QUALITY MANUAL Document Code :

Revision No :
Edition No : PROCESS MAP AND DESCRIPTION MATRIX Date of Issue :
Date of Release : Page No :

Material Resources Process Owner

Process Name
INPUTS OUTPUTS

Risks
Opportunities Documented Information
External Internal

Process Performance Measures

Prepared BY : Approved By :
 QUALITY SYSTEM MANUAL Document Code

Revision No

PROCESS MAP AND DESCRIPTION MATRIX- BD Date of Issue

Page No : 1 of 1

Material Resources Process Owner

Computer, Network, e-mail, Websites, Telephone, Fax, Printer, Scanner,

Manager - Marketing
Stationary.

Process Name
INPUTS OUTPUTS

Enquiry from Customer, Product data, Standards, Statutory & Regulatory Technical & Manufacturing Feasibility
requirements, Safety Requirements, Customer Specific Requirements, Decision, Quotation, Order Acceptance,
Internal cost data, Capacity and Capability, Previous Experience, Marketing Approval for acceptance of PO, Despatch
Competitors data, Quality Objectives Plan, Customer Score Card, MIS record

Risks
Opportunities Documented Information
External Internal
1. Insufficient product inputs 1. Delay in submission of 1. Cost consciousness 1. DM/MKTG/PP/12- Process Procedure for
2. Improving Negotiation Process Performance Measures Marketing Process,
2. Amendments to Statutory Quotation Skills
& Regulatory requirements 2. Wrong estimation of 3. Customer satisfaction 2. Feasibility Report
3. More upcoming competitors cost enhancement
4. No clear specifications 3. Non adherence of 4. Organization's business 3. Enquiry Register,
/ Standards from customers commitments given to Growth
4. Cost estimation sheet
5. Short lead time for customer 5. Compliance to statutory 1) No. of Enquiries receipt per month
development 4. Not understanding the and regulatory requirements 2) Quotations target per Year
6. Frequent modifications customer requirements 3) On time Offer & Samples
during development properly 4) Business Turnover from new
5. Less focus for NPD products / customers
Products.
6. Capacity constraints

Prepared BY : Approved By :
 QUALITY SYSTEM MANUAL Document Code QM/11A-01

Revision No : 00

PROCESS TURTLE DIAGRAM-BUSINESS PLANNING Date of Issue 01.10.2020

Page No : 1 of 20

Material Resources Process Owner

Computer, Laptop, Internet, Published Journals, Websites, Customer

Top Management (MD & CEO)
Websites

Process Name
INPUTS OUTPUTS

Business Plan, Increased market

Industry scenario, Opportunities, Customer information, Inventory, Sales,
Cost of quality, Internal data analysis results Business planning share, Business decisions, Process
& Performance monitoring

Risks
Opportunities Documented Information
External Internal
Lack of Forecasting & Planning
Market Fluctuations Business Plan
New Automotive Business
Covid Pandemic Improper Internal Communication Process Performance Measures
Emerging E-Cars Market
Government Policies Wrong Internal Data Experience in Sprockets
Lack of Analysis of Data Good Machining Sales Turnover Target VS Actual
Economics Situations Infrastructure
Buyers Behaviour Poor Execution of Business Plan Access to Quality Vendors Customer Satisfaction
Poor Controls in Shopfloor Employee Satisfaction
Profitability of the Business
Growth of the Organization

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code QM/11A-02

Revision No : 00

PROCESS TURTLE DIAGRAM-MANAGEMENT REVIEW Date of Issue 01.10.2020

Page No : 2 of 20

Material Resources Process Owner

Computer, Laptop, Internet, Data analysis results, Customer feed back,

Customer needs, Field failures, Meeting room LCD projector screen, WIFI Top Management & MR
Connectivity, Data server

Process Name
INPUTS OUTPUTS

Business decisions,
Process Performance, Product Conformity, Customer Feedback, Corrective actions, MRM
Inventory, Sales, Cost of Quality, Internal data analysis, Potential field Management Review Minutes,
failure, MRM input Corrective Actions, Additional
resources identified

Risks
Opportunities Documented Information
External Internal

Delay in getting Customer Delay in conducting Management Opportunity to Improve

Review 1. Agenda of MRM
Feedback System
Wrong Communication to Wrong Input Data Opportunity to Improve Process Performance Measures 2. Minutes of MRM
Customers Customer Satisfaction
Delay in getting Data from No Actions generated from MRM Opportunity to Improve
Suppliers Business Performance
No Continual Improvement Adherence to MRM calendar
Internal Audits Results not
Business Objective Target VS Actual
available
Quality Objectives Target VS Actual

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code QM/11A-03

Revision No : 00

PROCESS TURTLE DIAGRAM-ENQUIRY HANDLING Date of Issue 01.10.2020

Page No : 3 of 20

Material Resources Process Owner

Computer, Network, e - mail, Telephone, Transports, National &

Marketing Executive, Design & Development Head
International Standards, Internal Capability Documents

Process Name
INPUTS OUTPUTS

Customer Enquiry, Drawings, Specifications, Customer Specific Feasibility Review Output, Cost
Requirements, Supplier Quotations, Process Knowledge & Capability Enquiry Handling Working sheet, Quotation

Risks
Opportunities Documented Information
External Internal
Changes in Customer New Product contributing for
Inaccurate Cost Working Enquiry Register
requirement Sales Turnover
Inaccurate Quotation from New Customers inclusions
Inaccurate Feasibility Review Process Performance Measures Feasibility Review Check List - Commercial
Suppliers
Increase in Plant & Machine
Delay in CFT meetings utilization Feasibility Review Check List - Technical
Material Price change
Increase in employment
High Lead Time for Quotation Lead Time for Quotation Product Cost Estimation Sheet
opportunities to operators
Enquiry to Order Conversion Ratio Quotation File

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code QM/11A-04

Revision No : 00

PROCESS TURTLE DIAGRAM-ORDER HANDLING Date of Issue 01.10.2020

Page No : 4 of 20

Material Resources Process Owner

M/C availability, Raw material availability, Man power, Computer, Sales

Network, e - mail, Telephone, Transports Executive, Production Head

Process Name
INPUTS OUTPUTS

Sales plan,
Customer requirement, Customer Schedules, Customer PO, Stock Order Monthly Production schedule,
reports, Schedule change note, Manufacturing Capacity, Man power Weekly
availability Handling/Scheduling schedule , Daily
production plan.

Risks
Opportunities Documented Information
External Internal
Inacurate Forecast from Capacity limitation not Opportunity to reduce Inventory
1. Product capacity planning
Customers considered
Unexpected schedule In - effective contingency Opportunity to improve ontime
delivery & Customer Satisfaction Process Performance Measures 2. Customer directed Logistics
change planning

Delay in Internal Scheduling

Delay from Suppliers 3. Monthly Production Plan
Raw Material shortage in the
Sales in Crores. As per plan 4. Production Plan vs Actual
market
On Time Delivery to customer 5. Monthly schedule

Weekly despatch plan Based on

6. Monthly customer wise plan vs Actual
customer
Customer satisfaction score 7. Premium Freight Register
Premium Freight
Production plan vs Actual

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code QM/11A-05

Revision No : 00

PROCESS TURTLE DIAGRAM-DESIGN & DEVELOPMENT Date of Issue 01.10.2020

Page No : 5 of 20

Material Resources Process Owner

Machine availability, Raw material availability, Computer, Network, e-mail,

Manager - NPD
Telephone, Manpower

Process Name
INPUTS OUTPUTS

APQP Timing Plan, Team

Customer Specific Requirements, Customer drawings, Standard, Statutory
Feasibility Commitment, all PPAP
& Regulatory requirements, Previous Development Experience, Work Order Design & Development documents, Prototype, Pre-launch
from Marketing
and Production output

Risks
Opportunities Documented Information
External Internal
Delay in CFT meetings Usage of technology in Design &
Changes in Customer Design Development APQP Timing Plan with Design

Changes in Statutory & Regulatory Delay in Design & Mistake Proofing/POKA-YOKE in

Process Performance Measures APQP Timing Plan without Design
requirements Development Design & Development
Prototype sample not Cycle time rejection for New
Delay from Supplier Development Design & Development Input
approved by Customer Product
activities
PPAP not approved by
Customer Adherence to APQP Timing Chart
Team Feasibility Commitment
High rejections in New Ontime submission of Samples and
Product Cost Estimation sheet
Product Pre-Launch
Difficulty in Manufacturing
during Bulk Production Rejection in Development parts Design & Development Output

Samples not approved by Customer in

DFMEA
First time
Product Target Cost VS Actual PFMEA
Control Plan
Design Drawings
PPAP Documents

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code QM/11A-06

Revision No : 00

PROCESS TURTLE DIAGRAM-TOOLING MANAGEMENT Date of Issue 01.10.2020

Page No : 6 of 20

Material Resources Process Owner

Machines, Raw Material, Measuring Equipments, Computer, Network,

Sr.Manager -Production
e-mail , Bins, Manpower, CNC Programs, Design software, Tools

Process Name
INPUTS OUTPUTS

Fixture drawings, Fixture history

Product drawing, National/International standards, Raw Material, Machines,
Skilled man power, Measuring equipments, Production data, Spares, Tools Tooling Management card and Validation and
revalidation reports

Risks
Opportunities Documented Information
External Internal
Delay in receipt of materials Machine breakdown Mistake Proofing in Fixtures Work Instructions/ SOPs
Power shutdown Operator absenteesm Machining rejection control Process Performance Measures Process Specifications
Skilled labour availability Inaccurate production data Cycle time reduction Jigs & Fixture Inspection report
Design software not updated Cost reduction Tool life monitoring Jigs & Fixtures validation report
Changes in customer Revalidation schedule not
followed Rejection due to Jigs & Fixtures Jigs & Fixtures revalidation report
requirements
Fixture damages On time development of Jigs and
Jigs & Fixture History card
Fixtures
Improper storage List of Critical Spares
Less skill of Design Engineers Skill matrix - Design

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code QM/11A-07

Revision No : 00

PROCESS TURTLE DIAGRAM-PURCHASE Date of Issue 01.10.2020

Page No : 7 of 20

Material Resources Process Owner

Purchase program, Computer, Net work ,Communication channel with vendors, e-mail, Incharge - Purchase, Head Quality
Telephone, act

Process Name
INPUTS OUTPUTS

Approved Supplier List,

Purchase order & Schedule,
Material requirement plan from planning, Purchase requisition, Engineering release from
development, PO tracker, Supplier Evaluation. Purchase Amendments, Supplier
Performance Rating,
Supplier Audit report and CA

Risks
Opportunities Documented Information
External Internal
Wrong scheduling leading to line stoppage (or)
Cost reduction of
Delayed supplies from Supplier excess inventory List of approved suppliers
Materials
Inaccurate information to supplier on part Supplier Quality Process Performance Measures
exchange Purchase Order
Poor Quality of Material Improvement
Scheduling after PO quantity is exhausted. Reduction in Raw Supplier registration form
Increase in Raw Material price Material Inventory
Increases in premium freight because of
wrong scheduling Supplier Performance Rating Supplier performance rating
Non Availability of Material
Supplier Development Activities
Supplier QMS development plan
Improper selection of Supplier completed
On time receipt - RM & consumables
Cost reduction - RM & consumables

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-08

Revision No : 00

PROCESS TURTLE DIAGRAM-OUTSOURCING Date of Issue :01.10.2020

Page No : 8 of 20

Material Resources Process Owner

Purchase program, Computer, Net work ,Communication channel with vendors, e-mail, Incharge - Outsourcing, Head Quality
Telephone, act

Process Name
INPUTS OUTPUTS

Approved Supplier List,

Purchase order &
Schedule, Amendments,
Sub-Contracting Schedule, Drawings, Work Instructions, PO tracker, Supplier Evaluation. Outsourcing Supplier Performance
Rating, Supplier Audit
report and CA

Risks
Opportunities Documented Information
External Internal
Wrong scheduling leading to line stoppage (or)
Cost reduction of
Delayed supplies from Supplier excess inventory List of approved suppliers
Materials
Inaccurate information to supplier on part Supplier Quality Process Performance Measures
exchange Purchase Order
Poor Quality of Material Improvement
Scheduling after PO quantity is exhausted.
Supplier registration form
Increase in Conversion Cost Reduction in Lead time
Changes in Environmental Increases in premium freight because of
wrong scheduling Supplier Performance Rating Supplier performance rating
requirements
Supplier Development Activities
Supplier QMS development plan
Improper selection of Supplier completed
On time receipt
Cost reduction

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-09

Revision No : 00

PROCESS TURTLE DIAGRAM-MANUFACTURING Date of Issue :01.10.2020

Page No : 9 of 20

Material Resources Process Owner

Machines, Raw Material, Measuring Equipments, Computer, Network,

Sr.Manager -Production
e-mail , Bins, Manpower, CNC Programs

Process Name
INPUTS OUTPUTS

Raw Material, Tools, Jigs & Fixtures, Production Consumables, Documents, Right products as per plan &
Drawings, Production Schedule Manufacturing Quality requirements.

Risks
Opportunities Documented Information
External Internal
Delay in receipt of materials Machine breakdown Batch Card Implementation Process procedures
Power shutdown Operator absenteesm Inventory reduction Process Performance Measures Control plans
Skilled labour availability Operator attrition Cycle time reduction Work Instructions/ SOPs
Changes in customer Instruments not calibrated Cost reduction Rejection in Machine Shop Process Specifications
requirements Higher parts rejection Rework in Machine Shop PFMEA
Changes in statotory and Accidents/incidents Machining cost control PFD
regulatory requirements On time delivery Delivery Performance Plan vs Actual
Natural disasters Accident Job setup approval
Kaizen Implementation Production log
Inventory

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-10

Revision No : 00

PROCESS TURTLE DIAGRAM-QUALITY ASSURANCE Date of Issue :01.10.2020

Page No : 10 of 20

Material Resources Process Owner

Measuring & Test equipments, Infrastructure such as surface table, Clean room
Manager - QA
facilities

Process Name
INPUTS OUTPUTS

Incoming materials, Machining inprocess output, Machining final product, Measuring Inspection reports, Job setup approval,
and test equipments, Control Plan, CSR, Customer drawings, Sampling Plan,
Quality Assurance First piece inspection, PDIR, SPC
National/International standards, Work Instructions results

Risks
Opportunities Documented Information
External Internal
Changes in Customer requirements Poor skill level of inspectors Less Customer complaints List of lab equipments
Instruments with high MSA variation
Poor Quality performance of Supplier Process Performance Measures Control Plan
Less Customer returns
Inspectors attrition Less Cost of Poor Quality List of visual inspection standard
Inspectors absenteesm Supplier performance
Customer complaints Incoming sampling plan
improvement
Lack of knowledge about statistical
tools Customer returns NC register

Inadequate process knowledge Cost of Poor Quality Concession acceptance

Supplier Quality performance First stage inspection report
Process capability improvements Final stage inspection repot
Dimensional inspection report
Lay out inspection report
Deviation permit

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-11

Revision No : 00

PROCESS TURTLE DIAGRAM-CHANGE MANAGEMENT Date of Issue :01.10.2020

Page No : 11 of 20

Material Resources Process Owner

Machinery, Measuring equipments, Computer, Network, Design software, WIFI etc., Manager - D & D, Sr. Manager - Production

Process Name
INPUTS OUTPUTS

ECN, PCN, Amended

Customer drawing changes, Process Change Trail Request, CSR, Customer Change Management Purchase Order, Updated
complaints, High internal rejections/Rework, Low productivity
PPAP

Risks
Opportunities Documented Information
External Internal
Changes in Customer requirements Delay in change implementation Productivity improvement PCTR
Improper communication from Improper feasibility review of
changes PCN
Customer Less Customer returns Process Performance Measures
High cost for change implementation
Improper communication from field Less Cost of Poor Quality ECN
Changes in National/International Improper internal communication of Supplier performance
Lead time for change implementation Feasibility review
standards changes improvement
Lack of resources for change
implementation Cost reduction through changes Purchase Order

High rejection/rework in process

Cost of Poor Quality PPAP documents
changes
Supplier Quality performance Document Change Note
Process capability improvements Document Issue register

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-12

Revision No : 00

PROCESS TURTLE DIAGRAM-DOCUMENTED INFORMATION CONTROL Date of Issue :01.10.2020

Page No :12 of 20

Material Resources Process Owner

International Standards MR - Quality System

Process Name
INPUTS OUTPUTS

Quality Manual, Process

ISO 9001 & IATF 16949 standard requirements, CSR, Internal processes, Documented Information Procedures, Documented
Change request, National/International standards Control Information, Amendment and
Issue records

Risks
Opportunities Documented Information
External Internal
Non compliance to standard Unauthorised changes to the Improvement in QMS Quality Manual
requirement documents performance
Insufficient retention of records Software for handling of Process Performance Measures
Process Procedures
Changes in external standards QMS documentation
Improper issue of documents Master list of Documented Information
Different versions of same
documents being used Repeated NCs in QMS audit Master list of External Origin documents

NCs in audits related to

Documented Information NCs ( Customer / External audit closure) Master list of Customer drawings
CP/ FMEA/PFD - Updation CSR matrix

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-13

Revision No : 00

PROCESS TURTLE DIAGRAM-TOTAL PRODUCTIVE MAINTENANCE Date of Issue :01.10.2020

Page No :13 of 20

Material Resources Process Owner

Tools, Instruments, Machines, Computer network, Spares inventory,

Head - Maintenance
Tooling management system , Telephone.

Process Name
INPUTS OUTPUTS

Completed Breakdown reports,

Maintenance request form, PM Schedules, Spares supplier list,
Completed PM & Predictive
Machine supplier details, Tools, Consumables, Preventive
Maintenance & Predictive Maintenance schedules, Maintenance Total Productive Maintenance Maintenance Check list,
Machine ready to use
check list

Risks
Opportunities Documented Information
External Internal

Delay from machine Accident Improved OEE 1. List of machineries

suppliers Non - availability of spares Less maintenance cost 2. List of Critical spares
Process Performance Measures
Delay from spare Improved life of the
Lack of maintenance skill
suppliers machines 3. Annual PM Schedule
Poor Quality of input Schedules not being adhered OEE 4. Contingency plan
power supply Automation
Absenteesm of maintenance
MTTR 5. Predictive maintenance plan and report
Poor Quality of spares technicians
Machines not released for
maintenance schedule MTBF 6. PM plan
Breakdown hours 7. Work report
Preventive maintenance plan vs actual 8. Breakdown
Availability of critical spares 9. Machine history card
10. Generator log sheet
11. Fire extinguisher refilling / Servicing schedule
12. Daily abstract
13. Corrective action report

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-14

Revision No : 00

PROCESS TURTLE DIAGRAM-MEASUREMENT SYSTEM CONTROL Date of Issue :01.10.2020

Page No :14 of 20

Material Resources Process Owner

Measuring & Test equipments, Infrastructure such as surface table, Clean room
Manager - QA
facilities, Master Instruments, Environmental Infrastructure, Skilled Man Power

Process Name
INPUTS OUTPUTS

Measurement System Calibration Certificate, Instrument

List of Measuring & Monitoring equipments, List of approved Laboratories, Laboratory History Card, MSA Reports,
Procedure, Standards, Computer Software, CSR, Calibration Schedule, MSA Schedule Control Corrective Action Reports, New
equipment Purchase

Risks
Opportunities Documented Information
External Internal

External Laboratories not following Not Calibrated as per Schedule

List of Measuring & Monitoring equipments
NABL Procedure Less Customer complaints
MSA variation high in Customer End Instruments with high MSA variation Process Performance Measures
List of approved Laboratories
Measurements Less Customer returns
Frequent changes in CSR High Instrument Bias error Less Cost of Poor Quality Laboratory Procedure
Frequent changes in External Lack of knowledge about statistical Adherence to Calibration Schedule VS
Calibration Schedule
Standards tools Actual
Misuse of Measuring Equipments Adherence to MSA Schedule VS
MSA Schedule
Actual
Number of Instruments not accepted
CSR
in Calibration
Number of Instruments not accepted
Instrument History Card
in MSA studies
MSA Reports
Corrective Action Reports

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-15

Revision No : 00

PROCESS TURTLE DIAGRAM-HUMAN RESOURCE DEVELOMENT Date of Issue :01.10.2020

Page No :15 of 20

Material Resources Process Owner

Man power, computer networks, E-mail, Telephone, Training hall, Projector, Screen,
Head - HR
Whiteboard and markers, Training material

Process Name
INPUTS OUTPUTS

Training Plan,
Human Resource Training Record,
Training need identification form, statutory and regulatory requirements, CSR,
Training Feedback &
Process and product performance, Customer feedback, New employees joining Development Effectiveness, On the job
training record, Skill matrix

Risks
Opportunities Documented Information
External Internal
Changes in Customer Absenteeism
Competence matrix
requirement Automation of process reduce
Mass absenteeism due to festivals Process Performance Measures List of motivation schemes
dependence on man
Unskilled man power
Personnel profile
High attrition rate among migrant employees Multi skill training
Multi location person Manpower productivity Training record
requirement automation of
Non adhrence to training plan process On time recruitment On the job training record
Trainings not effective Training man hours per employee Training feed back form
Opportunity to create
awareness Number of KAIZENs implemented Training effectiveness form
OJT not completed
Employee satisfaction survey analysis
Statutory payments and periodical and report
registers

Training plan vs actual

Prepared by MR Reviewed by DGM Approved by CEO
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 QUALITY SYSTEM MANUAL Document Code :QM/11A-16

Revision No : 00

PROCESS TURTLE DIAGRAM-CUSTOMER RELATION MANAGEMENT Date of Issue :01.10.2020

Page No :16 of 20

Material Resources Process Owner

Computer, Network, Customer 8D reports,FMEAs,Corrective action reports MR

Process Name
INPUTS OUTPUTS

Customer Complaints, Customer rejections, Warranty claims, Customer Customer Relation Corrective action reports,
specific requirements, Customer feedback, Customer rating, OTD performance Management Improved Customer ratings

Risks
Opportunities Documented Information
External Internal
Failure of network Improved Customer
Dissatisfied customer Customer complaints register
satisfaction
Wrong analysis Improved Business
Field and Warranty issues Process Performance Measures Customer returns register
performance
Issues related to Statutory and Failure of communication channel Increase in new
Safety requirements Customers Customer feedback survey
High lead time for resolving Lead time for closing Customer
Customer feedback rating
Repeated complaints complaints Increase in new orders complaints
High penalty cost from Ineffective corrective actions
Customer returns PPM CA report
Customers
Improper internal communication Customer satisfaction rating external
Customer satisfaction rating internal
Repested Quality complaints

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-17

Revision No : 00

PROCESS TURTLE DIAGRAM-INTERNAL AUDIT Date of Issue :01.10.2020

Page No :17 of 20

Material Resources Process Owner

International standards, Procedures, Audit observation sheets & Stationary,

MR- Quality System
Measuring and Monitoring equipments, Documents

Process Name
INPUTS OUTPUTS

Audit schedule - QMS,

Annual audit plan, Process Procedures, CSR, List of qualified auditors, Manufacturing Process and
Control Plan, Drawings, Measuring and Monitoring equipments Internal Audit Product audit, Audit NCR and
CAR, Audit summary

Risks
Opportunities Documented Information
External Internal

Non compliance to standard Non compliance to audit

schedule Improved Quality Annual audit plan
requirement performance
Non compliance to customer Wrong management decisions
Improved Customer Process Performance Measures Internal audit schedule *
requirement satisfaction
Improved Business
Incomplete audits Internal audit observation report *
Dissatisfied customer performance
Adequate NCs not identified Repeated NCs in QMS Audit Internal audit Non conformance report *
NCs in Manufacturing Process audit and
Non cooperation from auditee Internal audit NC summary *
Product audit
Repeated NCs Audit schedule adherence
Delay in implementing
Correction and Corrective Internal auditors performance rating
action

* for QMS, Manufacturing Process & Product

audits to be maintained separately
Prepared by MR Reviewed by DGM Approved by CEO
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 QUALITY SYSTEM MANUAL Document Code :QM/11A-18

Revision No :00

PROCESS TURTLE DIAGRAM-ANALYSIS & CORRECTIVE ACTION Date of Issue :01.10.2020

Page No :18 of 20

Material Resources Process Owner

Data analysis tools, Statistical tools, Computer network, Printer All HODs

Process Name
INPUTS OUTPUTS

Customer Feedback, Supplier Performance, Audit results, Process and Graphs, Charts, Root Cause
Product Performance, Quality Objectives status, Business Analysis & Corrective Action Analysis, Corrective Actions, Risk
Performance Management

Risks
Opportunities Documented Information
External Internal
Delay in reporting of field Higher lead time for Analysis & Improvement in Business
Action NC report
complaints performance
Improper Analysis by Repeated NCs Improvement in Process
Process Performance Measures Corrective Action report
Supplier performance
Ineffective Root Cause Improvement in Product
Analysis performance Risk Management Matrix
Lack of knowledge for
Lead time for Corrective Action Customer Satisfaction Survey
employees
Number of repeated NCs Customer Complaint register
Number of repeated Customer Complaints Supplier Performance rating
Supplier Audit report
Control Charts
Process Capability Study

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-19

Revision No :00

PROCESS TURTLE DIAGRAM-CONTINUAL IMPROVEMENT Date of Issue :01.10.2020

Page No :19 of 20

Material Resources Process Owner

Data analysis tools, Statistical tools,Computer,Network. DGM & MR- Quality System

Process Name
INPUTS OUTPUTS

KAIZENs, Suggestions
Customer feedback, Data analysis results, Productivity & Quality issues, implemented, Continual
Supplier performance, Business performance, Process performance Continual Improvement Improvement projects, Process
capability improvement

Risks
Opportunities Documented Information
External Internal

Dissatisfied customer Wrong decisions Productivity KAIZEN

Increase in manufacturing cost cost Process Performance Measures CIP report
Lack of motivation of employees to
do improvement Delivery Control charts
Un systematic improvements
Number of KAIZENs implemented Process capability study reports
without validation Quality
Safety Number of CIP implemented Suggestion forms
Number of Special characteristics with
Suggestion committee
Morale Cpk>1.67
Cost savings through improvements Meeting minutes
MRM minutes

Prepared by MR Reviewed by DGM Approved by CEO

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 QUALITY SYSTEM MANUAL Document Code :QM/11A-20

Revision No :00

PROCESS TURTLE DIAGRAM-RISK & OPPORTUNITY MANAGEMENT Date of Issue :01.10.2020

Page No :20 of 20

Material Resources Process Owner

Data analysis tools, Statistical tools, Computer network, Printer All HODs

Process Name
INPUTS OUTPUTS

Internal Issues, External Issues, Interested Parties requirements, Risk & Opportunity Risk, Opportunities, Significant
Product Performance, Process Performance, Business Performance, Risks, Mitigation Actions, FMEA &
Risk Management Procedure Management Control Plan

Risks
Opportunities Documented Information
External Internal
Delay in reporting of field Higher lead time for Risk Improvement in Business
complaints Management performance Risk Management Matrix
Improper Analysis by Repeated NCs Improvement in Process
Process Performance Measures Mitigation Action
Supplier performance
Improvement in Product
Ineffective Risk Analysis FMEA
performance
Lack of knowledge for Improvement in Customer Number of Significant Risks identified Control Plan
employees satisfaction
Opportunities not adequately
identified Number of Significant Risks reduced

Number of recommended actions

implemented from FMEA

Prepared by MR Reviewed by DGM Approved by CEO

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