
SC
SC
TRANSPORTATION
Vendor Code:
Core Team:

variation On Line / Off line SC
Blister
SC
SC
SC
Blister
Scratch
Damage
SC
1) Dust in air blow area Damage
SC1) No Dust
2) Damage Water
2) No oil mark
3) Scratch Spot
3) No lint
4) Contamination in IPA
SC
SC
Blister
Scratch
SC
Damage
SC
1) Dust on part Water
1) No Dust
Spot
2) oil mark on part
2) No lint
3) lint on part
SC
Blister
1) Dust on part SC
1) No Dust ,
2) lint on part Damage
2)Static charge (max 0.4 Kv)
TRANSPORTATION
Vendor Code:
Core Team:

1) Dust on part 1) No burn mark

2) Static charge on parts 2) Surface tension min 38 dynes
TRANSPORTATION
Vendor Code:
Core Team:

1) Expired primer
2) Wrong grade primer 1) Free from unmixed
3) Settling of primer 2) No less / More Viscosity
4) Dust 3) No dust
5) Pregelling 4) No gelling of primer
6) Skin formed in primer 5) No contamination
7) Separation in primer
TRANSPORTATION
Vendor Code:
Core Team:

1) No orange peal
2) No Uncover,
1) unmixed paint, 3) No Rundown,
2) less / More Viscosity 4) No Dust,
3) dust 5) NO scratch
4) gelling of primer 6) No spitting
5) Wrong grade primer 7) No water spot
6) Contaminated part 8) No blister
7) burn mark 9) No cissing
8) Surface tension less than 38 10) No Damage
dyne. 11) No Lint
12) No Pin Hole
13) No Dry finish
TRANSPORTATION
Vendor Code:
Core Team:

1) Water spot, 1) No No lint,Dust

2) Uncover, 2) No Blister
3) Rundown, 3) No Cissing
4) Dust, 4) No Damage
5) lint, 5) No Scratch
6) Blister, 6) No water spot
7) Cissing,
8) pin hole,
9) Dry finish (Rough paint surface)
10) Scratch,
11) Spitting,
12) Damage
13) orange peel
1) Expired paint
2) Wrong grade paint 1) Free from unmixed
3) Settling of paint 2) No less / More Viscosity
4) Dust 3) No dust
6) Skin formed in paint 5) No contamination
7) Separation in paint
TRANSPORTATION
Vendor Code:
Core Team:

1) Water spot,
1) No Shade variation
2) Uncover,
2) No over spray
3) Rundown,
3) No water spot
4) Dust,
4) No Paint cracking
5) lint,
5) No mottling
6) Blister,
6) No orange peal
7) Cissing,
7) No uncover
8) pin hole,
8) No Rundown
9) No Dust, lint
10) Scratch,
10) No scratch
11) Spitting,
11) No spitting,
12) Damage
12) No blister
13) orange peel
13) No cissing
14) unmixed paint,
14) No damage
15) less / More Viscocity
15) No pin hole
16) gelling of basecoat
16) No Dry finish
TRANSPORTATION
Vendor Code:
Core Team:

1) Water spot,
2) Uncover,
3) Rundown,
4) Dust,
5) lint,
6) Blister,
7) Cissing,
8) pin hole, 1) No lint,Dust
9) Dry finish (Rough paint surface) 2) No Blister
10) Scratch, 3) No Cissing
11) Spitting, 4) No Damage
12) Damage 5) No Scratch
13) orange peel 6) No water spot
14) Paint cracking
15) Shade variation
16) Mottling
TRANSPORTATION
Vendor Code:
Core Team:

1) Expired paint
2) Wrong grade paint 1) Free from unmixed
3) Settling of paint 2) No less / More Viscosity
4) Dust 3) No dust
6) Skin formed in paint 5) No contamination
7) Separation in paint
TRANSPORTATION
Vendor Code:
Core Team:

1) Water spot,
2) Uncover,
1) No Shade variation
3) Rundown,
2) No over spray
4) Dust,
3) No water spot
5) lint,
6) Blister,
5) No Gloss variation
7) Cissing,
6) No mottling
8) pin hole,
7) No orange peal
8) No uncover
10) Scratch,
9) No Rundown
11) Spitting,
10) No Dust, lint
12) Damage
11) No scratch
13) orange peel
12) No spitting,
14) Paint cracking
13) No blister
15) shade variation
14) No cissing
16) mottling
15) No damage
17) unmixed paint
16) No pin hole
18) less / More Viscocity
17) No Dry finish
19) gelling of clear
20) contamination
TRANSPORTATION
Vendor Code:
Core Team:

1) Water spot,
2) Uncover,
3) Rundown,
1) No lint,Dust
4) Dust,
2) No Blister
5) lint,
3) No Cissing
6) Blister,
4) No Damage
7) Cissing,
5) No Scratch
8) pin hole,
6) No water spot
10) Scratch,
11) Spitting,
12) Damage
13) orange peel
14) Paint cracking
15) Shade variation
16) Mottling
17) Gloss variation
1) Water spot, 1) No Damage

2) Scratch, 2) No Paint Cracking
3) Damage, 3) No Dust/Lint
4) Cissing, 4) No warpage, bend
5) Blister, 5) No over bake
6) Dust, 6) No under bake
7) lint
TRANSPORTATION
Vendor Code:
Core Team:

1) Over bake,
2) Underbake
3) Warpage,
1) No damage
4) Bend,
2) No scratch
5) Paint cracking,
6) Dust
7) Damage
TRANSPORTATION
Vendor Code:
Core Team:

1 ) Orange peal,
2) Over spary,
1 ) No Orange peel,
3) Uncover
2) No Over spary,
4) Rundown,
3) No Uncover
5) Dust,
4) No Rundown,
6) lint,
5) No Dust,
7) Blister,
6) No lint,
8) Cissing,
7) No Blister,
9) Cracking,
8) No Cissing,
10) pin hole,
9) No Cracking,
11) Dry finish (Rough paint
10) No paint peel off
surface) ,
11) No bend
12) Mottling,
12) No pin hole,
13) Scratch,
14) No Dry finish (Rough paint surface),
14) Spitting,
15) No Mottling,
15) Water spot,
16) No Scratch,
16) Damage
17) No Spitting,
17) Warpage
18) No Water spot,
18) Bend
19) No Damage
19) Dent
20) Shade variation
21) No shade variation
21) Gloss variation
22) Paint peel off
TRANSPORTATION
Vendor Code:
Core Team:

1 ) Orange peel,
2) Over spary,
3) Uncover
4) Rundown,
5) Dust,
6) lint,
7) Blister,
8) Cissing,
9) Cracking,
10) paint peel off 1) No Scratch,
11) bend 2) No Damage
12) pin hole, 3) No incompleted sanding of defect
surface),
15) Mottling,
16) Scratch,
17) Spitting,
18) Water spot,
19) Damage
20 Gloss variation
21) shade variation
1) No Damage
1) Scratch,
2) No Scratch,
2) Damage
3) Incompleted sanding of defect
4) No sanding mark
TRANSPORTATION
Vendor Code:
Core Team:

1 ) Orange peal,
2) Over spary, 1 ) No Orange peel,
3) Uncover 2) No Over spary,
4) Rundown, 3) No Uncover
5) Dust, 4) No Rundown,
6) lint, 5) No Dust,
7) Blister, 6) No lint,
8) Cissing, 7) No Blister,
9) Cracking, 8) No Cissing,
10) pin hole, 9) No Cracking,
11) Dry finish (Rough paint 10) No paint peel off
surface) , 11) No bend
12) Mottling, 12) No pin hole,
13) Scratch, 14) No Dry finish (Rough paint surface),
14) Spitting, 15) No Mottling,
15) Water spot, 16) No Scratch,
16) Damage 17) No Spitting,
17) Warpage 18) No Water spot,
18) Bend 19) No Damage
19) Dent 20) No Gloss variation
20) Shade variation 21) No shade variation
21) Gloss variation 22) No sanding mark
22) Paint peel off
23) Sanding mark
1) Damage
1)No Scratch,
2) Scratch
2) No Damages,
3) Painting defect
3) No Dent
4)Missing of Tow Hook
TRANSPORTATION
Vendor Code:
Core Team:

1 ) Orange peal,
2) Over spary,
3) Uncover
4) Rundown,
5) Dust,
6) lint,
7) Blister,
8) Cissing,
9) Cracking,
10) pin hole,
1) No Mist Spray on masked portion,
surface) ,
2) Finish ok.
12) Mottling,
3) No Paint Cracking
13) Scratch,
14) Spitting,
15) Water spot,
16) Damage
17) Warpage
18) Bend
19) Dent
20) Shade variation
21) Gloss variation
22) Paint peel off
23) Sanding mark
1) No Scratch,
1) Scratch,
2) No damages,
2) Damages,
3) No dent
3) Dent
DATE REVISION LEVEL

m
SYMBOLS
OPERATION STORAGE
INCOMING PARTS INSPECTION
DELAY
Special
Special
Characteri
Process Characteristics Characteristi Qty. Time (Sec.)
stics
cs (Process)
(Product)
MAN: Trained Operator. Skill level Min L-2

Machine : Nil,
Method : Part Movement as per Floor Layout NIL NIL Each Lot 300 Sec
Tool : Nil
Environment : Dust & Dirt free ,Lux level 600 min .
Man : Trained operator L-2 (Min) .

Machine : Nil,
Method : Sequential inspection, Use of PPE
NIL NIL Each part 30
Tool : Nil
Environment : Lux Level (600-800 Lux) , No Dust in
area.
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Skill Operator L-2 (Min) .

Machine : Nil
Method : Masking in define sequence,
Tool: quzing tool
Environment : Lux Level (600-800 Lux), No Dust in
area.
Man : Skill Operator L-2 (Min) .

Machine : Nil
Method : Loading in define sequence, Proper resting
& locking of bumper & tow hook cover on Hanger . NIL NIL Each part 100
Tool: Hanger for 4 parts with proper resting
area.
Man : Skill operator L-2 (Min).

Machine : Nil
Method : Sequencail Air blowing on part, Air pressure
( 0.4-0.6 Mpa) NIL NIL Each part 80
Tool : Air blowing Gun
area.
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Skill operator L-2 (Min)

Machine : Nil
Method : Wiping direction, Application on Bumper in
defined sequence, Cloth change frequency, NIL NIL Each part 90
Tool : Nil
area.

Machine : Nil
Method : Wiping direction, Application on Bumper in
defined sequence, Cloth change frequency after 2 Hrs NIL NIL Each part 50
Tool : Nil
area.
Machine : Transformer setting output voltage 3-5 KV,
Air pressure
Method : Sequencial Application of air, Work
instruction,
Tool : Static charge Meter
Environment : Lux Level (600-800 Lux) No Dust in
area.
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)

Machine : Nil
Method : Sequential application, gas pressure (1-
2Kg/Cm2 ), Colour of flame blue NIL NIL Each part 85
Tool : Flamming gun , Dynes Pen.
area.
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : 1) Eye testing of operator ,

2) Skill operator L-3 (Min)
Machine : Stirrer,
Method : 1) Primer Viscosity,(F/PS/001/83)
2) filter grade 400 mesh
3) Mesh Filter change frequency every change of
colour.,
NIL NIL Each lot 600
3) Mixing Ratio (Primer : Hardner:Thinner ),
(F/PS/001/83)
4) Pot Life(2k paint)- 4 hours
Tool : Thermometer,Ford cup & measuring cylinder or
measuring beakaer
Environment : Lux Level (600-800 Lux),
Temperature(25 - 30 C) , No Dust in area.
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Eye testing of operator,

Machine : Paint booth
Method : 1) Spray gun cleaning-Daily
3) Interior booth cleaning - Weekly
4) Water flow plates cleaning,-Weekly
5) Paint line Cleaning - Every Color change
NIL Each part 120
7) Sequencial Painting Application as per STD.
8) Air Pressure,( 0.4-0.6 mpa)
9) Air Velocity,(0.3-0.5 m/sec)
10) Paint Gun Flow Rate,(180-220)
Tool : Spray gun (HVLP)
Environment : Lux Level (600-800 Lux), Booth Temp
(25 - 30 C) & Humidity ( 60 15), No Dust in booth
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Nil
Machine : Nil
Method : 1) Time in Flash Off Zone (8-10 min), 2) Air
NIL Each part 120
Velocity (0.05- 0.1 m/sec)
Tool : Nil
Environment : No Dust in area.

Machine : Stirrer,
colour.,
(F/PS/001/83)
measuring beakaer
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)

NIL Each part 120
7) Sequencial Painting Application as per STD.
(25 - 30 C) & Humidity ( 60 15), No Dust in booth
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Nil
Machine : Nil
NIL Each part 120
Tool : Nil
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)

Machine : Stirrer,
colour.,
(F/PS/001/83)
measuring beakaer
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)

NIL Each part 200
7) Sequencial Painting Application as per SOP.
(25 - 30 C) & Humidity ( 60 15), No Dust in booth.
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Nil
Machine : Nil
NIL Each part 120
Tool : Nil
Man : Nil
Machine : Baking oven
Method : 1) Time (30 5 min)
2) Temp (75-85 C) NIL NIL Each part 120
3) TTR- Monthly (EMT- Min temp. 70 C for 20 min.)
Tool : Nil
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : Nil
Machine :Nil
Method : 1) Time (8-10 min)
2) Forced air
3) Air flow direction
Tool : Nil
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man :1) Eye testing of inspector.

2) Skill inspector L-3 (Min)
Machine :Nil NIL Each part 100
Method : Sequencial inspection of part
Tool : Nil
Environment : 1) No Dust in area.
2) Lux Level (800-1200 Lux)
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man :1) Eye testing of operator.

Machine : Nil
Method : 1) Water sanding
2) Emery paper grade (2500 grade)
Tool : Nil
Man :1) Eye testing of operator.

Machine : Nil
Method : 1) Polishing paste grade (S17+ )
2) Polishing time (2-3 min)
3) Polishing pad grade (3" Lambswool Pad)
Tool : Polishing tool
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man :1) Eye testing of inspector.

Machine :Nil NIL Each part 100
Method : Sequencial inspection of part
Tool : DFT Meter,Cross cutter,
Man : 1) Skill inspector L-2 (Min)

Machine : Nil
Method : Unloading process
Tool : Nil
m
SYMBOLS
OPERATION STORAGE
DELAY
Special
Special
Characteri
stics
cs (Process)
(Product)
Man : 1) Skill inspector L-2 (Min) (Min)

Machine : Nil
Method : Demasking Process
Tool : Nil
Man : 1) Skill inspector L-2 (Min)

Machine : Nil
Method : 1) Part storage in defined trolley
2) Defined no. of parts 20 Nos NIL NIL Each part 30
Tool : Trolley
REVISION HISTORY
DISCRIPTION OF REVISION REVIE

Distance
(Mts.)
21
3
Distance
(Mts.)
1
Distance
(Mts.)
1
Distance
(Mts.)
1
Distance
(Mts.)
7
Distance
(Mts.)
1
Distance
(Mts.)
5
Distance
(Mts.)
2
Distance
(Mts.)
9
Distance
(Mts.)
3
Distance
(Mts.)
2
Distance
(Mts.)
18
Distance
(Mts.)
6
Distance
(Mts.)
1
Distance
(Mts.)
1.5
1.5
Distance
(Mts.)
6
Distance
(Mts.)
REVIEWED BY
Part Name / Description:
Process Responsibility :
Part Number / Latest Change Level: Core Team:
|| N.O. - NEXT OPERATION || C.E. - CUSTOMER EFFECT || E.U. -END USER || O.S.- OPERATOR SAFETY|| M
Supplier / Plant:
C
l
Op. No. Process Description Requirements Core Team: Potential Effect(s) of Failure S a
s
s
Origin Moulded material 1)No Damage,
Part has to be replace befor loading due
Movement to paint 2) No Scratch, N.O 3
Date/No. shop 3) No Part mix up to part fitment on loading fixture
4) No Warpage on Part
5) No Dust/Lint on Part
S.O Nil 1
Problem during part fitment at customer

C.E 8
end (loss primary function)
8
poor apearence of part and noticed by
E.U 4
most of customer i.e.> 75%
O.S Nil 1
M.C Nil 1
Dust/Lint on part
part may have to be rework due to dust
N.O 7
on parts
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
Damage, Scratch
N.O 3 SC
to part fitment on loading fixture
S.O nil 1
C.E Part rejected for poor apearence 7 SC
7
E.U 4
O.S Nil 1
M.C Nil 1
Warpage on part
N.O 3
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
140 Incoming Inspection 1)No Damage, Part Mixup

of molded parts 2) No Scratch, Part has to be replace befor loading due
N.O 3
3) No Molding Defect to part fitment on loading fixture
4)No Punching Defect
5) No Mixup
S.O Nil 1

C.E 8
end (loss primary function)
8
E.U 4
O.S Nil 1
M.C Nil 1
Wrong packing
part may have to be scrap due to damage
N.O 7
and scratches on parts
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
Damage, Scratch
N.O 3 SC
S.O nil 1
C.E Part rejected for poor apearence 7 SC

7

E.U 4
O.S Nil 1
M.C Nil 1
Molding Defect (Burr, Dent

Mark/ sink mark, dust, Part has to be replace befor loading due
N.O 3
waviness, short molding, to part fitment on loading fixture
Flash, Parting line, warpage.)
Punching Defect
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
140.1 Masking 1) No Under masking (masking Under Masking ( Masking

problem), Problem) N.O Line Stoppage due to part rework 4
2) No Over masking (masking
problem),
3) No Shade variation,
4) No Over spray, S.O Short Supply 4
5) No Uncover,
6) No Dust
C.E Shortage of Material 4
4
E.U Nil
O.S Nil
M.C Nil
Overmasking ( Masking
Problem) N.O Line Stoppage due to part rework 4
S.O Short Supply 4
C.E Shortage of Material 4
4
E.U Nil
O.S Nil
M.C Nil
Shade variation
N.O Nil 1
S.O Nil 1
Parts with visual defects. A portion of the

C.E 7
parts may have to be scrapped.
7
E.U 3
O.S Nil 1
M.C Nil 1
Over spary
N.O Nil 1
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Uncover
N.O Nil 1
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Dust on part
part may have to be scrap due to damage
N.O 7
and scratches on parts
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
150 Loading of part on 1) No Warpage / Bend/Dent Warpage / Bend/Dent

painting hanger N.O nil 1 SC
2) No Damage,
3) No Dust
4) No Scratch
5) No wrong part loading S.O nil 1

C.E end (loss primary function) more gap and 8
flush

E.U 3
O.S Nil 1
M.C Nil 1
SC
Damage
N.O nil 1 SC
S.O nil 1

C.E 7

E.U 4
O.S Nil 1
M.C Nil 1
SC
SC
Scratch
N.O nil 1 SC
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1 SC
M.C Nil 1 SC SC
Dust
N.O nil 1
S.O nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
Wrong part loading

N.O nil 1
S.O nil 1

C.E end (loss primary function) more gap and 8
flush
8
E.U 3
O.S Nil 1
M.C Nil 1
Bumper and toe hook cover

loading missing N.O nil 1
Assy line disurption and production loss.

S.O Portion of production to be done offline to 5
achieve plan vs actual
Customer line disturption due to short

C.E deliver supply, Portion of production to be 5
rework offline due to shortage of bumper
5
E.U Nil 1
O.S Nil 1
M.C Nil 1
160 Air blowing 1) No Dust/Lint Dust/lint

2) No Damage N.O nil 1
3) No Scratch
S.O nil 1

C.E 5
parts may have to be reworked.
5
E.U 4
O.S Nil 1
M.C Nil 1
Damage & scratch

N.O Nil 1 SC
S.O Nil 1

C.E 7
7
7
E.U 4
O.S Nil 1
M.C Nil 1
170 IPA Application 1) No Dust Dust

2) No oil mark N.O Nil 1
3) No lint
S.O Nil 1

C.E 7

E.U 4
O.S Nil 1
M.C Nil 1 7
Oil mark
N.O Nil 1
S.O Nil 1

C.E 7

E.U 4
O.S Nil 1
M.C Nil 1
Lint
N.O Nil 1
S.O Nil 1

C.E 7

E.U 4
O.S Nil 1
M.C Nil 1
180 Tag-Rag Application 1) No Dust Dust

2) No lint N.O Nil 1
S.O Nil 1

C.E 7

E.U 4 7
O.S Nil 1
M.C Nil 1
lint
N.O Nil 1
S.O Nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
190 Antistatic air blow 1) No Dust , Dust

2)Static charge (max 0.4 Kv) N.O Nil 1
S.O Nil 1

C.E 7
7
7
E.U 4
O.S Nil 1
M.C Nil 1
Static charge more than

0.4 Kv N.O Part rejected due to dust on parts 4
S.O Part rejected due to dust on parts 4
Minor disruption in customer schedule

C.E 7
adherence
E.U nil 2
O.S Nil 1
M.C Nil 1
200 Flaming 1) No burn mark Burn mark

2) Surface tension min 38 N.O Nil 1
dynes
S.O Nil 1

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
Surface tension less than 42

dynes N.O Nil 1
S.O Nil 1

C.E 7
adherence
7
E.U 4
O.S Nil 1
M.C Nil 1
210 Primer Mixing 1) Free from unmixed Paint not mixed homogeneous
2) No less / More Viscosity Line stop due to error in painting ( portion
3) No dust N.O of production may have to be rework in 4
4) No gelling of primer station)
5) No contamination
S.O Short Supply of part for assy 4

C.E 7
adherence
7
E.U 4
O.S Nil 1
M.C Nil 1
less / More Viscosity

N.O Line stop due to error in painting 4
Line Stoppage due to part rejection due

S.O 7
to paint defects on parts.

C.E 7
adherence
7
E.U 4
O.S Nil 1
M.C Nil 1
Dust in paint
Line stop due to error in painting ( portion
N.O of production may have to be 5
reworkoffline)

S.O of production may have to be 5
reworkoffline)

C.E 7
7

E.U 4
O.S Nil 1
M.C Nil 1
Gelling of primer
S.O Short Supply 8

C.E 7
adherence

E.U 4
8
O.S Nil 1
M.C Nil 1
contamination in paint
N.O Portion of paint have to be rework. 4
S.O Portion of paint have to be rework. 4

C.E 7
adherence
E.U 4 7
O.S Nil 1
M.C Nil 1
220 Primer application 1) No orange peal Orange peal

2) No Uncover, N.O Nil 1
3) No Rundown,
4) No Dust,
5) NO scratch S.O Nil 1
6) No spitting
7) No water spot
8) No blister Parts with visual defects. A portion of the
C.E 7
9) No cissing parts may have to be scrapped.
10) No Damage
11) No Lint poor apearence of part and noticed by
12) No Pin Hole E.U 4
13) No Dry finish
O.S Nil 1
M.C Nil 1
7
Uncover/Thin Painting
N.O Nil 1
S.O Nil 1

C.E 5
parts may have to be reworked.

E.U 3
O.S Nil 1
M.C Nil 1
5
Rundown
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Dust
N.O Nil 1
S.O Nil 1
C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7 SC

E.U 3
O.S Nil 1
M.C Nil 1
7
Spitting
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Water spot
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC SC
Blister
N.O Nil 1 SC
S.O Nil 1
C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
SC
7
Cissing
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Damage
N.O Nil 1 SC
S.O Nil 1 SC

C.E 7
E.U 3
O.S Nil 1
M.C Nil 1
7
Lint
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
pin hole
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Dry finish (Rough paint
surface) N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
230 Flash off 1) No No lint,Dust Dust, lint
2) No Blister N.O Nil 1
3) No Cissing
4) No Damage
5) No Scratch
6) No water spot S.O Nil 1

C.E 7

E.U 3
O.S Nil 1 7
M.C Nil 1
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7
E.U 3
O.S Nil 1 7
M.C Nil 1 SC
Cissing
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Damage
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
7
M.C Nil 1
SC SC
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Water spot
N.O Nil 1 SC
S.O Nil 1

C.E 7
7
E.U 3 SC SC
O.S Nil 1
M.C Nil 1
240 Base-Coat Mixing 1) Free from unmixed 1) Free from unmixed Line stop due to error in painting ( portion
2) No less / More Viscosity N.O of production may have to be rework in 4
3) No dust station)
4) No gelling of primer
5) No contamination S.O Short Supply of part for assy 4

C.E 7
adherence

E.U 4
O.S Nil 1 7
M.C Nil 1
Nil 1
2) No less / More Viscosity


S.O 7

C.E 7
adherence
7
E.U 4
O.S Nil 1
M.C Nil 1
3) No dust Line stop due to error in painting ( portion

reworkoffline)
reworkoffline)

C.E 7
7
E.U 4
O.S Nil 1
M.C Nil 1
4) No gelling of base
S.O Short Supply 8

C.E 7
adherence

E.U 4
8
O.S Nil 1
M.C Nil 1
5) No contamination

C.E 7
adherence

E.U 4 7
O.S Nil 1
M.C Nil 1
250 Base coat application 1) No Shade variation Shade variation

2) No over spray N.O Nil 1
3) No water spot
5) No mottling S.O Nil 1
6) No orange peal
7) No uncover
8) No Rundown Parts with visual defects. A portion of the
C.E 7
9) No Dust, lint parts may have to be scrapped.
10) No scratch
11) No spitting, poor apearence of part and noticed by
12) No blister E.U 3
13) No cissing
14) No damage
15) No pin hole O.S Nil 1
16) No Dry finish
M.C Nil 1
7
Over spary
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Water spot
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC
Paint cracking
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC
Mottling
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Orange peal
N.O Nil 1
S.O Nil 1

C.E 7

E.U 4
O.S Nil 1
M.C Nil 1
7
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Rundown
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Dust, lint
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
7
Spitting
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
SC
7
Cissing
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Damage
N.O Nil 1 SC
S.O Nil 1 SC

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Pait peel off
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
pin hole
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7

surface) N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
260 Flash off 1) No lint,Dust Dust, lint
3) No Cissing
4) No Damage
S.O Nil 1
5) No Scratch
6) No water spot
C.E 7

E.U 3
O.S Nil 1 7
M.C Nil 1
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1 7
M.C Nil 1 SC
Cissing
N.O Nil 1
S.O Nil 1

C.E 7
E.U 3
O.S Nil 1
M.C Nil 1
No wet surface
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1 7
Damage
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
7
M.C Nil 1
SC SC
Scratch
N.O Nil 1 SC
Scratch
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Water spot
N.O Nil 1 SC
S.O Nil 1

C.E 7
7
E.U 3 SC SC
O.S Nil 1
M.C Nil 1
270 Clear-Coat Mixing 1) Free from unmixed 1) Free from unmixed

2) No less / More N.O of production may have to be rework in 4
Viscosity station)
3) No dust
4) No gelling of primer S.O Short Supply of part for assy 4
5) No contamination
C.E 7
adherence

E.U 4
O.S Nil 1 7
M.C Nil 1
2) No less / More Viscosity Line stop due to error in painting ( portion

N.O of production may have to be rework in 4
station)

S.O 7

C.E 7
adherence
7
E.U 4
O.S Nil 1
M.C Nil 1
3) No dust
reworkoffline)

reworkoffline)

C.E 7
7

E.U 4
O.S Nil 1
M.C Nil 1
4) No gelling of clear
S.O Short Supply 8

C.E 7
adherence

E.U 4
8
O.S Nil 1
M.C Nil 1
5) No contamination

C.E 7
adherence

E.U 4 7
O.S Nil 1
M.C Nil 1
280 Clear coat application 1) No Shade variation Shade variation

2) No over spray N.O Nil 1
3) No water spot
5) No Gloss variation S.O Nil 1
6) No mottling
7) No orange peal
8) No uncover Parts with visual defects. A portion of the
C.E 7
9) No Rundown parts may have to be scrapped.
10) No Dust, lint
11) No scratch poor apearence of part and noticed by
12) No spitting, E.U 3
13) No blister
14) No cissing
15) No damage O.S Nil 1
16) No pin hole
17) No Dry finish
M.C Nil 1
7
Over spary
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Water spot
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC SC
Paint cracking
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC
Gloss variation
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Mottling
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Orange peal
N.O Nil 1
S.O Nil 1

C.E 7

E.U 4
O.S Nil 1
M.C Nil 1
7
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Rundown
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Dust, lint
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Spitting
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Water spot
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
SC
7
Cissing
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Damage
N.O Nil 1 SC
S.O Nil 1 SC

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
pin hole
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7

surface) N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
290 Flash off 1) No lint,Dust Dust, lint

3) No Cissing
4) No Damage
5) No Scratch
6) No water spot S.O Nil 1
C.E 7

E.U 3 7
O.S Nil 1
M.C Nil 1
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1 7
M.C Nil 1
Cissing
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Damage
N.O Nil 1 SC
S.O Nil 1
C.E 7

E.U 3
most of customer i.e.> 50% 7
O.S Nil 1
M.C Nil 1
SC SC
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Water spot
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3 SC SC
7
O.S Nil 1
M.C Nil 1
M.C Nil 1
300 Baking 1) No Damage Damage

N.O Nil 1 SC
3) No Dust/Lint
4) No warpage, bend
5) No over bake S.O Nil 1
6) No under bake

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
SC
SC SC
Paint cracking
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Dust/Lint
N.O Nil 1
S.O Nil 1
C.E 7 7

E.U 3
O.S Nil 1
M.C Nil 1
Warpage/ Bend
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Over bake
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
7
Unnder Bake
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
310 Cooling 1) No damage Damage

N.O Nil 1 SC
2) No scratch
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1 SC
M.C Nil 1 SC SC
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
320 Pre checking 1 ) No Orange peel, 1 ) Orange peel,

2) No Over spary, N.O Nil 1
3) No Uncover
4) No Rundown,
5) No Dust,
6) No lint, S.O Nil 1
7) No Blister,
8) No Cissing,
9) No Cracking,
10) No paint peel off Parts with visual defects. A portion of the
C.E 7
11) No bend parts may have to be scrapped.
12) No pin hole,
14) No Dry finish (Rough paint
surface), E.U 3
15) No Mottling,
16) No Scratch,
17) No Spitting,
18) No Water spot, O.S Nil 1
19) No Damage
M.C Nil 1
2) Over spary,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
3) Uncover
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
4) Rundown,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
5) Dust,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
6) lint,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
8) Cissing,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Paint cracking
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
12) pin hole,

N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
surface), N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
15) Mottling,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
17) Spitting,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
18) Water spot,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Damage
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
20) Gloss variation
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
21) Shade variation

N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Paint peel off
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Bend
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
330 Sanding defect on 1) No Scratch, Damage
N.O Nil 1 SC
part 2) No Damage
3) No incompleted sanding of
defect
S.O Nil 1 SC

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Scratch
N.O Nil 1 SC
S.O Nil 1 SC

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Incomplete sanding
N.O Nil 1
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
340 Polishing of sanding 1) No Damage Damage

N.O Nil 1 SC
part 2) No Scratch,
4) No sanding mark
S.O Nil 1 SC

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Scratch
N.O Nil 1 SC
S.O Nil 1
C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Gloss variation
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
7
O.S Nil 1
M.C Nil 1
Sanding mark
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1 7
350 Inspection 1 ) No Orange peel, 1 ) Orange peel,

2) No Over spary, N.O Nil 1
3) No Uncover
4) No Rundown,
5) No Dust,
6) No lint, S.O Nil 1
7) No Blister,
8) No Cissing,
9) No Cracking,
10) No paint peel off Parts with visual defects. A portion of the
C.E 7
11) No bend parts may have to be scrapped.
12) No pin hole,
12) No pin hole,
14) No Dry finish (Rough paint
surface), E.U 3
15) No Mottling,
16) No Scratch,
17) No Spitting,
18) No Water spot, O.S Nil 1
19) No Damage
22) No sanding mark M.C Nil 1
2) Over spary,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
3) Uncover
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
4) Rundown,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
5) Dust,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
6) lint,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Blister
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
8) Cissing,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Paint cracking
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
10) Sanding mark,

N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Sanding mark
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
12) pin hole,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1

surface), N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
15) Mottling,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
17) Spitting,
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
18) Water spot,

N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Damage
N.O Nil 1 SC
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
20) Gloss variation

N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
21) Shade variation
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
Bend
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
Paint peel off
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
360 Unloading 1)No Scratch, Damage

N.O Nil 1 SC
2) No Damages,
3) No Dent
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1 SC SC
M.C Nil 1
Scratch
N.O Nil 1 SC
S.O Nil 1

C.E 7
7

E.U 3
O.S Nil 1
M.C Nil 1
Dent
N.O Nil 1
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
360.'1 Demasking 1) No Mist Spray on masked Mist Spray on masked portion

portion, N.O Nil 1
2) Finish ok.
S.O Nil 1

C.E 4
4
E.U 3
O.S Nil 1
M.C Nil 1
Finsih Ok
N.O Nil 1
S.O Nil 1

C.E 4 4

E.U 3
O.S Nil 1
M.C Nil 1
Paint cracking
N.O Nil 1
S.O Nil 1

C.E 7

E.U 3
O.S Nil 1
M.C Nil 1
7
370 Loading on Trolley 1) No Scratch, Damage

N.O Nil 1 SC
2) No damages,
3) No dent
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1 SC SC
M.C Nil 1
Dent
N.O Nil 1
S.O Nil 1

C.E 7
7
E.U 3
O.S Nil 1
M.C Nil 1
Handling scratches,
N.O Nil 1 SC
S.O Nil 1

C.E 7
7

E.U 3
O.S Nil 1
Handling scratches,
M.C Nil 1
A Detection for failure mode

B Detection for cause
C Prevention for cause
Rev No Date Description of revision

PFMEA
FMEA No.:
Origin Date/No.: Rev. Date/No:
Prepared By :
sc
ATOR SAFETY|| M.C- MACHINE SAFETY, sc
R
Current Process Control Current Process Control
Potential Causes O PREVENTION DETECTION D SO P
N
2 A. 100% inspection of parts by operator
B.1) 100% inspection of label on trolleys by

Material Mixed up in WIP storage 2 Identification of trolley or boxes or bean
operator.
B. 1) Verification during process audit and

Unskilled operator 2 Skill person deployed
LPA
WIP Storage location is not define for B.1) Self inspection by operator for storage
2 Specific trolleys and location define for all parts
molded part. and trolleys.

Packing standard not defined 2 1) Packaging standard display at station
LPA
Packing material not available 2 1) Min max level define for each part B 1) empro alert.

Unskilled operator 2 1) Skill person deployed
LPA
Cleaning procedure revised to add cleaning of

Existing cleaning procedure not suitable to
2 bumpers/parts with cloth from inside where the 1) Self inspection by operator
remove these dust particles / flashes. flash/dust is sticking at back side of parts.
A. 100% inspection of parts by operator

6
B. SPC (p/np chart)

1) Part storage trolley damage 2 Premaintainance of trolley LPA
2) Self inspection by operator
2) Damage during handling 6 Training to operator for handling of parts 2) Self inspection by operator

3) Standard packagiing not available 2 Packaging define for all parts LPA
4) PPE not use by operaator 2 Training to operator for PPE 1) Self inspection by line leader
1)Ok & Not ok material mixed up in 1) Self inspection of molded part by operator
2 1) WI display in loading area
molding. and line engineer in between.
2) Part skiped from inprocess inspection 2 2) Periodical training by operator 2) Self inspection
3) Reworked not done by operator 2 3)Trecebility marking on parts for rework. self inspection by operator
B.1) 100% inspection of label on trolleys by

Material Mixed up in WIP storage 2 Identification of trolley or boxes or bean
operator.

Unskilled operator 2 Skill person deployed
LPA
WIP Storage location is not define for B.1) Self inspection by operator for storage
2 Specific trolleys and location define for all parts
molded part. and trolleys.

LPA

LPA

6
B. SPC (p/np chart)

1) Part storage trolley damage 2 1) Premaintainance of trolley LPA
2) Damage during handling 6 2) Training to operator for handling of parts 2) Self inspection by operator

3) Standard packagiing not available 2 ) Packaging define for all parts LPA
4) PPE not use by operaator 2 2) Training to operator for PPE 1) Self inspection by line leader
1)Ok & Not ok material mixed up in 1) Self inspection of molded part by operator
2 1) WI display in loading area
molding. and line engineer in between.
2) Part skiped from inprocess inspection 2 2) Periodical training by operator 2) Self inspection
3) Reworked not done by operator 2 3)Trecebility marking on parts for rework. self inspection by operator
4
1) identification not done on diecuts 1) WI display on masking table Self Inspection by operator
2
2) Periodical Training to masking & loading
2) Unskilled operator Self Inspection by operator
2 operator
3) Incoming inspection in masking area Self Inspection by operator

2
4) Incoming inspection by paint shop engineer

Self Inspection by operator
before GRIN approval
2
Operator pressed the fine line more 2 Point added in work instruction Self Inspection by operator
Fine line get loose 3 Squeeze provided for pressing the fine line Self Inspection by operator
1. Point of Squeeze application mention in

Operator not able to stick the fine line due Masking Work instruction
4 Squeeze provided for pressing the fine line
to groove area 2. Training to be given to operator for using
the squeeze
No grove at c piller due to that uniform

4 Masking SOP updated Self Inspection by operator
masking is difficult

4
(1) Monitoring & note down LUX in process

1) Tube rod not in glow condition Self inspection by Process engineer
monitoring sheet
2
2) Monitoring & note down LUX in process
2) LUX level not checked Self inspection by Process engineer
2 monitoring sheet
3) Glass not properly cleaned 3) Maintainace plan Self inspection by Process engineer
2
4) Use of 3 fine line Tape in operation 2 Fine line sequence update in SOP Self inspection by Process engineer
1. Point of Squeeze application mention in

Operator not able to stick the fine line due Masking Work instruction
Squeeze provided for pressing the fine line
to groove area 2. Training to be given to operator for using
4 the squeeze
No grove at c piller due to that uniform

Masking SOP updated Self Inspection by operator
masking is difficult
4
inspection by QA Inspector with

3
spectophotometer
Pipe not cleaned 2 Flushing of pipe at every color change Self inspection by operator
Self inspection by operator and note down the

Fan Pattern Application not proper. 2 Fan pattern define of every part
reading durng startup
Self inspection of operator for due date of

Instruments not calibrated 2 Instrument calibration frequency define
calibration
Preventive Maintainance of water flow

Water flow plates/venturi Not cleaned 2 Self inspection by maintainace engineer
plates/venturi Not cleaned
Spray gun cleaning at evry startup & Preventive

Spray gun not cleaned 2 Self inspection by operator
Maintainance of gun
Fixture cleaning frequency define and Preventive

Fixture not cleaned. 2 Self inspection by operator for fixture
Maintainance of fixture
Interior booth cleaning not proper/not done 2 Preventive Maintainance of Booth Self inspection by maintainace engineer
Light not proper 2 Preventive Maintainance of lights Self inspection by maintainace engineer
Booth humidity define for all booth and monitor Self inspection by operator and note down the
Booth Humidity high 2
at evry shift reading in process/ startup sheet
Booth Humidity low 2
Booth temp define for all booth and monitor at Self inspection by operator and note down the
Booth Temp high 2
evry shift reading in process/ startup sheet
Booth Temp low 2
Gun flow rate define for all all parts and monitor Self inspection by operator and note down the
Gun Flow Rate Low 2
Gun Flow Rate High 2
inspection by inprocess engineer and note

Air velocity define for all booth and monitor at
Air velocity high 2 down the reading in air velocity monitoring
evry week
sheet

Air velocity low 2 down the reading in air velocity monitoring
evry week
sheet
Gun pressure define for all all booth and monitor Self inspection by operator and note down the
Compressed air pressure high 2
Compressed air pressure low 2
Distance between componant and gun is Distance between component and gun fixed for
2 Self inspection by operator
less all parts
Both maintainace not done 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Air supply filters not cleaned/change 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Plenum chamber door open 2 Automatic door closer of all booth Self inspection by maintainace engineer
Painting sequence define for all parts nad Self inspection by operator & line engineer in
Painting sequence of part not define 3
training to operator between
Biscuit area masking started for RP part 1. Biscuit area check point added in AIS
RP part not route through masking station 2. Checking sequence added in AIS
2
due to Point missed during SOP prepration
1. SOP made and displayed for paint

1. Pre Paint batch approval for shade selection.
Without tinting paint use 2 2. Green tag stick with titing operation by QA for 2. Checking sequence added in AIS
all paint tins
2 100 % Visual inspection by QA Inspector


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Painting sequence of part not Painting sequence define for all parts nad Self inspection by operator & line engineer in
2
define/followed training to operator between

Incorrect booth balancing Booth balancing done before painting
reading in process/ startup sheet
2

2
B. SPC (p/np chart)

Gun pattern not ok 2 Fan pattern define of every part

calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts
Painting sequence of part not define/ Painting sequence define for all parts nad Self inspection by operator & line engineer in
2
followed training to operator between
Parameter checking and note down during Self inspection by operator and note down the
Booth Parameter 2
startup and color change reading in process/ startup sheet

Painting Gun 2 Self inspection by operator
Maintainance of gun
Low Lux Level 2 Preventive Maintainance of booth as per plan nspection by QA engineer by lux meter
Stroke miss 2
Skip out Operation 2 Training to operators as per plan Training sheet records
VARIATION IN PAINT SHADE 2 Incoming Inspection of paint Mixing record of paint
WRONG TYPE OF MATERIAL 2 Incoming Inspection of paint Mixing record of paint
Painting application wrong 2
PROCEDURE NOT UPDATED 2 verification of WI during LPA Audit NC closure system
WRONG PROCEDURE ADOPTED 2 verification of WI during LPA Audit NC closure system
Air pressure gauge not available 2

Air pressure guage not working 2 Preventive maintainance of guage
DFT high 2 DFT define for all parts Inspection by QA inspector
Self inspection by operator & line engineer in

Excess painting 2 Painting sequence and stroke define
between
Conveyor speed fixed for flash off in auto Inspection by line engineer & maintainance
Conveyor speed less 2
programme engineer by contolled panal
1) Painting sequence define for all parts nad

Corner area skipped during painting 2 training to operator
between
2) Brush touch up done
Jigs are corrected to controlling the painting

Pinting jigs ate bend 2 Inspection by Paint shop operator
operation

LPA

LPA

6
B. SPC (p/np chart)
molded part received in warpage condition 2 Inspection of part at loading by loading operator (1) Self inspection by operator
Wrong fixture use. 2 Part wise fixture matrix display for all component (1) Self inspection by operator
Fixture not cleaned. 2 Preventive Maintainace of fixture (1) Self inspection by operator
Fixture damage,warpage, bend. 2 Preventive Maintainace of fixture (1) Self inspection by operator
Loading position not defined 2 Part wise fixture matrix display for all component (1) Self inspection by operator
warpage at supporting corner due to 1. Storage area defined for all hanger storage. B. 1) Verification during process audit and
2
storage area not defined 2. Storage rack made for all hanger. LPA
Loading method is incorrect due to Part B. 1) Verification during process audit and
2 New hanger to be design for complet locking
resting position mismatch LPA
Hanger sharp as a welding burr on hanger Addition of " No Sharp corner " point in hanger
2 (1) Self inspection by operator
due to poor hanger repairing wrapping checksheet
Trolley has been made for keeping & movement
Hanger bend 6 (1) Self inspection by operator
of the S-18 hanger
Hanger locking position change 3 Preventive Maintainace of fixture (1) Self inspection by operator
Locking to be stress more as lock width is

3 Preventive Maintainace of fixture (1) Self inspection by operator
more
Hanger lock impression on part 3 Preventive Maintainace of fixture (1) Self inspection by operator
HANGER LOCK IS BEND 3 Hanger lock height increase for better locking (1) Self inspection by operator
Preventive Maintainace of fixture & Design

Hanger sharp edges 6 (1) Self inspection by operator
change for hanger edge
1. location change for hanger movement

Less space available for hanger movement 4 (1) Self inspection by operator
2. Preventive maintainace of fixture
Hanger kept on floor as location ot identified
3 Storage location define (1) Self inspection by operator
for storage of hanger
Hanger bend due to hanger edge is more out Preventive Maintainace of fixture & Design
from corner change for hanger edge
Hanger bend due to distance between hanger
3 Hanger hook distance increase (1) Self inspection by operator
hook is less
6
Part received in damage condition 2 Inspection of part at loading by loading operator (B) Self inspection by operator
1) Periodical Training to loading operator 2) (1) Self inspection by operator

Component damaged during loading 2
Opertor observation 2) Supervisor daily work management record
Fixture damage,warpage, bend. 2 Preventive Maintainace of fixture (1) Self inspection by operator
Locking position not defined 2 Part wise fixture matrix display for all component (1) Self inspection by operator
Part not locked with hanger completely 2 Preventive Maintainace of fixture (1) Self inspection by operator
Part store after painting in polybag insist of

Tai vac cover due to Operator unawareness 2 Work instruction display (1) Self inspection by operator
about tai vac cover
1. Stopper no.43 to stopper no.44 conveyor

1. Due to continues tolley moment & joints ,parts alignment done with support fit stud
conveyor weight stud quality get poor & lock nut
2. High tensil strenght stud provided
1. Trolley not kept parellel to conveyor 2 Point added in work instruction (1) Self inspection by operator
2. Hanger base lock is crack 2 Preventive Maintainace of fixture (1) Self inspection by operator
Locking point have no support 2 Preventive Maintainace of fixture (1) Self inspection by operator
Dolly get slip from conveyor at loaing stage

2 Repaired the conveyor track (1) Self inspection by operator
as conveyor track is wear
Check sheet to be made for checking the dolly

Dolly steam moving plate bend 2 (1) Self inspection by operator
during new dolly loading
Sample dolly hanger stuck to the part 2 Gangway mark and instruction displayed (1) Self inspection by operator

1. Dolly replaced with old dolly for cleaning 2 (1) Self inspection by operator

2. Dolly steam is loose 2 (1) Self inspection by operator
part fall down from hanger because out

6 Preventive Maintainace of fixture (1) Self inspection by operator
side hanger bend
Metal to plastic part contact 5 Leather cushing provide on piller Startup check sheet of loading
Poor strenght of part due to rib broken at

3 Thickness increase and correction done on tool (1) Self inspection by operator
hanger mounting part

5
B. SPC (p/np chart)
received parts having scratch 2 Inspection of part at loading by loading operator (1) Self inspection by operator
1) Periodical Training to loading operator 2) (1) Self inspection by operator

Component scracth during loading 5
Opertor observation 2) Supervisor daily work management record
Due to pillar in between loading area

5 Leather cushing provide on piller Startup check sheet of loading
scratch generated
4 100% visual inspection by QA inspector
Preventive Maintainace of loading area for

Dust in loading area 2 Dust count by inprocess inspector
cleaning
Dust from fixture 4 Preventive Maintainace of fixture (1) Self inspection by operator
Preventive Maintainace of dolly during loading,

Dust from dolley . 2 (1) Self inspection by operator
Greece apply on dolly
Wrapping done with the srink wrap insist of

3 Point added on Preventive maintaince of fixture (1) Self inspection by operator
sticky tape
2 100% visual inspection by operator
Loading position not defined 2 Part wise fixture matrix display for all component (1) Self inspection by operator
Part storage and identifcation in trolley as per

Part mix up in receipt condition 2 (1) Self inspection by operator
packing standard
2 100% visual inspection by loding operator
fixture damage or warpage 2 Preventive maintainace of fixture fixture verificatiob by operator during loading
Daily stock monitoring by PPC

less quantity supply from molding 2 Min/max stock level define after molding
self inspection by loding and air blowing

part fall down from hanger 2 locking position define
operator
Dust in air blow area 2

Preventive Maintainace of loading area for cleani Dust count by inprocess inspector
Dust from fixture 4 Preventive Maintainace of fixture Self inspection by operator

Dust from dolley . 2 self inspection by operator
Air blow nozzle design to be changed to jet type

No air blow 2 self inspection by operator
from exisitng point type.

6
B. SPC (p/np chart)
Gun strike on part 2 self inspection by operator

Distance standardise for air application
PPE not used by operator 2 PPE matrix display at work station self inspection by operator
Self inspection by operator & Process

Incomplete IPA Wiping on part 2 1) WI display at IPA wiping area
engineer in between.
1) Skill person deployed B. 1) Verification during process audit and

Unskill Operator 2
2) Periodical training to operator LPA
1) WI display at IPA wiping area for usage of

cloth Self inspection by operator & Process
Lint free cloth not use 2
2) Sample display of lint free cloth in IPA engineer in between.
Application booth
Skip out from operator 2 1) Periodical Training operator Monitoring of skill level in record
1) Incoming inspection by QA engineer before

Wrong grade IPA. 2 Incoming Inspection
GRIN approval

Sequential wiping not done, 2 1) WI display at IPA wiping area
1) Incoming inspection by QA engineer before

Contamination in IPA 2 Incoming Inspection
GRIN approval
Wrong supply from suplier 2 verification from challan & TC Incoming Inspection
Wrong tag on container 2 Suplier Awareness Incoming Inspection

Cloth change frequency not followed 2 Cloth changing frequency define in WI
2 100% visual inspection by operator


Unskill Operator 2 Periodical Training operator

Lint free cloth not use 2 cloth 2) Sample display of lint free cloth in IPA
Application booth
Skip out from operator 2 1) Periodical Training operator Monitoring of skill level in record
(1) Incoming inspection by QA engineer before

GRIN approval


GRIN approval

spray is used to avoid catching on part 2
2


Lint free cloth not use 2 cloth 2) Sample display of lint free cloth in IPA
Application booth
Skip out from operator 2 Periodical Training operator Periodic Training to operator

GRIN approval


GRIN approval

Preventive Maintainace of loading area for

Dust in air tag rag area 2 Dust count by inprocess inspector
cleaning


Lint in air tag rag area 2

Lint from fixture 2 Preventive Maintainace of fixture (1) Self inspection by operator

Lint from dolley . 2 self inspection by operator

Dust in antistatic area 2

Inspection by process inspector by adhesion

2
tape

air blown not uniform 2 Work Instruction display in process area

Application not as per Work instruction 2 Work Instruction display in process area
1) Self inspection by operator & inprocess

Transformer not ON or not working 2 Checking during start up engineer in between. 2) Static charge
measurement on part

Skip out from operator 2 Work Instruction display in process area engineer in between. 2) Static charge
measurement on part

Air pressure low 2 Air pressure min-max specification fixed engineer in between. 2) Static charge
measurement on part

Ionizer not working 2 Preventive Maintainace engineer in between. 2) Static charge
measurement on part

Gun trigger not working 2 Preventive Maintainace Of Gun engineer in between. 2) Static charge
measurement on part
Inspection by process inspector by adhesion

2
tape
Excess Flaming 2 WI display for partwise flaming Surface tension checking by ink test
Self inspection by masking operator &

High Gas pressure 2 Gas pressure set in control panel
maintainance engineer in between.
Self inspection by masking operator &

Variation in flame 2 Flame setup during starup for blue flame
maintainance engineer in between.

2 Inspection by operator by dyne ink pen
Improper flaming 2 WI display for partwise flaming Surface tension checking by ink test
Self inspection by operator & maintainance

High Gas pressure 2 Gas pressure set in control panel as per WI

Low air pressure 2 Air pressure set in control panel as per WI

Air not circulating to gun from compressor 2 Preventive Maintainace of compressor

Variation in flame 2 Flame setup during starup for blue flame
2 Inspection By QA inspector
(1) Painting specification sheet F/PS/001/058

1) Painting system not defined 2 Inspection by inprocess QA Engineer
Display in paint mixing
(1) Painting specification sheet F/PS/001/058 Self inspection by operator & counter check
2) Wrong Hardner use 2
Display in paint mixing by line engineer in between
3) Expaired paint 2 Life checking for evry new batch Empro
4) Mixing Ratio (Primer : Hardner:Thinner ) (1) Painting specification sheet F/PS/001/058 Self inspection by operator & counter check
2
not maintained Display in paint mixing by line engineer in between
1) Painting specification sheet F/PS/001/058

Self inspection by operator & counter check
1) Painting system not defined 2 Display in paint mixing recording of viscocity for
by line engineer in between
evry batch
1) Ford cup cleaning SOP display at paint Self inspection by operator & counter check
2) Ford Cup not cleaned 2
kitchen by line engineer in between

3) Paint Kitchen Temp. High/Low 2 3) Temp checking during viscosity checking.

4) Viscocity at lower side of Ground coat 4 Point added in Paint System

1) Paint drum not clean 2 1) Paint mixing SOP WI/PS/STD/015

2) Paint mixing container not clean 2 1) Paint mixing SOP WI/PS/STD/016
1) Paint Filteration Self inspection by operator & counter check

3) Dust in paint /Hardner / Thinner 2
2) Paint mixing SOP WI/PS/STD/016 by line engineer in between
4) Paint filteration done with single layer 3 Stage filter provided and Point added in work Self inspection by operator & counter check
4
filter instruction by line engineer in between

5) Paint pump system not OK 2
1) Mixing Ratio (Primer : Hardner:Thinner ) 1) Painting specification sheet F/PS/001/058 1) Self inspection by operator & counter
2
not maintained Display in paint mixing check by line engineer in between
1) Painting specification sheet F/PS/001/058 1) Self inspection by operator & counter

2)Wrong hardner, thinner , primer use 2
Display in paint mixing check by line engineer in between

1) Paint drum not clean 2

3) Contamination in paint /Hardner / Trial of paint for batch approval before using to Self inspection by operator & counter check
2
Thinner production. by line engineer in between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts


between
High Air pressure of gun due to Difficult to

Gauge is cleaning
check 2 Self inspection by operator
air presure on Gauge , as Over spray on Ok Range mark with green & not ok with red.
gauge Plastic covers to gauge which is eazy to change

4
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts
2
Booth Parameter 2

Maintainance of gun
Stroke miss 2

Upper Hanger bend 4 Addition support given to hanger lock
between

1) Painting sequence define for all parts and Self inspection by operator & line engineer in
Excess painting 2
1) Painting sequence define for all parts and

between
4
B. SPC (p/np chart)


calibration


Spray gun nozel choked up 2 Self inspection by operator
Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Painting Gun not cleaned 2 Self inspection by operator
Maintainance of gun
low Lux Level 2 Preventive Maintainance of booth as per plan inspection by QA engineer by lux meter
Operator Skill 2 Skill evaluation Updation of skill matrix
Procedure Violation 2 Training to operators as per plan Training sheet records
Acceptance Criteria not Clear 2 Training to operators as per plan Training sheet records
Lack of Awareness 2 Training to operators as per plan Training sheet records
New Operator 2 Training to operators as per plan Training sheet records

between
Air pressure guage not working 2

Air pressure gauge not available 2 Preventive maintainance of guage
Low hiding power 2

Hiding power check during bath approval Inspection by QA Engineer

Paint flow variation 4 Stratup cum setup check sheet updated

calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun
Lux Level 2 Preventive Maintainance of booth as per plan nspection by QA engineer by lux meter

Air pipe dust 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer

Hanger overspray 2 Preventive Maintainance of hanger as per plan
between

Trolley overspray 4 Preventive Maintainance of trolley as per plan
between
ASU Filter not ok 2 Preventive Maintainance of booth as per plan

Trolley cleaning 2 Preventive Maintainance of trolley as per plan
between
Booth cleaning not done 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer

6
B. SPC (p/np chart)

Gun striking to component 2 Gun pipe length fixed as per part.
2) Gun distance to component during painting Self inspection by operator & counter check
Handling scratch 6
must be 6-10 inches by line engineer in between
3) Handling scratch during polishing & sanding Self inspection by operator & counter check
PPE not used by operator 2
avoided by use of protective covers by line engineer in between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun
Cleaning with emery paper 2 Training to operators as per plan Self inspection by operator


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

gun nozel block 2 Self inspection by operator
Maintainance of gun
Conveyor speed high / less 2


Pipe get bend as excess length of pipe 2 length of pipe fixed
between
(1) Self inspection of molded part by operator

1) water on part from filters 2 1) preventive maintainance of filters
and line engineer in between.

2) water lickage from booth 2 2) preventive maintainance of booth


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
water tank leakage 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Leakage 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Leakage from pipe 3 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Water tank leakage 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer

Contaminated air 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Nozzle not clean 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Water on component 5 1.Hanger to be store under oven area Self inspection by Shift engineer
Due to water on hanger water mark observed on 1. Packing Station defined

1. Location defined for hanger storage of S-18
component as No STD location defined for 4 2. Minimum Skill level defined for packing
storage the hanger Spoiler
operation

5
B. SPC (p/np chart)

calibration


Maintainance of gun

Booth Temp high 5
evry color change reading in process/ startup sheet
Booth Temp low 2
Gun Flow Rate Low 2
Gun flow rate define for all parts and monitor at Self inspection by operator and note down the

evry week
sheet

evry week
sheet
less all parts
Painting sequence define for all parts nad

Excess painting 2 Self inspection by maintainace engineer
training to operator
Booth balance not ok 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer
Air pipe chokeup 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer

stroke applied high 2

DFT low/high 2 Inspection by QA
1)Clean the paint deposited in blower impeller
ASU Blower get trip due to over current , venture
as Blower impeller jam due to Paint 2 2)Frequency of cleaning of ASU is hange from Self inspection by maintainace engineer
deposted in blower impeller venture monthly to 2 time in a month
Autostart system implemented during electricity Inspection by line engineer & maintainance
ASU blower get trip due to electricity off 2
get off engineer by contolled panal
Due to summer season thinner evaporation 1. Additive mixed for slow evapouration Self inspection by operator & line engineer in
3
is fast 2. Point added in work instruction between
1. Paint Mixing Chart Self inspection by operator & line engineer in

Application Viscocity Low 4
2. Paint Mixing Report between

Mixing Pot not clean 4 Setup check sheet
between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2
evry week
sheet

evry week
sheet
less all parts




between

6
B. SPC (p/np chart)

Part fall down from hanger 6 Preventive Maintainance of all hangers
Self inspection by loading operator &

Antiback stopper not working 2 preventive maintainance of conveyor
Maintenance engineer in between.
locking point disturb due to paint overspray
2 preventive maintainance hanger Self inspection by paintshop engineer


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

hanger welding is weak 2 Welding point improved
between

Weared hanger 2 Excess support given to hanger
between
Point added in PM check sheet for Stopper limit Self inspection by operator & line engineer in
Faulty in limit switch 2
switch function. between
Part fall doe from hanger due to operator not Self inspection by operator & line engineer in
3 SOP is updated
kept dolly parellel to conveyor between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun

Hanger overspray 2 Preventive Maintainance of trolley as per plan
between

between

between
Booth cleaning 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer

4
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

High DFT 2 Painting stroke define for all part
between




Paint Batch wrong 4 Slow Evapourating solvent added
between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

between



Booth balancing not done 2 Booth balancing done to avoid overspray Inspection by QA
100% visual inspection of part by QA

4
inspector
(1) Dust count in flash off zone by inprocess

Dust in flash off booth 2 Preventive Maintainance of flash off zone weekly
engineer by dust count meter

Flash off booth door not cleaned 2 Preventive Maintainance of flash off zone weekly
Preventive Maintainance of flash off zone ASU (1) Dust count in flash off zone by inprocess
ASU filter not clean in flash off booth 2
weekly engineer by dust count meter
Preventive Maintainance of flash off zone ASU (1) air velocity checking in flash off zone by
Booth balancing not ok in Flash off booth 2
weekly inprocess engineer Anomometer

5
B. SPC (p/np chart)
Less time in flash off zone 2
More time in flash off zone 2
Inspection by line engineer & maintainance
Conveyor stopper not working in flash off 2 Preventive Maintainance of conveyor as per plan
engineer by contolled panal
Conveyor speed high in flash off 2

Flash off booth temp high 5 Contineous ASU Air circulating in flash off booth
engineer by thermometer

Flash off booth temp low 2 Contineous ASU Air circulating in flash off booth

Booth balance not ok 3 Preventive Maintainance of conveyor as per plan
Due to summer season thinner evaporation is Inspection by line engineer & maintainance
fast
3 Slow Evapourating solvent added
Lesson learnt displayed at primer & base coat

Slow Evapouratiiong Thinner 4 Thinner will be add in every rainy season
paint kitchen

3
inspector




6
B. SPC (p/np chart)
Antiback stopper not working in flash off Self inspection by loading operator &
2 preventive maintainance of conveyor
zone Maintenance engineer in between.
Conveyor speed less in flash off 2

Tranfer unit no.2 cylinder not operating due

2 Air pipe replaced aand monitering started (1) Self inspection by operator
to Tranfer unit no.2 air supply pipe get burst

Part fall down from hanger 6 Preventive Maintainance of all hangers & Dollly

Dolly steam bolt is bend 3 Preventive Maintainance of all hangers & Dollly

6
B. SPC (p/np chart)


5
inspector


2) water lickage from ASU 2 2) preventive maintainance of ASU
Water on component 5 Plastic place on upperside of ASU Self inspection by maintainace engineer

component as No STD location defined for 2. Minimum Skill level defined for packing
operation

2

evry batch



3 Stage filter provided and Point added in work Self inspection by operator & counter check
Paint filteration done with single layer filter 4
instruction by line engineer in between
2



2

2
spectophotometer


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
2

all paint tins


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
2



calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Lack of Awareness 2
Water leakage from pipe 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer


operation

5
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Painting sequence of part not Painting sequence define for all parts and Self inspection by operator & line engineer in
2
Work Instruction not Available 2 Work instruction displayed Self inspection by operator
Procedure not Followed 2 Training to operators as per plan Self inspection by operator
PPE Not used 2 Training to operators as per plan Self inspection by operator
Gun pressure define for all booth and monitor at Self inspection by operator and note down the

Painting sequence not followed 2 Training to operators as per plan Self inspection by operator
WI not followed 2 Training to operators as per plan Self inspection by operator
Paint system defined & Fast evaourating solvent

Paint thinner attack subsequent coat 5 Self inspection by operator
added on primer
PROCEDURE NOT UPDATED 2 Training to operators as per plan Self inspection by operator


calibration


Spray gun not cleaned / Nozel block 3 Self inspection by operator
Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts


between

Gauge is cleaning
Viscocity is on higher side due to tolerance Viscocity tolerance reduced and updated in paint
is high as per supplier reccomendation mixing system

2
B. SPC (p/np chart)


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts
2
Booth Parameter 2

Maintainance of gun
Stroke miss 2



between

between

Upper Hanger bend
between
4 Addition support given to hanger lock

4
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun
low Lux Level 2 Preventive Maintainance of booth as per plan nspection by QA engineer by lux meter


between

Low hiding power 2




calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun

between

between

between
5
B. SPC (p/np chart)

Handling Scratch 4


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

Maintainance of gun


between
5
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 5
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts




Checking & Repair all the pump & monitoring Inspection by line engineer & maintainance
ASU-3 Water pump get trip & have leakage 3
started in JH check sheet engineer by contolled panal
Due to summer season thinner evaporation is 1. Additive mixed for slow evapouration Self inspection by operator & line engineer in
fast
3
2. Point added in work instruction between


between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts




Mxing Pot not clean 3 Setup check sheet
between
6
B. SPC (p/np chart)

Part fall down from hanger 6 Preventive Maintainance of all hangers & Dollly




calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
between

between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

between



DFT low 2 Inspection by QA

4
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

between




Paint Batch wrong
between
4 Slow Evapourating solvent added


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

between



4
inspector



5
B. SPC (p/np chart)




Due to summer season thinner evaporation is

fast
3
Flash off time High due to Slow evaporating Lesson learnt displayed at primer & base coat
thinner
3 Thinner will be add in every rainy season
paint kitchen

3
inspector



2
inspector




6
B. SPC (p/np chart)



Part fall down from hanger Preventive maintance of All hanger and Dolly
6


6
B. SPC (p/np chart)


5
inspector


Water on component 5 Plastic place on upperside of ASU Self inspection by maintainace engineer

component as No STD location defined for 2. Minimum Skill level defined for packing
operation

2

evry batch




3 Stage filter provided and Point added in work Self inspection by operator & counter check
Paint filteration done with single layer filter 4
instruction by line engineer in between
2


1) Paint drum not clean 2

2

2
spectophotometer


calibration


Maintainance of gun
Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
2

all paint tins


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
2



calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Lack of Awareness 2
Water leakage from pipe 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer


operation

5
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Painting sequence of part not Painting sequence define for all parts and Self inspection by operator & line engineer in
2
Work Instruction not Available 2 Work instruction displayed Self inspection by operator
PPE Not used 2 Training to operators as per plan Self inspection by operator
Gun pressure define for all booth and monitor at Self inspection by operator and note down the

Painting sequence not followed 2 Training to operators as per plan Self inspection by operator
WI not followed 2 Training to operators as per plan Self inspection by operator
Paint system defined & Training to operators as

Paint thinner attack subsequent coat 5 Self inspection by operator
per plan
PROCEDURE NOT UPDATED 2 Training to operators as per plan Self inspection by operator

Fan Pattern Application not proper. 2 Flushing of pipe at every color change

calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

Settling of matting agent 4 Work instruction displayed
between


calibration


Spray gun not cleaned / Nozel block 3 Self inspection by operator
Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts


between

Gauge is cleaning

2
B. SPC (p/np chart)


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
air pressure high 2
air pressure low 2
less all parts
2
Booth Parameter 2

Maintainance of gun
Stroke miss 2


between

between

between

4
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun
low Lux Level 2 Preventive Maintainance of booth as per plan nspection by QA engineer by lux meter


between

Low hiding power 2




calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun

between

between

between

5
B. SPC (p/np chart)

Handling Scratch 4


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Booth Parameter 2

Maintainance of gun


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

Maintainance of gun


between




calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts
Water tank leakage 2 Preventive Maintainance of booth as per plan Self inspection by maintainace engineer


5
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 6
Gun Flow Rate Low 2

evry week
sheet
evry week
sheet
less all parts



Due to summer season thinner evaporation is 1. Additive mixed for slow evapouration Self inspection by operator & line engineer in
fast
2
2. Point added in work instruction between


between


calibration

Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts




Mixing Pot not clean
between
3 Setup check sheet

6
B. SPC (p/np chart)

Part fall down from hanger 6 Preventive Maintainance of all hangers & dolly




calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

between

between

4
B. SPC (p/np chart)


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet
evry week
sheet
less all parts

between




Paint batch wrong 4 Slow Evapourating solvent added
between


calibration


Maintainance of gun

Booth Temp high 2
Booth Temp low 2
Gun Flow Rate Low 2

evry week
sheet

evry week
sheet
less all parts

between


4
inspector


5
B. SPC (p/np chart)




Due to summer season thinner evaporation

3
is fast

3
inspector




6
B. SPC (p/np chart)



Part fall down from hanger
6 Preventive maintance of All hanger and Dolly


6
B. SPC (p/np chart)


5
inspector


Water on component due to water leakage

5 Plastic place on upperside of ASU Self Inspection by maintainance engineer
from building roof

operation

6
B. SPC (p/np chart)
Inspection by maintainance engineer &

Effective sufrace temperature not good 2
paintshop engineer in between
Temp setting of oven as per Specification of part

High temperature setting 2

Low temperature setting 2

Air flow not proper 2
oven booth balancing

Low LPG pressure 2
Monitoring on LPG regulator & set 1 to 1.5
Recirculation fan not working 2 Inspection by maintainance engineer

Preventive Maintainance of oven fans
Burner trip 2 Automatic conveyor stop.

Preventive Maintainance of burner & oven
Time not defined 2 Conveyor speed match with time required for Inspection by maintainance engineer
baking
Improper oven cleaning 2 Inspection by maintainance engineer

Preventive Maintainance of oven as per plan

Exceess temp of oven 2
Filter chocked 2 Inspection by maintainance engineer

Preventive Maintainance of oven & filter as per pl

Low temperature setting as per component 2

Baking system not defined 2 Baking system define for all parts

Part fall down from hanger 6 Preventive Maintainance of all hangers & dolly
1. Oven Pannel Fixed and Taken Upperside Inspection by maintainance engineer &
Metal to plastic part contact 5
2. Structure of Portion cutted paintshop engineer in between

2 3. Conveyor straighten and balance

2
B. SPC (p/np chart)





Low LPG pressure 2

Burner trip 2 Inspection by maintainance engineer

baking





Baking system not defined 2
Baking system define for all parts
4
100% visual inspection by QA inspector
1. Dolly cleaning started after oven cleaning to

Dust from dolly 2 Check point added in cleaning check sheet
avoid dust from oven spread on dolly.
2.Canopy cover / Canopy to be provided in flash Check point added in PM check sheet for
2
off zones to avoid paint spary on dolly condition monitoring.
Dust in oven 4 Preventive Maintainance of oven & filter as per Inspection by maintainance engineer
plan
Dut from ASU 2 Preventive Maintainance of oven & filter as per Inspection by maintainance engineer
plan
Black dust comes on parts inside the oven 3 Wet mopping started on daily basisi Dust criteria training given to inspector

B. SPC (p/np chart)
6





Low LPG pressure 2


baking


Filter chocked 2 Preventive Maintainance of oven & filter as per Inspection by maintainance engineer
plan


Damage of flap & Hot air duct In center Preventive Maintainance of oven & filter as per
3 Inspection by maintainance engineer
area more heat observed plan
Over baking due to Burner not off by Line

leader during lunch break as No procedure 3 Poka-Yoke to interlink conveyor & oven burner is Checking fixture to be develope for warpage
display. put in place to avoid manual mistakes.





Low LPG pressure 2

baking










Low LPG pressure 2


baking





6
B. SPC (p/np chart)
(1) Tact time less in cooling zone 2 1) Defined tact time for oven Check on PLC
2 2) Avoid manual stoppages of conveyor Check on PLC
2 3) Periodic Training to operators Check on PLC

Part fall down from hanger Preventive Maintainance of all hangers
6

Metal to plastic part contact 5 Cooling zone duct Taken Upperside
Marking done with the yellow tape &
3 instructionstick near area for not kepping any
thing on gangway
6
B. SPC (p/np chart)
(1) Periodic maintenance of ASU filters as per Inspection by maintainance engineer &
Filter Chocked 2
preventive maintenance plan paintshop engineer in between
Preventive maintenance plan not available 2
Damper position disturbed 2
2 100% visual inspection
No Defect samples displayed 2 Defect sample display for OK --NOT OK

clearification Inspection by QA engineer
Light not proper 2

Lux level monitoring Inspection by QA engineer

Glass not properly cleaned 2
Preventive Maintainance of glass & tube light
Revalidation frequency not decided 2

Verification by process audit
Acceptance criterial no clear 2

MSA as per plan f Inspection by QA engineer
Unskilled operator 2
Periodic training to operator Inspection by QA engineer
Inspection Not Done 2

Trecebility identification for all parts 100% visual inspection by QA inspector
Validated reference sample not available 2

Verification by process audit Inspection by QA engineer
Instrument not Calibrated 2

Material Dispatch directly to customer in

2
Urgency/Shortages
Firewall inspetion by operator 100% visual inspection by QA inspector
Master shade panel not available 2

Calibration of measuring instruments & gauges.
Error in measuring instrument & gauges,
2
Inspection by QA engineer

Light not proper 2


Preventive Maintainance of glass & tube light Inspection by QA engineer





2
Urgency/Shortages

2

B. SPC (p/np chart)
2

Light not proper 2



Acceptance criterial no clear 2 MSA as per plan Inspection by QA engineer




2
Urgency/Shortages

2

between
Defect see after fitment as welding point

3 SOP updated Inspection by QA engineer
not defined on part during design

B. SPC (p/np chart)
4

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2

B. SPC (p/np chart)
5

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2

B. SPC (p/np chart)
2

Light not proper 2








2
Urgency/Shortages

2

B. SPC (p/np chart)
2

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2
6 B. SPC (p/np chart)

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages
2

Light not proper 2








2
Urgency/Shortages

2
Hanger location define
Water on component due to no provision Inspection by maintainance engineer &
3
define for hanger storage paintshop engineer in between


Light not proper 2








2
Urgency/Shortages
2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2
STD shade panel procure
Batch to batch variation due to no standard
3
pannel available

Light not proper 2








2
Urgency/Shortages

2
1. Identification matix to be display at Loading
No sanding after previous coat due to area
3 2. Addition of Colour code Repaint tracebility in
Scuffing paper change
LPA
Contaminated mateial due to spray is using
by operator on mold as to avoid catching 3 Mold get polished Inspection by QA engineer
on part

Light not proper 2







2
Urgency/Shortages

2
6
B. SPC (p/np chart)

1) Improper handling of component 6 1) Incoming quality inspection of molded parts
2) Ring, Wrist watch, Belt cover wearing 4) Periodic Training to all operators involved in Self inspection by operator & counter check
2
during sanding handling parts by line engineer in between

6
B. SPC (p/np chart)

2

Sanding not done 2 WI display for sanding
Incominginspection of sanding paper & sanding Self inspection by operator & counter check
Wrong sanding paper use 2
paprer grade fixed by line engineer in between

Uniform & circular sanding not done 2 WI display for sanding
Periodic Training to all operators involved in Self inspection by operator & counter check
Excess Sanding 2
handling of painted components by line engineer in between

Change frequency not defined 2 Changing frequency define for sanding paper

6
B. SPC (p/np chart)

2
4) Periodic Training to all operators involved in Self inspection by operator & counter check
3) polishing Gun striking on component 2
handling of gun by line engineer in between

5
B. SPC (p/np chart)

2
4) Periodic Training to all operators involved in Self inspection by operator & counter check
3) polishing Gun striking on component 2
handling of gun by line engineer in between

wrong buffing pad 2 Periodic Training to all operators
Low air pressure 2
Changing frequncy and cleaning frequency Self inspection by operator & counter check
Dirty buffing wheel 2
define for buffing pad by line engineer in between
Excess Polishing 2

wrong grade polish 2 polishing cream specification mention in WI

wrong polishing cream use by operator 2 Polishing cream provide by line engineer
wrong polishing cream received 2 Incoming inspection of polishing cream Incoming inspection
Polishing Not done Completely 3 WI display for sanding & Polishing Incoming inspection

wrong buffing pad 2 Periodic Training to all operators
Low air pressure 2
Changing frequncy and cleaning frequency Self inspection by operator & counter check
Dirty buffing wheel 2
define for buffing pad by line engineer in between
Excess Polishing 2

wrong grade polish 2 polishing cream specification mention in WI

wrong polishing cream use by operator 2 Polishing cream provide by line engineer
Incoming inspection of polishing cream &

wrong polishing cream received 2 Incoming inspection
minimum - maximum level defined

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

B. SPC (p/np chart)
2

Light not proper 2







2
Urgency/Shortages

2

Upper Hanger bend
between
4 Addition support given to hanger lock

B. SPC (p/np chart)
4

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

B. SPC (p/np chart)
5

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

B. SPC (p/np chart)
2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages


B. SPC (p/np chart)
2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2







2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages
2

Light not proper 2








2
Urgency/Shortages

2

Light not proper 2








2
Urgency/Shortages


Light not proper 2








2
Urgency/Shortages

2
1. Identification matix to be display at Loading
No sanding after previous coat due to area
3 Inspection by QA engineer
Scuffing paper change 2. Addition of Colour code Repaint tracebility in
LPA
Use of 3 fine line tape in operation 4 SOP updated for 2 fine line use Inspection by QA engineer

6
B. SPC (p/np chart)
Improper identification on trolley 2 Work instruction, Identification tag on trolley Self inspection by operator
WI not available on unloading 2 WI display at Work station Self inspection by operator
trolley not available 2 Identified troley for all component Self inspection by operator
Self inspection by operator and line

Part fall down from hanger 6 Preventive maintance of All hanger and Dolly
engineering
Fog lamp/Craddle & spoiler to be store paint Self inspection by operator and line
Handling damage due to store not available 3
shop back side area engineering
No protection on corner 3 Protection tape to be apply on corner Self inspection by operator

5
B. SPC (p/np chart)
Tai vac cover not used on part due that
4 WI display at Work station Self inspection by operator
part get scratch
(1.) Worng out masking during process

(1) Self inspection by demasking & loading
upto primer 2 1) Work instruction display
operator

2 2) Periodic training to operators
operator

2 3) Check sheet for masking
operator

6
B. SPC (p/np chart)
(1) All defined specifications & parameters

for primer painting, base coat painting,
Stage wise process control sheet,FPA sheet,
clear coat painting & all three coats paint 2 1) Brain storming through visual display
In process parameter sheet
mixing ,masking, ipa wiping, flaming, Paint
baking, polishing not followed
2) Display of Painting specification sheet Stage wise process control sheet,FPA sheet,
2
F/PS/001/058 in paint mixing/booth are In process parameter sheet
Stage wise process control sheet,FPA sheet,

2 3) Periodical Training to operators
In process parameter sheet
Blue fine line removing method not Blue fine line removing method defined in work
4 Limit sample displayed on stage
defeined in work instruction instruction & Training given to operator

B. SPC (p/np chart)
4

Light not proper 2








2
Urgency/Shortages

2
Work instruction updated & Training given to
Wrong Grade matrail used due to cleaning operator
4
agent not define in work instruction
No stand for Cleaning thinner container 4 Plunger dispenser provided for cleaning thinner Check point add in Start up check sheet

6
B. SPC (p/np chart)
Metal to plastic part contact 5 Preventive maintance of trolly Self inspection by operator
No seperated compartment available for

4 Compartment provided for storage Self inspection by operator
each part in trolley
Distance between rack on trolley is less 3 Trolley rack height increase Self inspection by operator
WI not available loading 2 WI display at Work station Self inspection by operator

5
B. SPC (p/np chart)
WI not available loading 2 WI display at Work station Self inspection by operator
Revised byApproved By
Rev. Date/No:
Approved By :
R
Recomm. Resp & Target Date Action
Actions of completion taken S O D P
N
Conveyor to be made for part

28.11.2016
movement moulding to paint shop

28.11.2016
28.11.2016

28.11.2016
Hanger movement area to be
12.07.2016
increase

12.07.2016
increase

12.07.2016
increase
28.11.2016

12.07.2016
increase
All toucable portion cover with

04.10.2015
leather cushing

28.11.2015

04.10.2015
leather cushing

04.10.2015
leather cushing
28.11.2016
28.11.2016

04.04.2016
leather cushing
Shed to be made for hanger
25.11.2015
stoarage
25.11.2015
stoarage
Additive add in primer and base

25.08.2015 closed
coat
25.08.2015 closed
coat
25.08.2015 closed
coat
28.11.2016

28.11.2016
25.08.2015 closed
coat
28.11.2016

28.11.2016

28.11.2016
25.11.2015
stoarage

25.11.2015
stoarage
25.11.2015
stoarage
25.11.2015
stoarage

25.06.2016
coat
28.11.2015

28.11.2015
25.08.2015 closed
coat

25.08.2015 closed
coat
25.08.2015 closed
coat
28.11.2016

28.11.2016
25.08.2015 closed
coat
28.11.2016

28.11.2016

28.11.2016
25.11.2015
stoarage

25.11.2015
stoarage
25.11.2015
stoarage
25.11.2015
stoarage

28.11.2016
28.11.2015

28.11.2015
25.11.2015
stoarage
25.11.2015
stoarage

25.08.2015 closed
coat

25.06.2016
coat
25.08.2015 closed
coat
28.11.2016

28.11.2016
25.08.2015 closed
coat

28.11.2016
28.11.2016

28.11.2016

25.11.2015
stoarage

25.11.2015
stoarage

28.11.2016
28.11.2015
12.07.2016
increase
28.11.2016

28.11.2016
28.11.2016
25.08.2015 closed
coat
coat
28.11.2016
25.11.2015
stoarage

28.11.2016
28.11.2016

28.11.2016

28.11.2016

28.11.2016

28.11.2016

28.11.2016

28.11.2015

28.11.2015
25.08.2015 closed
coat
coat
28.11.2015
25.11.2015
stoarage
28.11.2016
28.11.2016

28.11.2016

28.11.2015
28.11.2015
closed
28.11.2016

28.11.2015

28.11.2015

28.11.2015
CP
Wrong part Part as per plan visual
Prototype Pre-Production / Pre-Launch DirectProduction issue
material Checked material visual
Operator Skill min L3 level visual 100%
Storage location is not define for
Location wise part storage visual
molded part.
Wrong packing as per packing std visual
Packing standard not defined as per packing std visual
100%
Packing material not available as per packing std visual
Moulded
material Operator Skill min L3 level visual
130 Trolley
Movement to Damage SC No Damage visual
paint shop Part storage trolley damage as per packing STD visual
100%
Damage during handling No Damage visual
Standard packagiing as per packing STD visual
PPE not use by operaator PPE as mention in WI visual 100%
Molding Defect ( Burr, Dent Mark/ sink mark,

dust, waviness, short molding, Flash, Parting As per master sample visual 100%
line, warpage.)
Wrong part Part as per plan visual

Direct material issue Checked material visual
100%
Operator Skill min L3 level visual
Storage location is not define for
Location wise part storage visual
molded part.
Wrong packing as per packing std visual
Packing standard not defined as per packing std visual
100%
Packing material not available as per packing std visual
Incoming Damage SC No Damage visual
LUX mete,
140 Inspection of Part storage trolley damage as per packing STD visual
work table 100%
molded parts
Damage during handling No Damage visual
Standard packagiing as per packing STD visual
PPE not use by operaator PPE as mention in WI visual 100%
Molding Defect ( Burr, Dent Mark/ sink mark,

dust, waviness, short molding, Flash, Parting As per master sample visual 100%
line, warpage.)
1. LUX Meter
Lux level 600-800 LUX . - 100%
2. Visually
Under masking (masking problem) No under masking visual 100%
1)Part damage or warpage No damage or warpage visual 100%
2) Unskill Operator L2 level visual 100%
3) Masking diecut not as per

as per design visual
design
4) masking Skip out from
no skip out visual
operator
Die cut not stick or partialy open Die cut pack to part visual
Masked area not fully covered mask area fuly vovered visual
100%
100%
masking not done masking as per aplicability visual
gaps on masked surface. no gaps visual
Wrong tape use as per design visual
Wrong masking diecuts as per design visual
Over masking (masking problem) No over masking visual 100%
1)Part damage or warpage No damage or warpage visual 100%
2) Unskill Operator L2 level visual 100%

design
4) Skip out from operator no skip out visual
Die cut not stick or partialy open Die cut pack to part visual
Masked area not fully covered mask area fuly vovered visual
100%
masking not done masking as per aplicability visual
gaps on masked surface. no gaps visual
Wrong tape use as per design visual
Wrong masking diecuts as per design visual
visual & By
Shade variation No shade variation
spectophotometr
100%
Masking table,
diecuts , tape
140.1 Masking
& Cutter,
demasking tool
1)Part damage or warpage No damage or warpage visual
Masking table,
diecuts , tape 2) Unskill Operator L2 level visual
140.1 Masking
& Cutter,
demasking tool
design
100%
5) Die cut not stick or partialy

mask area fuly vovered visual
open
6) Masking not done masking as per aplicability visual
Over spray No over spray visual 100%
1)Part damage or warpage No damage or warpage visual
2) Unskill Operator L2 level visual

design
100%
Die cut not stick or partialy open mask area fuly vovered visual
Booth balancing nor done no skip out visual
Uncover No Uncover visual 100%
1)Part warpage No damage or warpage visual
2) Unskill Operator L2 level visual

as per design visual 100%
design
Die cut not stick or partialy open mask area fuly vovered visual
Painting Jigs are bend No bend/damage visual
Dust No Dust visual 100%

1) Dust form masking paper No dust in masking paper visual 100%
1. LUX Meter
Lux level 600-800 LUX . - 100%
2. Visually
Warpage / Bend SC No warpage/Bend visual 100%
Damage/Scratch SC No damage visual 100%
Part damage or warpage No damage or warpage visual

Wrong fixture use. Fixture as per part fixture matrix visual
Fixture not cleaned. clean fixture visual
Component damaged during 100%
no damage visual
loading
Fixture damage,warpage, bend. no damage warpage fixture visual
Loading position not defined Fixture as per part fixture matrix visual
Dust No dust visual 100%
Dust in loading area No dust in area Dust count meter once
Loading of part Conveyor

150 on painting Trolley,
Dust from fixture No dust on fixture visual
hanger Fixtures
100%
Dust from dolley . No dust on dolly visual
Wrong bumper and Toe hook cover loading

Loading position not defined 4 bumper per fixture visual 100%
Part mix up in receipt condition seprate trolley for front bumper visual 100%
Bumper and toe hook cover loading missing
fixture damage or warpage no damage warpage fixture visual 100%
less quantity supply from

supply qty as per plan visual 100%
molding
part fall down from hanger As per Loading Fixture matrix visual 100%
Dust in air blow area No dust in area Dust count meter once
Dust from fixture No dust on fixture visual

100%
Dust from dolley . No dust on dolly visual
160 Air blowing air gun

Damage/Scratch SC No damage visual 100%
160 Air blowing air gun
Part damage or warpage No damage or warpage visual

Wrong fixture use. Fixture as per part fixture matrix visual
Fixture not cleaned. clean fixture visual
Component damaged during 100%
no damage visual
loading
Fixture damage,warpage, bend. no damage warpage fixture visual
Loading position not defined Fixture as per part fixture matrix visual
No Dust No Dust visual 100%
No oil mark No oil mark visual 100%
100%
No lint No Lint visual
5 Parts
Partial IPA Wiping on part IPA Wiping on overall part visual

100%
5 Parts
IPA cloth, ipa,
170 IPA Application
lint free cloth
Lint free cloth not use lint free cloth visual 100%
Wrong grade IPA. IPA grade

Sequential wiping not done, sequential wiping visual
Contamination in IPA no Contamination in IPA visual 100%
Wrong supply from suplier AS per specification visual 5 Parts
Wrong tag on container AS per specification visual
visual
100%
Dust/lint No Dust or Lint visual
5 Parts
Dust in air tag rag area No dust in area Dust count meter once
Tag-Rag
180 tag rag cloth
Application
Dust from fixture No Dust from fixture visual
100%
5 Parts
Dust from dolley . No Dust from dolley . visual
100%
Dust No Dust visual
5 Parts
Dust in air tag rag area No dust in area Dust count meter once
Dust from fixture No Dust from fixture visual

100%
5 Parts
Dust from dolley . No Dust from dolley . visual
1 Part
air gun, static Static charge max 0.4 kv Static charge meter
190 Antistatic air blow
charge meter 1 Part
Uniform air folw Uniform air folw visual
Application of Antistatic air blow as per WI visual
Static Charge Static charge 0.4 kV visual

Transformer not ON, Transformer on visual
Air pressure 0.4-0.6 mpa Pressure guage
Ionizer not working ..... visual
Gun trigger not working ..... visual
No burn mark No burn mark visual 100%
No Flash on part No Flyash on part visual 100%
1 Part
Surface tension 38-48 dyne Ink test
200 Flaming flamig gun, ink
1 Part
Gas pressure 1-2 kg/cubic cm pressure guage 1 Part

air pressure 25-30 kg/cubic cm pressure guage
flame length and color Blue flame visual 1 Part
1. LUX Meter
Lux level 600-800 LUX . - 100%
2. Visually
Unmixed paint Mixed paint visual 100%
gelling of primer No gelling of primer visual 100%
Dust, lint NO Dust visual 100%
100%
Less / more viscocity Viscocity as per chart By viscocity cup
100%
100%
Painting system As per Paint system visual
100%
As per Paint mixing chart product 100%

Paint viscosity visual
wise 100%
100%
Paint kitchen temp 25-30o C Thermometer
100%
viscocity cup,
stirrer, pump,
air pressure
guage, filtre
210 Primer Mixing cloth, stop
watch,
measuring
cylender,
beake
viscocity cup,
stirrer, pump,
air pressure
guage, filtre
210 Primer Mixing cloth, stop As per Paint mixing chart product 100%
watch, Hardner use visual
wise 100%
measuring
cylender,
beake
100%
Pot life 4 hr By viscocity cup
100%
Mixing Ratio (Primer : As per Paint mixing chart product 100%

visual
Hardner:Thinner ) wise 100%
100%
Ford Cup not cleaned ford cup clean visual
100%

primer grade visual
wise 100%
100%
Filtre cloth 400 mesh visual
100%
Orange peal No orange peal visual 100%

Uncover No uncover Visually 100%
Rundown No Rundown Visually 100%
Dust, lint No dust, lint Visually 100%
Scratch SC No Scrtach Visually 100%
Spitting No spitting visual 100%
Water spot SC No water spot visual 100%
Blister SC No Blister visual 100%
Cissing No cissing visual 100%
Cracking No cracking visual 100%
Damage SC No Damage visual 100%
pin hole No pin hole visual 100%
Paint Bubble No paint bubble visual 100%
Dry finish (Rough paint surface) No dry finish visual 100%
Pipe Properly Clean Visually - Once
17cm for cjhild part 27 cm for big

Fan Pattern scale - once
parts
Instruments not calibrated Calibrated instruments for use Visually - 100%
Water flow plates/venturi Not

ventury clean visual 100%
cleaned
gun,
hygrometer,
gun,
hygrometer,
dust count Spray gun Spay gun properly Clean Visually - Once
Primer
220 metre, pipe,
application
pressure
guage,
anonmometre
Fixture not cleaned. Fixture properly Clean Visually - 100%
Interior booth cleaning not

booth clean - Once/week
proper/not done
600-800 LUX . 1. LUX Meter

Lux level - 100%
2. Visually
Booth Humidity 7015 Thermohygrometer

100%
100%
Booth Temp 25-30 C Thermohygrometer -
visually with measuring

Gun Flow Rate 180-220 ml/ min 100%
cylender & stop watch
Visual inspection on Air

Air velocity 0.3 to 0.5 m/Sec - Once/week
velocity meter
visual inspection on
air pressure 0.4-0.6 mpa - Once
Pressure Gauge
Distance between componant

10-12 inch Scale once
and gun is less
Both maintainace not done Booth maintainace as per plan visual
Air supply filters not
Booth maintainace as per plan visual once
cleaned/change
Plenum chamber door open Door closed visual
Painting sequence of part not

Pinting sequence WI as per part visual 100%
define
Booth balancing not done As per WI visual 100%
Dust, lint No dust, lint visual 100%
Cissing no cissing visual 100%
Damage SC NO damage visual 100%
Scratch SC No scratch visual 100%

conveyor,
230 Flash off Water spot SC No water spot visual 100%
anomometre
flash off Time 8- 10 min visual in contolled panel Once

Conveyor speed 14.66 m/min visual in contolled panel once
Flash off booth temp 25-30o C Visualy by thermometre Once
Conveyor speed less in flash off 14.66 m/min visual in contolled panel once
Antiback stopper not working in
14.66 m/min visual in contolled panel once
flash off zone
Conveyor stopper not working in
flash off
100%
Unmixed paint Mixed paint visual
100%
100%
gelling of primer No gelling of primer visual
100%
100%
Dust, lint NO Dust visual
100%
100%
100%
100%
100%

wise 100%
100%
100%
viscocity cup, As per Paint mixing chart product 100%
Hardner use visual
stirrer, pump, wise 100%
air pressure
guage, filtre
240 Base-Coat Mixing cloth, stop
watch,
measuring
cylender,
beaker
watch,
measuring
cylender,
beaker
100%
100%

visual
100%
100%

primer grade visual
wise 100%
100%
100%
Visualy & by
spectophotometer
100%
Over spary No Over spray Visually 100%

Mottling No Mottling visual 100%
Pait peel off No paint peel off visual 100%

parts

ventury clean visual 100%
cleaned
gun,
hygrometer,
dust count
Base coat
250 metre, pipe,
gun,
hygrometer,
dust count
Base coat
250 metre, pipe,
application
pressure
guage,
anonmometre
Spray gun not cleaned Spay gun properly Clean Visually - Once

booth clean - Once/week
proper/not done
1. LUX Meter
Light not proper 600-800 LUX . - 100%
2. Visually
Booth Humidity 7015 Thermohygrometer 100%
Booth Temp 25-30 C Thermohygrometer - Once

100%
Gun Flow Rate 180-220 ml/ min
Once

velocity meter
Air pressure 0.4-0.6 mpa - Once
Pressure Gauge
100%
10-12 inch Scale
and gun is less
Once
cleaned/change

Pinting sequence WI as per part visual 100%
define

conveyor,
260 Flash off Water spot SC No water spot visual 100%
anomometre

flash off zone
flash off
100%
Unmixed paint Mixed paint visual
100%
100%
gelling of primer No gelling of primer visual
100%
100%
Dust, lint NO Dust visual
100%
100%
100%
100%
100%

wise 100%
100%
100%
viscocity cup, Hardner use visual
wise 100%
stirrer, pump,
air pressure
guage, filtre
270 Clear-Coat Mixing cloth, stop
watch,
measuring
cylender,
beaker
100%
100%

visual
100%
100%

primer grade visual
wise 100%
100%
100%
Visualy & by
spectophotometer
100%
Over spary No Over spray Visually 100%
Gloss variation No gloss variation visual 100%
Mottling No Mottling visual 100%

parts

gun, ventury clean visual 100%
cleaned
hygrometer,
dust count
Clear coat
280 metre, pipe,
application
pressure
guage,
anonmometre Spray gun Spay gun properly Clean Visually - Once

booth clean
proper/not done
1. LUX Meter
Lux level 600-800 LUX . - 100%
2. Visually
Booth Humidity 7015 Thermohygrometer 100%
Booth Temp 25-30 C Thermohygrometer - Once
100%
Gun Flow Rate 180-220 ml/ min
Once

velocity meter
air pressure 0.4-0.6 mpa - Once
Pressure Gauge
100%
10-12 inch Scale
and gun is less
Once
cleaned/change

Painting sequence WI as per part visual 100%
define

conveyor,
290 Flash off
anomometre

flash off zone
flash off
300 Baking oven, air,

burner No Dust No dust visual 100%
Effective sufrace temperature ET 80+/- 5 oC TTR - once
High temperature ET 80+/- 5 oC TTR - once
Air flow Contineous air flow Visual - 100%
LPG pressure LPG pressure 1-2 kg/cm2 Visual - 100%
Recirculation fan not working contineous working Visual - 100%

No burner tripping during oven in
Burner trip Visually on panel - 100%
operation
Baking Time 30+/- 5 min TTR - 100%
oven cleaning Clean oven Weekly Visual - 100%
temp of oven 80+/- 5 oC Visually - 100%
Filter chocked Filtre clean Visual - 100%
Baking system 80+/- 5 oC for 30+/- 5 min TTR - once
Paint cracking NO pain cracking Visual 100%
Warpage/ Bend No warpage/Bend visual 100%
Over bake No over bake Visual 100%
Unnder Bake NO under bake visual 100%
Effective sufrace temperature

not good ET 80+/- 5 oC TTR - once
High temperature setting ET 80+/- 5 oC TTR - once
Low temperature setting ET 80+/- 5 oC TTR - once
Air flow not proper Contineous air flow Visual - 100%

Low LPG pressure LPG pressure 1-2 kg/cm2 Visual - 100%
Recirculation fan not working contineous working Visual - 100%

No burner tripping during oven in
Burner trip Visually on panel - 100%
operation
Time not defined 30+/- 5 min TTR - 100%
Improper oven cleaning Clean oven Weekly Visual - 100%
Exceess temp of oven 80+/- 5 oC Visually - 100%
Filter chocked Filtre clean Visual - 100%
Low temperature setting as per

component ET 80+/- 5 oC Visually - 100%
Baking system not defined 80+/- 5 oC for 30+/- 5 min TTR - once
310 Cooling cooling dumper

Filter Chocked Filtre clean Visual once
Preventive maintenance as per plan Visual once
Damper position Damper partially open Visual once
Damage SC No damage Visual 100%
Scratch SC No scratch Visual 100%
No visual defects (No Orange peal, No

Shade variation, no Over spary, No Uncover,
No Rundown, No Dust, No lint, No Blister,
No Cissing, No Cracking, No Sanding mark,
No Patch mark, No Paint peel off, No pin SC No visual defect visual 100%
hole, No Paint Bubble , No Dry finish (Rough
paint surface) , No Mottling, No Scratch, No
Spitting, No Water spot, No Gloss variation
paint peel off, pencil test )
Display of defect sample in

Defect awareness Visual - 100%
Prechecking area
1. LUX Meter
Lux level min 1000 - 100%
2. Visually
1. LUX Meter
Glass clean as per pan - 100%
lux metre, 2. Visually
gloss meter,
320 Pre checking
spectophotome Revalidation frequency 1 yr visualy once
tre, glass pencil
Acceptance criterial As per aceptance criteria visual 100%
Operator Skill min L3 level operator observation 100%
Inspection 100% inspection visual 100%
Validated reference sample validated reference sample visually once

Instrument Calibration Calibrated instruments for use Visually 100%
Master shade panel not

Shade matches with STD pnel Visual 100%
available
Error in measuring instrument &

gauges, as per plan Visually 100%
No incomplete sanding No sanding mark Visual 100%
Sanding defect sanding paper,

330
on part water
Sanding sanding as per WI Visual 100%
sanding paper grade 2500-grade paper, visual 100%
handling of component handling of component as per WI Visual 100%
Ring, Wrist watch, Belt cover

use PPE Visual 100%
wearing during sanding
polishing Gun striking on

safe distance from part Visual 100%
component
Polishing area- Sanding mark No sanding mark visual 100%

Polishing Tool,
Polishing Pad,
Polishing of back up pad,
340
sanding part polish, 2500-
grade paper, wrong buffing pad Buffing pad as per WI visual 100%
Polishin paste-
S 17+ Abrafi
Dirty buffing wheel Buffing pad as per WI visual 100%

Polishing As per WI visual 100%
polish grade S 17 + abrafi visual 100%
No visual defects (No Orange peal, No

Shade variation, no Over spary, No Uncover,
No Rundown, No Dust, No lint, No Blister,
No Cissing, No Cracking, No Sanding mark,
No Patch mark, No Paint peel off, No pin
No visual defect visual 100%
hole, No Paint Bubble , No Dry finish (Rough
paint surface) , No Mottling, No Scratch, No
Spitting, No Water spot, No Gloss variation
paint peel off, pencil test , sanding mark, Dry
film thickness)
SC
Display of defect sample in
No Defect samples displayed Visual - 100%
Prechecking area
1. LUX Meter
Light not proper min 1000 - 100%
2. Visually
1. LUX Meter
Glass not properly cleaned as per pan - 100%
2. Visually
Revalidation frequency not

1 yr visualy once
decided
lux metre,
gloss meter, Acceptance criterial no clear As per aceptance criteria visual 100%
350 Inspection
spectophotome
tre, glass pencil Operator Skill min L3 level operator observation 100%
Inspection Not Done 100% inspection visual 100%

Validated reference sample not
validated reference sample visually once
available
Instrument not Calibrated Calibrated instruments for use Visually 100%
Material Dispatch directly to

100 % inspection visual 100%
customer in Urgency/Shortages
Master shade panel not

Shade matches with STD pnel Visual 100%
available
DFT 65-85 DFT meter 5

Shade variation Delta E 2 Spectophotometre 100%
Pencil Hardness Min B pass Mistubishi Pencil 1
Gloss Min 80 Glossometer 5
Adhession tape
Adhession 0/100 adhession test
(permacel -P254)
1
Damages, Scratch SC No Damage, scratch visual 100%

Identification on trolley for part name
Identification on trolley Visual - 100%
and Project.
360 Unloading trolley
Work instruction not displa WI display at station Visual - 100%
parting line No parting line Visual 100%
1) Masking tape uneven border As per WI Visual 100%
Mist Spray on masked portion, No mist Visual 100%
(1.) Worn out masking during

process upto primer Masking as per specification Visual 100%
360.'1 Demasking cutter
Incomplete Demasking Complete demasking Visual 100%
1) WI not available
WI display Visual 100%
2) Work instruction not followed Work as per WI Visual 100%
Damages to the component SC No damage Visual 100%
Handling scratches, SC No scratch Visual 100%
Dent No Dent Visual 100%
loading trolley, Identification on trolley for part name

Loading on Identification on trolley Visual - 100%
370 poly bag, tie and Project.
Trolley
wac cover
Work instruction not displa WI display at station Visual - 100%

loading trolley,
Loading on
370 poly bag, tie
Trolley
wac cover
Revision status
Rev No Date Description of revision Revised by Approved By

CP
1) Inprocess inspection by operator
2)Defect dcision matrix MTP-QAD-DDM -001 Inform to line engineer, IMG /PPC in
(1) Return back defective component to
Each job Masking operator IMG/Stores(2) Inform PPC regarding short fall
3) Defective sample display charge
of components as per plan

Inform to line engineer, IMG /PPC in
Each job Incoming inspection by masking operator Masking operator
charge
IMG/Stores(2) Inform PPC regarding short fall
1) Inprocess inspection by operator 2)Defect dcision

Each job matrix MTP-QAD-DDM -001 Masking operator
charge
3) Defective sample display of components as per plan
Each job Incoming inspection WI Line Enginner

1) Inprocess inspection by operator (1) Return back defective component to
charge
1) Inprocess inspection by operator

3) Defective sample display charge

Each job Incoming inspection by masking or loading operator Masking operator
charge
1) Inprocess inspection by operator 2)Defect dcision

Each job matrix MTP-QAD-DDM -001 Masking operator
charge
Each job Incoming inspection WI Line Enginner

1) Inprocess inspection by operator (1) Return back defective component to
charge
Recording in lux monitoring check sheet MTP-QAD- (1) For calibration inform QA department (2)
Engineer Paint shop (1) Information to QA & Maintenance
Weekly Inform Maintenance for tube change resulting
FM-LUX-001 dep't.
in low LUX
Each job
Self inspection by operator & Inspection by QA Engineer Paint shop QA
Checked as per defect decision matrix
Decision as per defect decision matrix
operator at final inspection. MTP/QAD/DDM/03

Each job
(1) Self inspection by operator Engineer Paint shop
Inform to line engineering engineer, IMG/Stores(2) Inform PPC regarding short fall
(2) In between inspection by Line engineer PPC in charge of components as per plan (3) Rectify
improper masking by doing rework
Inspection by Line engineer Engineer Paint shop Inform to HR Training to operator
(1) Masking record check sheet F/PS/001/01 (2)

Work instruction for masking Case-2
(WI/PS/M&M/CASE2/002), Case-1
(WI/PS/M&M/CASE1/002), U206 bumper
(WI/PS/M&M/U206B/002), U206 grill
Each job
(WI/PS/M&M/U206G/002), s-18 (WI/PS/s- Engineer Paint shop Inform masking operator/line engineer
(1) Rectify improper masking by doing rework
Each job
18/TML/001), X2 Frt or replace with new one
bumper(WI/PS/BUMPER/TML/001),X2 Grill
(WI/PS/GRILL/TML/002).Avventura Front Bumper
(WI/PS/FIATFR/01) , Avventura Rear Bumper
(WI/PS/FIATRR/01) , Avventura Fog lamp
(WI/PS/FIATFOG/01)
Each job

Each job
(1) Self inspection by operator (2) In between Engineer Paint shop
Inform to line engineering engineer, IMG/Stores(2) Inform PPC regarding short fall
inspection by Line engineer PPC in charge of components as per plan (3) Rectify
improper masking by doing rework
inspection by Line engineer Engineer Paint shop Inform to HR Training to operator

Each job
(WI/PS/FIATFOG/01)
Each job
Each job
(WI/PS/FIATFOG/01)
Each job

(WI/PS/M&M/U206B/002), U206 grill Engineer Paint shop Inform masking operator/line engineer
or replace with new one
Each job
(WI/PS/M&M/U206G/002), s-18 (WI/PS/s-
18/TML/001), X2 Frt
(WI/PS/FIATFOG/01)
Each job

Each job
(WI/PS/FIATFOG/01)
Each job
Self inspection by operator & Inspection by QA Engineer Paint shop QA Inform masking operator/line engineer
operator at final inspection. or replace with new one
Each job Self inspection by operator Engineer Paint shop Inform masking operator/line engineer
or replace with new one
FM-LUX-001 dep't.
in low LUX
Each job
Each job
If some small scratches problem found which

Each job
Work instruction WI/PS/STD/003, Loading Fixture Loading operator /Engineer
Inform to line engineer
can be rectified on line than rectify it, if not
matrix WI/PS/STD/021 Paint shop feasible than remove component & Inform
supervisor/Engineer
Each job
Inform to line engineer & paintshop

weekly Dust count measurement by inprocess engineer Inprocess engineer
maintainace department
Work instruction WI/PS/STD/003, Loading Fixture If some small problem found which can be
Each job
matrix WI/PS/STD/021 (2) adherence of fixture Loading operator /Engineer
rectified on line than rectify it, if not feasible
maintenance & paint shop preventive maintenance Paint shop than remove component & Inform
supervisor/Engineer
plan F/PS/001/23 (3) Periodical training to operator
Each job If some small problem found which can be

Each job matrix WI/PS/STD/021 Paint shop than remove component & Inform
supervisor/Engineer
Each job
Inform to line engineer If some small problem found which can be
matrix WI/PS/STD/021 Paint shop rectified on line than rectify it, if not feasible
than remove component & Inform
Loading operator /Engineer
Each job verification of par as per plan Paint shop
Inform to line engineer supervisor/Engineer
If some small problem found which can be

Each job
matrix WI/PS/STD/021 Paint shop than remove component & Inform
supervisor/Engineer
Each job
Self inspection by operator & Inspection by QA Loading operator /Engineer Checked as per defect decision matrix
operator at final inspection. Paint shop MTP/QAD/DDM/03

If some small problem found which can be

Each job
matrix WI/PS/STD/021 Paint shop than remove component & Inform
supervisor/Engineer
Each job
If some small scratches problem found which
Each job
can be rectified on line than rectify it, if not
matrix WI/PS/STD/021 Paint shop feasible than remove component & Inform
supervisor/Engineer
Each job
Each job
Each job Self inspection by operator & Inspection by QA Checked as per defect decision matrix
Engineer Paint shop QA Decision as per defect decision matrix
Onec per lot by QA operator at final inspection. MTP/QAD/DDM/03
(1) If IPA operator is found not doing process
Each job (1) Work instruction display WI/PS/STD/005 IPA application
as defined than do re wiping of all
components flaming and then Tag-o-rag (2)
(2) Periodic Training to operators(3) checking operator/Engineer Paint Inform operator& line engineer
Importance & awareness of IPA wiping to
Onec per lot by QA shop
by line engineer in between operator for process adherence (3) Skill Up
gradation of operator
(1) Work instruction display WI/PS/STD/005 IPA application
After 2Hr (2) Periodic Training to operators(3) checking operator/Engineer Paint Inform operator& line engineer
shop

Each job (1) Work instruction display WI/PS/STD/005 IPA application
(2) Periodic Training to operators(3) checking operator/Engineer Paint Inform operator& line engineer
Onec per lot by QA shop

Each job (1)Work instruction display(WI/PS/ STD/ 006)(2) IPA application (1) Importance & awareness of Tag Rag
Tag-Rag cloth provide to operator as per batch operator/Engineer Paint Inform operator& line engineer wiping cloth change to operator for process
Onec per lot by QA shop adherence
quantity (3) Periodic training to operator

Each job (1)Work instruction display WI/PS/ STD/ 006)(2) (1) If operator is found not doing process as
Inform to tag-org application operator &
Engineer Paint shop defined than do antistatic air blowing before
Onec per lot by QA Periodic training to operator Line /maintenance engineer
flaming
Evry lot
(1) If operator is found not doing process as

(1)Work instruction display WI/PS/ STD/ 006)(2) Periodic training to Inform to tag-org application operator &
Daily Engineer Paint shop defined than do antistatic air blowing before
operator Line /maintenance engineer
flaming
Each job
Each job
If surface tension is not in range check air,

Evry lot
gas pressure if any deviation observed (1)
Onec per lot by QA Check sheet for Surface tension F/PS/001/06 Engineer Paint shop Inform to & line /maintenance engineer Check for restart of compressor after power
failure(2) Change LPG bank in case of low
gas pressure
If surface tension is not in range check air,
Evry lot
gas pressure if any deviation observed (1)
Onec per lot by QA Wi display for flaming(WI/PS/STD/ 007) Engineer Paint shop Inform to & line /maintenance engineer Check for restart of compressor after power
failure(2) Change LPG bank in case of low
gas pressure
FM-LUX-001 dep't.
in low LUX
Each Lot Self inspection by operator Engineer Paint shop QA
MTP/QAD/DDM/03

MTP/QAD/DDM/03
Self inspection by operator & Inspection by QA

operator Paint mixing chart F/PS/001/18-A(X-2),
F/PS/001/18-B(s-18), U-206 F/PS/001/60 (spoiler),
Each Lot F/PS/001/070(c1&c2 bumper), (u206 bumper) Engineer Paint shop QA
Each Lot F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), MTP/QAD/DDM/03
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
Paint mixing chart F/PS/001/18-A(X-2),

F/PS/001/070(c1&c2 bumper), (u206 bumper) Paint mixing
For every batch of paint operator/Engineer Paint
mixing F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop & QA
Hold the lot of paint & mix new one mix the new lot
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

For every batch of paint operator/Engineer Paint Check for adherence of paint kitchen check
mixing & Twice in a shift F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop & QA
Re-correct the viscosity
sheet
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
Per Shift Start of operator/Engineer Paint Reset the temperature setting, check for
Painting F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop & QA
Inform maintenance operator/Engineer
working of heater & chiller
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

For every batch of paint operator/Engineer Paint Reset the temperature setting, check for
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

sheet
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
Paint mixing
Each job
Self inspection by operator & Inspection by QA operator/Engineer Paint Checked as per defect decision matrix
operator at final inspection. shop & QA MTP/QAD/DDM/03
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
(1) Adherence of Preventive maintenance record (2)

Training to operators (3) Self inspection by operator Operator /Engineer Paint
Inform maintenance
Weekly shop/maintenance Clean pipe, skill upgradation of operator
& counter check by maintenance/line engineer in operator/line/maintenance Engineer
between. F/PS/001/15
(1)Observation Note down in Start-up cum Setup

Inform maintenance
Daily check sheet F/PS/001/08 , As per WI Line Operator
operator/line/maintenance Engineer
Adjust fan pattern of gun
WI/PS/STD/033
(1) Updated master list of defined gauge &
Calibration Frequency
instruments (2) Monthly monitoring of due Engineer Q.A (1) Information to QA . (1) Do not use uncallibrated instrument
instruments/gauges through master list
MATE/QAD/MME/FM/01
Inform maintenance Clean booth area when conveyor empty, skill
Weekly shop/maintenance
& counter check by maintenance/line engineer in operator/line/maintenance Engineer up gradation of operator
between
(1) Adherence of Preventive maintenance record (2) Operator paint
Daily
Periodic training to operators (3) Self inspection by booth/Engineer Paint Inform maintenance
Clean gun, skill upgradation of operator
operator (4) Countercheck by maintenance/line shop/maintenance operator/line/maintenance Engineer
engineer in between. F/PS/01/08
(1) Adherence of Fixture Maintenance Record

weekly
F/PS/001/23 (2) Periodic training to operators (3) Engineer Maintenance Inform maintenance
Clean fixture, skill up gradation of operator
Self inspection by operator (4) Inspection in between operator/line/maintenance Engineer
by line /maintenance engineer
Weekly AS per booth cleaning F/PS/001/15 Maintainance closed the door Inform to maintainance
FM-LUX-001 dep't.
in low LUX
Start of Painting each (1) Reading Note down in statup cumsetup check Engineer Paint shop
Reset the temperature setting, check for
shift. sheet F/PS/001/08 working of heater & chiller
Start of Painting each (1) Reading Note down in statup cumsetup check Engineer Paint shop
Reset the temperature setting, check for
shift. sheet F/PS/001/08 working of heater & chiller
(1) Reading Note down in statup cumsetup check Operator paint booth
Every product/ Colour Reset the flow rate, skill upgradation of
/Engineer Paint shop Inform Painting operator/line engineer
change sheet F/PS/001/08 operator
Start of Painting
(1) Reading Note down in Locationwise Air Velocity, Engineer Paint shop
Check manometer reading, plan for filter
Dust particle count & Lux sheet F/PS/001/13 change if reading is not as per standard
((1) Reading Note down in Start up cum setup

check sheet F/PS/001/08. (2) Marking of safe limit
Start of Painting each (1) Check for restart of air compressor after
shift. on pressure gauge(3) Periodic training to painting Engineer Maintenance Inform maintenance operator/Engineer
power failure
operators (2) Marking of safe limit on pressure
gauge(3) Periodic training to painting operators
Start of Painting each

shift. As per work instruction WI/PS/STD/033 Painter Adjust the distance and start painting Adjust the distance and start painting
daily AS per booth cleaning F/PS/001/15 Maintainance closed the door Inform to maintainance
Work instruction display in clear booth

WI/PS/STD/008 (2) Painting Sequence sheet
display for TML (WI/PS/TML/036),For M&M (Case-1
FR.Bumper WI/PS/Case-1FR/035,Case-1
RR.Bumper WI/PS/Case-1RR/035,Case-2
RR.Bumper WI/PS/Case-2RR/035,U206 FR.Bumper
WI/PS/U206FR/035,U206 Spoiler operator/painters/Engineer
Inform painting/paint mixing Skill matrix review & skill updation plan of
Each Job Paint shop/Maintenance
WI/PS/U206SPOILER/035,U206 Grill operator/line, maintenance engineer operators
WI/PS/U206GRILL/035, U301 FR.Bumper
WI/PS/U301FR/035,U301 RR.Bumper
WI/PS/U301RR-A/035) Fiat (WI/PS/FIAT/041)
((3)Periodic training to operators(4) Paint shop
preventive maintenance plan(5)Self inspection by
operator (6) Inspection in between by line engineer.
Each Job
Work instruction display in clear booth Engineer Paint shop
Inform operator/Engineer Check as per plan
WI/PS/STD/008
Each job
Each job
Each job
Each job
Each job
Each job
daily Start up check sheet F/PS/001/75

daily Start up check sheet F/PS/001/75 Engineer Maintenance Inform maintenance operator/Engineer
daily AS per booth cleaning F/PS/001/15 Maintainance Inform maintenance operator/Engineer Inform to maintainance
Each job
Each job
operator at final inspection.
Each job
Each job

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

mixing & Twice in a shift F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop & QA
sheet
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

Per Shift Start of operator/Engineer Paint Reset the temperature setting, check for
Painting F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop & QA
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
For every batch of paint operator/Engineer Paint Reset the temperature setting, check for
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

sheet
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
Paint mixing
Each job
Self inspection by operator & Inspection by QA operator/Engineer Paint Checked as per defect decision matrix
operator at final inspection. shop & QA MTP/QAD/DDM/03
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
(1) Adherence of Preventive maintenance record

(2) Training to operators Operator /Engineer Paint
Inform maintenance
(3) Self inspection by operator & counter check by operator/line/maintenance Engineer
maintenance/line engineer in between. F/PS/001/15

Inform maintenance
WI/PS/STD/033

instruments Engineer Q.A (1) Information to QA . (1) Do not use uncallibrated instrument
(2) Monthly monitoring of due instruments/gauges
through master list MATE/QAD/MME/FM/01

(2) Training to operators Operator /Engineer Paint
(3) Self inspection by operator & counter check by operator/line/maintenance Engineer up gradation of operator
maintenance/line engineer in between
(2) Periodic training to operators Operator paint
booth/Engineer Paint Inform maintenance
Daily (3) Self inspection by operator shop/maintenance operator/line/maintenance Engineer
(4) Countercheck by maintenance/line engineer in
between. F/PS/01/08

weekly
(2) Training to operators Engineer Maintenance Inform maintenance
(3) Self inspection by operator & counter check by operator/line/maintenance Engineer
maintenance/line engineer in between
Weekly AS per booth cleaning F/PS/001/15 Maintainance closed the door Inform to maintainance
FM-LUX-001 dep't.
in low LUX
Start of Painting (1) Reading Note down in Process monitoring sheet
Engineer Paint shop Reset the temperature setting, check for
(paint booth) F/PS/001/08 Inform maintenance operator/Engineer
each shift.
2) Verification By QA
Every product/ Colour (1) Reading Note down in statup cumsetup check Operator paint booth
change Reset the flow rate, skill upgradation of
sheet F/PS/001/08 /Engineer Paint shop Inform Painting operator/line engineer
operator
each shift. 2) Verification By QA
Start of Painting

check sheet F/PS/001/08.
Start of Painting each (2) Marking of safe limit on pressure gauge Engineer Maintenance Inform maintenance operator/Engineer
(1) Check for restart of air compressor after
shift. (3) Periodic training to painting operators power failure
(4) Marking of safe limit on pressure gauge
(5) Periodic training to painting operators
Start of Painting
As per work instruction WI/PS/STD/033 Painter Adjust the distance and start painting Adjust the distance and start painting
each shift.

Each job
Each job
Each job
Each job
Each job
Each job

daily AS per booth cleaning F/PS/001/15 Maintainance Inform to maintainance
Each job
Each job
Each job
Each job

mixing F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

mixing & Twice in a shift F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), shop
sheet
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/070(c1&c2 bumper), (u206 bumper)
Per Shift Start of Engineer Paint shop Reset the temperature setting, check for
Painting F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), Inform maintenance operator/Engineer
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/070(c1&c2 bumper), (u206 bumper)
For every batch of paint Engineer Paint shop Reset the temperature setting, check for
mixing F/PS/001/058, F/PS/001/074-A (c-2 grill bezel), Inform maintenance operator/Engineer
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

sheet
F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)

F/PS/001/65 (c1 bezel),F/PS/001/82
(Fiat)F/PS/001/83 (u301),F/PS/001/84
(S101),F/PS/001/85 (Eagle)
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job
Each job

Inform maintenance
& counter check by maintenance/line engineer in operator/line/maintenance Engineer
between. F/PS/001/15

Inform maintenance
WI/PS/STD/033
instruments (2) Monthly monitoring of due Engineer Q.A (1) Information to QA . (1) Do not use uncallibrated instrument
instruments/gauges through master list
MATE/QAD/MME/FM/01
& counter check by maintenance/line engineer in operator/line/maintenance Engineer up gradation of operator
between
(1) Adherence of Preventive maintenance record (2) Operator paint

Daily
Periodic training to operators (3) Self inspection by booth/Engineer Paint Inform maintenance
operator (4) Countercheck by maintenance/line shop/maintenance operator/line/maintenance Engineer
engineer in between. F/PS/01/08
(1) Adherence of Fixture Maintenance Record

weekly
F/PS/001/23 (2) Periodic training to operators (3) Engineer Maintenance Inform maintenance
Self inspection by operator (4) Inspection in between operator/line/maintenance Engineer
by line /maintenance engineer
FM-LUX-001 dep't.
in low LUX
Start of Painting (1) Reading Note down in Process monitoring sheet Engineer Paint shop Reset the temperature setting, check for
each shift. (paint booth) F/PS/001/08 working of heater & chiller
Every product/ Colour

(1) Reading Note down in statup cumsetup check Operator paint booth
change Reset the flow rate, skill upgradation of
/Engineer Paint shop Inform Painting operator/line engineer
sheet F/PS/001/08 operator
each shift.
Start of Painting

check sheet F/PS/001/08. (2) Marking of safe limit
Start of Painting each (1) Check for restart of air compressor after
shift. on pressure gauge(3) Periodic training to painting Engineer Maintenance Inform maintenance operator/Engineer
power failure
operators (2) Marking of safe limit on pressure
gauge(3) Periodic training to painting operators
Start of Painting
As per work instruction WI/PS/STD/033 Painter Adjust the distance and start painting Adjust the distance and start painting
each shift.

Each job
Each job
Each job
Each job
Each job
Each job

daily AS per booth cleaning F/PS/001/15 Maintainance Inform to maintainance
Each job
Engineer Q.A
monthly TTR Recording on monthly basis inform line/maintenance engineer Check filter condition, proper filter placement
Engineer Q.A
Engineer Maintenance.
Weekly Preventive maintenance record F/PS/001/22 Inform line/maintenance engineer Clean oven in between gap available
Check for lpg pressure if found low than
Daily LPG pressure record in LPG bank Engineer Maintenance inform line/maintenance engineer
change bank
Daily at oven start LPG pressure record in LPG bank Engineer Maintenance inform line/maintenance engineer
change bank
Engineer Paint shop Check filter condition, proper filter placement,
monthly TTR Recording on monthly basis inform line/maintenance engineer
conveyor stoppages
Daily at oven start

Note down temperature Set in Oven temperature Engineer Paint shop
inform line/maintenance engineer Reset correct temperature
monitoring sheet. F/PS/001/17
Engineer Q.A
Each job
Each job
Each job
Each job
Each job
Engineer Q.A
Engineer Q.A
Engineer Q.A
Daily LPG pressure record in LPG bank Engineer Maintenance inform line/maintenance engineer
change bank
Daily at oven start LPG pressure record in LPG bank Engineer Maintenance inform line/maintenance engineer
change bank
Engineer Paint shop Check filter condition, proper filter placement,
monthly TTR Recording on monthly basis inform line/maintenance engineer
conveyor stoppages
Daily at oven start

Daily at oven start

Engineer Q.A
Weekly
(1) Periodic maintenance plan of ASU filter (2) Engineer Maintenance.
Inform line /maintenance engineer
Checking through manometers reading change if reading is not as per standard
Weekly
Weekly
Each job
Self inspection by operator & Inspection by QA Engineer QA & PS Inform line /maintenance engineer Repaint the parts and scrap defective parts
Each job
Self inspection by operator & Inspection by QA Engineer QA & PS Inform line /maintenance engineer Repaint the parts and scrap defective parts
(1)W.Instruction display (WI/PS/STD/011) (2) Use

of Lint free wear by painters, line engineers & QA Check all painting process parameters as per
Engineer paint (1) Information to
Each Job process sheet & F/PS/001/70, find the
operators (3) Training to all painters, shop/Maintenance operator/line/maintenance engineer
problematic area & rectify it
operators& Engineers
Weekly
Display of defect sample in Prechecking area Engineer paint shop
(1) Information to QA & Maintenance
(Periodic training to operator for Prechecking dep't.
Monitoring & note down LUX in process monitoring (1) For calibration inform QA department (2)
Weekly Engineer paint shop Inform Maintenance for tube change resulting
sheet MTP-QAD-FM-LUX-001 dep't.
in low LUX
in low LUX
Two month Monthly verify in process audit Engineer Paint shop/QA
dep't.
(1) For calibration inform QA department
Reschedule the training for operator
As per plan Periodical training to operator HR Inform line engineer
upgradation
upgradation
Each Job as per WI dispaly WI/PS/STD/011 QAInspector Infor to QA Engineer Revise the WI
(1) Review validation/revalidation plan &
yearly Updated validation plan Engineer Paint shop/QA Inform line engineer
validate components.
Updated master list for measuring instruments (2)
Do not use uncallibrated instrument (2) Send
yearly Monthly monitoring of instrument/gauges through Engineer QA Inform QA
instrument for calibration
master list MATE/QAD/MME/FM/01
Every Batch
Display of Std Shade sample in Prechecking area Engineer paint shop Inform line engineer Review of samples& display of new defects
(Periodic training to operator for Prechecking

Each job
Each job
Each job
(2) W.Instruction display(WI/PS/ STD/ 012) (3)

Engineer Paint shop Skill matrix review & skill updation plan of
Each Job Training to operator (4) Self inspection by operator Inform operator/ line engineer
operators
& check by line engineer in between

operators
Each job
Each job

operators
operators
operators
Each job
(1)W.Instruction display WI/PS/STD/012 (2)

Each lot
Periodic Training to Polishing operator & painters (3) Engineer paint shop Inform line engineer
Self inspection by operator (4) work instruction in
polish area.
Each lot
polish area.
Each lot
polish area.
Each lot
polish area.
(1)W.Instruction display (WI/PS/ STD/025) (2) Use

of Lint free wear by painters, line engineers & QA Check all painting process parameters as per
Engineer paint (1) Information to
Each Job operators (3) Training to all painters, shop/Maintenance operator/line/maintenance engineer
process sheet & F/PS/001/70, find the
problematic area & rectify it
operators& Engineers
4)
Weekly
Display of defect sample in Prechecking area Engineer paint shop
(Periodic training to operator for Prechecking dep't.
in low LUX
in low LUX
Two month Monthly verify in process audit Engineer Paint shop/QA
dep't.
(1) For calibration inform QA department
upgradation
upgradation
Each Job as per WI dispaly WI/PS/STD/025 QAInspector Infor to QA Engineer Revise the WI
(1) Review validation/revalidation plan &
yearly Updated validation plan Engineer Paint shop/QA Inform line engineer
validate components.
If not ok parts found take decision as per
Each Job Trecebality on all part for date & shift with POK mark Engineer QA Recheck the parts
Defect decision matri
Every Batch
Display of Std Shade sample in Prechecking area Engineer paint shop Inform line engineer Review of samples& display of new defects
(Periodic training to operator for Prechecking
per lot Daily checking in performance test report Engineer QA Hold lot, Inform Production incharge Repaint the parts and scrap defective parts
each job Daily checking in performance test report Engineer QA Hold lot, Inform Production incharge Repaint the parts and scrap defective parts
per lot Daily checking in performance test report Engineer QA Hold lot, Inform Production incharge Scrap parts
Each job
(1)Work instruction WI/PS/STD/026 display at
Each component
stages,(2) Periodic training to operator for proper Engineer Paint shop Inform unloading operator/line engineer Re inspect the parts
handling (3) Self inspection by operator
,Identification tag on trolley
(1)Work instruction WI/PS/STD/026 display at
Each component
stages,(2) Periodic training to operator for proper Engineer Paint shop Inform unloading operator/line engineer Re inspect the parts
handling (3) Self inspection by operator
,Identification tag on trolley
Each job
(1) Inspected material used in masking (2) Periodic

Skill matrix review & skill updation plan of
Each component training to operator (3) Visual display through work Engineer Paint shop (1) Inform to operator/line engineer
operators
instruction(4) self inspection by operator
Each job
Each job
Work instruction display on all stages Engineer Paint shop (1) Inform to operator/line engineer
(WI/PS/STD/014) operators
Each job
Each job
Each job
Each job
Each job
Each job
(1)Work instruction display on all stages,(2) Periodic

Each Job
training to operator for proper handling (3) Self Engineer Paint shop Inform unloading operator/line engineer
Use specified trolley with identification (2)
inspection by operator (4) In-between inspection by Unload components from no specified trolley
line engineer (5) Identification tag on trolley
(1)Work instruction display on all stages

WI/PS/STD/026 (2) Periodic training to operator Trolley condition check, standard trolley
Each component for proper handling (3) Self inspection by operator Engineer Paint shop Inform unloading operator/line engineer check, if standard trolley not found than
replace
(4) In-between inspection by line engineer (5)
Identification tag on trolley

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Part Number / Latest Change Level:

Machine / Process Description

130 Trolley Moulded material Movement to paint shop

140 Lux meter, stand Incoming Inspection of molded parts

Machine / Process Description

Masking table, diecuts ,

160 air gun Air blowing

Machine / Process Description

IPA,Lint free cloth,Lux

180 Tag-Rag cloth Tag-Rag Application

Machine / Process Description

200 Flaming Flaming

Machine / Process Description

Ford cup (B4) ,Filter

Machine / Process Description

Painting Spray gun,

Machine / Process Description

230 Air velocity meter Flash off

Machine / Process Description

Painting Spray gun,

Machine / Process Description

260 Air velocity meter Flash off

Machine / Process Description

Machine / Process Description

Painting Spray gun,

Machine / Process Description

290 Air velocity meter Flash off

300 Oven Baking

Machine / Process Description

310 Cooling zone Cooling

Machine / Process Description

Machine / Process Description

Machine / Process Description

Light lab equipment,

360 Empty trolley Unloading

Machine / Process Description

360.'1 LIGHT &CLOTH Demasking

370 Empty trolley Loading on Trolley

Incoming source of Symbol

Incoming source of Symbol

1) No Under masking (masking problem),

Incoming source of Symbol

Incoming source of Symbol

1) Dust on part 1) No burn mark

Incoming source of Symbol

Incoming source of Symbol

Incoming source of Symbol

1) Water spot, 1) No No lint,Dust

Incoming source of Symbol

Incoming source of Symbol

Incoming source of Symbol

Incoming source of Symbol

Incoming source of Symbol

1) Water spot, 1) No Damage

Incoming source of Symbol

Incoming source of Symbol

Incoming source of Symbol

Incoming source of Symbol