Académique Documents
Professionnel Documents
Culture Documents
UNDERTAKEN AT
KUREKSHETRA UNIVERSITY
c
Acknowledgement
I would also like to extend my thanks to all the Development & production
Staff members who have been very helpful through out my training in
supplying with all the necessary information.
Lastly I would like to thank Ms. Imperial Auto Industries Ltd, for
accepting me as a summer trainee in such an esteemed organization.
AMIT MALIK
ROLL NO. 3407333
S.D.I.T.M
.UUnivity
c
Preface
The summer training was completed at Imperial Auto Industries Ltd. under
the guidance of Mr. Pawan saharan (Development Head). This training is a
part of my four years course. During the stipulated time period my aim was
to gain as much as knowledge and information possible and to be well
familiar with the working conditions of the Organization. In this report also
are the details of the project work allotted to me.
The training was to study the different processes used in the production of
the final product. I also went to understand ERP software running in the
company.
c
IMPERIAL AUTO INDUSTRIES LIMITED
DATE OF
INCORPORATION THMAY
REGD. OFFICE
AAUSALAZAR
HRUcLAC
DLHI
MAIN FACTORY & ccSITRAILAYDS
OFFICE SHD
ARIDAAD
PLANT II cLTSCTR
ARIDAAD
PLANT III SCTR C
ARIDAAD
PLANT IV cLT
SCTR
ARIDAAD
PLANT V
M thu R
ARIDAAD
BRAKE IDLInuti
HOSE A
PLANT ARIDAAD
c
PRODUCT PORTFOLIO
ULI CTICLUSTRcIcSTSRMULTI
CYLIDRIS
RAILAYDISLISHAVYTA
TC.
HYDRAULICHIHcRSSURHS
ASSMLY
SAAMLSSTUASSYSRHIHcRSSUR
MAILDSADHYDRAULICAccLICATIS
NYLON TUBES
ULSYSTMS
RA
STRcIcSLURICATIcIcS
CLUTCHVACCUMLURICATIcIcS
c
BRAKE LINE & CLUTCH COMPONENTS
HYDRAULICRA
HSS
AIRRA
HSS
CCTILIS
RA
TUS
cRSTARIHSS
CLUTCHTUS
AIRLIS
FUEL LINE COMPONENTS
ULLIS
ULRTURLIS
VRLLISMAILDS!ScILLcIcS)
LLTHRLLSL"ILHSSITHcVCCA
c
TUBULAR COMPONENTS
"HAUSTcIcSCMcTS
ILATR#AIRDLIVRYcIcS
STRUCTURALAUTMTIVARICATDTUS
ULTA
C
S
cIcS#HSSRTA
SARMURDVHICLS
TC
CMcTSRAIRSTARTISYSTMS
RUBBER PRODUCTS
HSSITHUTDITTIS
RADIATRDHSS
ULHSSAScRIVMTRY
MULTILAYRDHSS
MRCSM
c
MAIN BUSINESS GROUPS
MANUFACTURER OF
AUTMTIVSTLTUI
RA
TUS
ULTUS
ULI CTITUS
RADIATRTUS
ULILTcIcS
VRLLIS
ARICATDTUASSY.
CRSSMMRS
L"ILHSS
ULHSASSY.
RADIATRHSS
RA
HSASSY.
HYD.HIHcRSSURHSASSY.
VACCUMHSASSY.
AUTMTIVULSYSTM
c
CUSTOMERS
ÿ TATAMTRS
ÿ MARUTIUDYLTD.
ÿ MAHIDRA#MAHIDRA
ÿ SARA MAZDALTD.
ÿ A A VHICLS
ÿ A A AUT
ÿ HRHDA
ÿ HYUDAI
ÿ CIDIA
ÿ cU ATRACTRSLTD.
ÿ ICHRMTRS
ÿ cIAIVHICLS
ÿ L#T HDR
ÿ CUMMISIDIA
ÿ
IRLS
AR
ÿ SCRTSIDIA
ÿ ASH
LYLAD
ÿ TA
ÿ HIDUSTAMTRS
ÿ CUMMISUSA
ÿ HDRRAC
ÿ RALMTRSUSA
ÿ TRIUMcHMTRCYCLS
c
PROCEDURE
$ %ut$ n niz tin%ivth&ui$nt'hi%hi(n'n
cURCHASRDR.
Th)u%h $ y* n)n y n
)%ii%ti$)i.A%%intthivn*y%ut$%hui
in$nthytnihty'(y iy* i.
$ cu%tin ) t$nt i M ti !M) i *t in.
Mith $unt '$ ti &ui in)i%$ ti .
iththh)M nS%huth '$ ti &uii% %u t.
Ath)% n*yc nninD) t$nt.
Resource Planning
At thi th u% th niz tin h v t * ) nn
)u%tin&u ity$ ti .
' y $ty niz tin '( n zinvntyv
)in%i). ut th i ' y t%( ' $ ti 'ith $ t n
i($ +i$u$t%($ini$u$t%( n*ut%(.
Tht%(h t*%h%(n iy* i'iththt n .Ith
t%(i tthnth$ +i$u$t%(th'i*n)u%h .It%(
, *u t%( i in *t'n th $ +i$u$ t%( n $ini$u$ t%( thn
)u%h inintnth'i$ ti h t*)u%h .
cu%h in incu%h D) t$nt.)u%h in it inth t
'hth &ut tin &ui nt. I &ui thn &ut tin
*t in $ vn n %%iny thy ' $ ti
&ui.
c
hn vn n th $ ti t )%in i n. it th
) ti%u %h%(.Ch%(in$ ti %%int%huin.
I
thn ny th $ ti &u ntity %h%(in th'i th
%n%n)ni%nt %t n%%tin nthn nth.At
th t) ti%u %h%(.
Si$i yitin&u ntity%h%(in.Atth tth&u ityth
$ ti i%h%(.Ith$ ti i
$ ti intttth'i
it i n th t 'hth $ ti i unt nt. In % it i n th t
'hth tin vi tin'(i)i*'ith $ ti . I
) tin&uiin nnttn* %(.
Production
At ) nnin th u% th ' $ ti i iu *y t. *
% %%int%hu. Th v iu)u%tin)%
))i.I$-*'(i&uith $vn'ht (
th $ ti ) tinnth t n tun* %(.A % $ ti i
iu i $ int in.Th i*un tinn vnt tunth $ ti
'ithin yth'ith i +%i n n'*iin h t*
n.
n th i$)t nt ) t )u%tin i in)%tin. Th $ ti
)u% h t un v iu tt. I it i nt %%in t &u ity
&ui it i n th t $ ti i &ui in un%y i it i . $
vi tin i n 'ith )$iin ni i%. I nt $ ti i
-%t nt% ).
Th $ ti )) i nt t +%i t. At )u%tin
$ ti h t*ntt%ut$.Iti) %())y nnt*yuit *
c
$ nt n)t. %hivythi*iin.Ithu*ntth t
i) t%hi %%int%hunt.
c
C !ninin Ch n tin) / S$ %h n in in
n. A%%in t th %h n $) )) n tt n
) $t.I $) nt
$n$nt n n in $)
)) .Atth titti)) .Ith)u%ti %%)t*yth
%ut$ % )u%tininth'i $n$nt nin
in.A in $)i)) n'h)%it*) t.
c
AUDIT SYSTEM
PROCESS AUDIT VISUAL
( FREQ. - WEEKLY, MONTHLY ) DIMSIAL
DSTRUCTIVTST
PRODUCT AUDIT LAYOUT AccARAC
( FREQ. - DAILY, WEEKLY,
MONTHLY ) DIMSIAL
SURACTRATMT
cRRMAC
PRODUCT LAYOUT AUDIT ULLDIMSIAL
( FREQ. - YEARLY ) ITMTUCTI
cRRMAC
MATRIAL
PRODUCT TESTING & EVALUTION DIMSIAL
SURACTRATMT
cRRMAC
MCHAICALcRcRTIS
CLALISS
c
KEY QUALITY FUNCTIONS
PRE PRODUCTION ASIILITYSTUDY#CMMITMT
QUALITY PLANNING cRCSSSLDIARAM
AILURMD#CTAALYSIS
cRCSS
cRCSSCTRLcLA
cRCSSCAcAILITYAALYSIS
UACALIRATIADUA
R#RSTUDY
TL#I"TURCTRL
SUccLIRSLCTI#AccRVAL
PRODUCTION PROCESS cARTLVLCTRLcLA
VALIDATION cRDUCTIcARTSAccRVAL
cRCSS!ccAc)
cRDUCTI0UALIICATI
c
INSPECTION SYSTEM
c
TYPES OF PIPES USED IN THE INDUSTRY
) unyTu*
) Tu*Du* !TD)
*) Tu*Sin !TS)
) %ti% yRit n%uttci)!R)
) CD 'nci)!CD)
) CD 'nS $ci)!CDS)
) Hihcuci)
) St inStci)
Di $tci)u$$t$$
Hu (Hci)HS#L
St n intn i $t* (h
. $$
c
c
INTRODUCTION
In th $ nu %tuin inuty MRc !M ti R&ui$nt c nnin)
*% $ th un $nt %n%)t)u%tin $ n $nt n%nt in
th $i . At thi t M !i M ti ) 'hi%h i )u%h
$ n $nt th t utiiz ) t it $ n $nt n ) t
v)$nt ' in th $ int $. An thi %n%)t !MRc) un
$ invnty $ n $nt $ ti t ) nt n )nn
) nnin n iti*utin ) nnin 'hi%h in tun *% $ MRcII
!M nu %tuinRu%c nnin).Thiin%) tin n%i %%untin
hu$ n u% $ n $nt un%tin iti*utin $ n $nt un%tin
n$ n $nt %%untinun%tin.It% $t* y%v
nt)i$ int y*uin nvntu y% $t*% ERP.
What is ERP?
u
u
ERP ) %( int t !%vin
*uinun%tin)t' ) %( th tu))tth *vRc%n%)t.
iin y Rc ) %( ' t t t th $ nu %tuin
inuty n%nit$ inyun%tin) nnin n$ n in%
*uin u%h $ n $nt )u%tin $ n $nt %%untin
n in n%i i t%. H'v in %nt y )t tin nt ny t
th$ nu %tuininuty*ut tivty)inutyh *%$
c
)i* nth+) nini$)$nt tin nuh *n)in
n * v.
Rc t' i in t $ n ut$ t $ ny th * i%
)% %$) ny $ in n% t th h) 'ith th
int tin in$ tin % th %$) ny n i$in tin %$)+
+)nivin(*t'n%$)utyt$th t'nv$ nttt (t
%hth.
Rct' i $ii$ th$ -*uin)% n
niz tin u%h %ut$ ui$nt n $ nu %tuin. It
u%%)n u)n %h %i%u$%i*Rcyt$ in¶t $u%h *tt
th nth %yyt$it) %.In$ ny% iti'*% uth
% t t ' 'ittn )%ii% y th %$) ny n th t (. u
hn ' hu in i
nt %ut$%+ $)th t ' ut$ ti% ytth
inth%$) ny'hntittthin n%) t$nt tth%$) ny
h &u tinMu$* i ntth$ nu %tuin) ntinChnn i.Thu
in$ tin int tin tu%( %h 'ith C n CRc
vn¶)i$ yt t n Rct(inth y.
REASONS FOR THE GROWTH OF ERP MARKET
Th i n u*t th t th $ (t nt)i Ru% c nnin !Rc)
yt$iin t$ n.Inuty n yt % tin'th t
$th n
1 t tthn+tivy .hy $ ny%$) ni
) %inthi(y*uinyt$2Th n'i
c
. Tn *i$)v*uin)$ n%
ÿ Cy%ti$u%tin
ÿ In% *uin iity
ÿ Invntyu%tin
ÿ ui$nti$)v$nt
. Tu))t*uin'th&ui$nt
ÿ ')u%t)u%tinn'%ut$
ÿ * &ui$nt in%uin $uti)
nu n%un%i
.T)vi+i*int t ti$%iinu))t
ÿ I$)v)nivn %th niz tin
.Ti$in ti$it tinin %yyt$
ÿ Cntuy tiniu
ÿ $nt tin t n)%in
ÿ In+i*iityt%h n
ÿ Inu))t *t%hni
.Tt ( v nt thunt ))$i$ (t
ÿ In% un%tin ity t n *%t
ÿ Cintv)nyt$t%hny
ÿ Vti% $ (tutin
Th $ th n th +)iv 'th t th
Rc $ (t n th Rc vn. A $ n $ %$) ni
-ininth %thRcvn hitinthi%u$*itun
%$) ni t int $ (t $nt !$iu$ iz %$) ni
$ %$) nit%.).Thutu'ii%* tt$ (th n
$ n %&uiitin t ti% n %$)titiv v nt . Th
c
uti$ t 'inn in thi % 'i * th %ut$ 'h 'i t *tt
)u%t n*ttvi% t *)i%.
ADVANTAGES OF ERP
Int in nRcyt$h $ ny v nt *thi%t nini%t.Th
i%t v nt in%u i$)v i%in%y in$ tin int tin
*tt %iin $ (in t )n ti$ t %ut$ &ui t%. Th
ini%t *nit in%u *tt %) t i$ i$)v %ut$
'i %ut$ ti %tin n n. Th 'in $ th
i%t*nit nRcyt$
ÿ uinInt tin
ÿ +i*iity
ÿ ttAn yi nc nninC ) *iiti
ÿ UL ttT%hni
Y. Business Integration
Thit n$t v nt iinth)$tinint tin.Th n
'hy Rc ) %( %ni t * int t i th ut$ ti% t
u) tin th t i )i* $n th t *uin %$)nnt. Sin%
%nvntin %$) nyin$ tinyt$ $t '' (int$
th %$$uni% tin n int tin in$ tin th t t n%n th
int*uinun%tin.Inth% %$) niin) ti%u th
ti$in yt$ %ntu%tin n i%tiv i %h )u%t n
) t$ntun%tin n$ti$thy i%nn%t.thi n
it h *%$ n *t % in th hit t n' )u%t n *uin
c
% ii% tin. In th % Rc ) %( th t t *uin
un%tini ut$ ti% yu) t tthti$ t n %tin%%u.
thi nn i *t )*uint i in ti$ n% yut
v iu ty) $ n $nt %iin in ti$y $ nn * n th t
in$ tin.
. Flexibility
Th %n v nt Rc ) %( i thi +i*iity. Dint
nu %un%i %%untint n nn% n*%vinn
yt$ nun%tinth t%$)hnivy$ n $uti)% tin
%$) ny % n * ) %( n i$)$nt ut$ ti% y. T %) 'ith
%$) ny * iz tin n yt$ unii% tin thi +i*iity i nti
n n % n y th t it h $ - v nt nt i$)y v)$nt
n$ intn n%*ut int$$ n $nt.
3. Better Analysis and Planning Capabilities
Yt nth v nt ith*ttth) nninun%tin.yn *inth
%$)hniv n unii $ n $nt t *uin n it t it
*%$)i*tuyutiiz$ nyty)%iinu))tyt$ n
i$u tin un%tin. uth$ in% it *%$ )i* t % y ut
+i*iity nin ti$thiin n n yi t $ v ity
i$nin n i * t iv th %iin $ ( th in$ tin thy
' nt.thun *inth$t$ (*tt nin$%iin.
c
4. Use of Latest Technology
Th uth v nt i th utiiz tin th tt v)$nt in
In$ tin T%hny!IT). Th Rc vn' vy&ui%(t iz
th t in t ' n t ut in th t 'th. thy h t $* % th
ttv)$ntinthiIn$ tinT%hny.Ththy
&ui%(y )t thi yt$ t t ( v nt th tt t%hni
i( )n yt$ %intv t%hny IntntInt nt CALS
!C$)utAiA%&uiitin nLiti%Su))t)%tni%%$$%
t%. It i thi &ui%( )t tin t th tt %h n in In$ tin
T%hnyth t$ (th+i* )t tint%h ninutu*uin
nvin$nt )i*. It i thi +i*iity th t $ ( th in%) tin
th ttt%hny)i*uinyt$%ut$iz tin$ intn n% n
+) nin)h .
Ah *nt t *vRcin%u$ nythun%tinth t'i*
n% y utu yt$. H'v unt (in $ t %$) ny
tu%tu n*uin)% tn *thuuth$ -
tuith ttt (%$) nith t'iuth$.Itin% y
t t ( nt th t % u y )%in 'ith th i$)$nt tin Rc
$y nyt$%ntu%tin)) tinthy
i i(y t ut in tunin th *v $ntin v nt n
i v nt .
c
BUSINESS MODULES IN AN ERP PACKAGE
Introduction
h ti *uin2Itint-ut*uiin$ %hiny$ny.uini
))ntny))'hvunt iy%$tth*% uthy% n
$u%h $ '(in tth th n thy %u '( n *ut ))
'h'(nthi'n nt)nu.uinthn% n*in
th %tiviti iniviu u) th t invv in v)in
)u%in n iti*utin th n vi% n t tiy th
))¶n.
uin u u% t )u% n vi%. Th
u% n * n % )it . Th th u% *%$
)u%tiv 'hn %$*in in tin ' y $ % tiv inu
)u). Thi i th un%tin th uth u%nt)nuhi)
$ n $nt. nt)nu $ n %$*in th u% i( n
* n % )it in int ' y t )u% vi%. It i th
un%tin th $ n $nt t ) n th %tiv n i%int u th
u% v i *tthnt)i.Thnt)iu%) nnin!Rc)
yt$ h) th $ n $nt in $ (in th ) nnin )% $
)u%tiv ni%int.
ARc) %( %nt in$ ny$u.Thnu$* n tu
th$uv i'iththRc) %( .Inth'in''i$
th $t %$$n $u v i * in $t ) %( . Thy
in n% M nu %tuin n cu%tin c nnin S n Diti*utin
c ntM intn n%0u ityM n $ntM ti M n $nt nn.
Thii*yn$ n %$)hnivit.S$) %( 'ih v u*t
c
thi n $ 'i h v $ $u n tu. t i
in$ tin yu 'i h v t %nut th )u%t it tu th )%ii%
Rcyt$.
C$)utizyt$+itthint*uin$uvn
*thRc .ut'h t$ (Rcint n% ) *)u%in
$ ti% ut i th int tin n ut$ tin th v iu *uin
un%tin.R thth nun%tininini tin% tintthnthi
'n ) t$nt th int $u in n Rc yt$ int t.
Thy n n %iv t % ) t$nt * i. Anth tu
th t i$)v )u%tivity n u% )n n %tin ti$ i th
ut$ tin th v iu )%u n t (. Mt th t ( 'hi%h
'n $ nu y inth )Rc n' ut$ t. At ( 'hi%h
invvth%in tint'th) t$nt'ut ( yin
nnRcnvin$nt.H'v'ithth)%u ut$ tin n$u
int tinth $t ('i*%$)t'ithin$inut nth tt-ut
*y n %tin initi t *y in )n !'hi%h ti t th
)%in$ nyint$u).
V iuint$uRcin*uin
Y. Finance
Thi%tin)vi nvvi'thin n%i utinin$t
th Rc ) %( . In t y¶ *uin nt)i yu n t (n' th t
yuin n%i %iin * nt y¶ t ntnu$*$%
% $nth vn '( . An yu n t (n' th t thi
$ 3t y¶¶ t )nt vy $nt yu niz tin¶
%tiviti 'hth yu nt)i tt%h % $ un th
c
*.Thiinti *% uth$ti%int' yttyunt)i
t'hyu' ntitt$'it(n'+ %ty'hitit y.
Thin n%$uh v'inu*yt$
ÿ !
ÿ á
ÿ
ÿ 2
ÿ u
. Production
M nu %tu $ut )n &ui%(y n %tivy t %ut$
$ n. hi iity i i * iity 'ithut n %tiv nt)i
$ nu %tuinyt$utin)'ithut)u).Thvyh t n
nt)i$ nu %tuinyt$%ntnitint t) nnin*uin
)% n+%utin% ) *iiti.T itin C L)MRc%n%)t
h v n h th i$)t n% %tiv ) nnin *uin )%
unt nin nti$y+%utin.St ti% y%tiv) nninut
ini$)vinvntytunin% )u%tivity ni$)vtunn
t. T %ti% y %tiv *uin )% )vi i$)v %ut$
ti %tinu%ti$t$ (t ni$)v$ (th .S$th
$ -u*yt$th$ nu %tuin$u
ÿ
ÿ
!
ÿ l
ÿ ´á2
ÿ
c
ÿ u !
ÿ u
ÿ
ÿ
ÿ 2
3. Human Resources
Hu$ nu%$ n $nti nnti %t nyu%%u
*uin. Th %$)titiv nvin$nt th n+t $inniu$ 'ith it
%n$i% n t%hni% %h n 'i %t th HR ) t$nt in
th $ ' y it 'i th th yu nt)i. In ht HR
$ n $ut %ntinu y vi' n )ti$iz thi *uin )%.
ThHR$u$tRcyt$h v ti%h tu n'i
int t $y'iththth$u n thuinv u * iin
i$)vin )u%tivity. Thy %$) ny'i utin HR
) t$nt n $ ( it )i* th ) t$nt t %% )%ii%
$)y t .V iuu*yt$unthi
ÿ
ÿ
ÿ
ÿ 2
ÿ
!
c
4. Plant Maintenance
c ntM intn n%)viyu'itht%hni% n*uin)t n
v iu )nt tin )tin %%in t th %iti u + $)
niz tin unit % tin +%utin )i th t ( yt$
$ nu %tu.Thiin$ tinh)yutu%thu tin n%t
) nt 'nti$ ut $ n t %niz )i* ' (
)int'ithinyut%hni% yt$inti$.It $th* i
inin n)ti$u$$ intn n%t tyinthn4Tt cu%tiv
M intn n%5!TcM)i()ti$iz$ intn n%.Th$ -u*yt$
c ntM intn n%$u
ÿ
ÿ u
"
ÿ "
ÿ
"
ÿ
"
V. Materials Management
ThM ti M n $nt$u)ti$iz )u%h in)%
'ith '('ivn )%in un%tin n * ut$ t u))i
v u tin ' )%u$nt n ' huin %t 'ith %%u t
invnty n ' hu $ n $nt n int t invi% vii% tin.
Th$ in$uM ti M n $nt
ÿ #
ÿ
ÿ r u
ÿ á
c
ÿ á r
á
A. Quality Management
Th IS i n ht t n in th un%tin
0u ityM n $nt nth$nt 0u ityM n $ntyt$.
Th un%tin in th 0u ity M n $nt $u u))t th nti
$nt u%h yt$. Th th int t $u in th yt$
%$)$nt thi un%tin ity. Th t n &ui th t 0u ity
M n $nt yt$ )nt t )% 'ithin n niz tin. Th
t ()iiti %%intth&u ity)hit)u%tint)u%tin
) nnin n )u%tin v)$nt t )%u$nt n n
iti*utin ' int th nti u )h . In th
)u%tin &u ity u n% i n n vi' in t$ in)%tin
nthi$in tin%t n.Int th)u%tin)%it
*%$th %u ttntin. Th0u ityM n $nt $u ui
th'inun%tin
ÿ l
ÿ l
á
ÿ l
c
%$)tn%i n%) tnhi)vth'hu))y%h in. H
in% i%in%yin niti*utini (y %ttnuth t
%$) nit in %$)titiv ni$)v*th)it$ in n
%ut$vi%.Inh)in*uint3* tth$nivy¶th
niti*utin$u$ nyRcvn %$)hnivt
*t* %$)nnt *th n iti% $ n $nt.
M ny th yt$ tihty int t 'ith th Diti*utin
R&ui$nt c nnin !DRc) nin th 3 -utinti$¶ ivi.
Thi int tin n * th $ ))in n u))y init $uti
it niz tin n th initin tinhi) in %$) ny¶
intn u))y %h in. Dv)in )%i iti% ) nnin -utin
ti$ ivi thi yt$ % n n t )nih$nt *y
uinin' hu&ui$nt.Th'in th t
t n %tin
.S &uiu%h in&uii n&ut tin
.S
.utin $ntu%h %nt %t n%huin $nt
.DivyShi)$nt
.Invi%iniin
.AtS R)t
c
A S n Diti*utin $u 'i %nt in th 'in
u*yt$
ÿ !
ÿ
ÿ
ÿ
ÿ
ÿ O
ÿ
ÿ
ÿ 2
ÿ ! 2
c
c
INTRODUCTION
Th)u)thi)%it%$$uni% tu))i¶%$$nAv n%
cu%t 0u ity c nnin !Ac0c) n Cnt c n uiin v)
-inty *y Chy n n Mt. Th )t )vi
uiinint)u% )u%t&u ity) n'hi%h'iu))tth
v)$nt )u%tvi%th t'i tiyth%ut$.Tht$
4)u%t5'i*uthuhutthi)t ni$ nt ith)u%t
vi%.Tht$4u))i5'i *uthuhutthi)t n
i $ nt t ))y t u))i n u*%nt %t. S$ th +)%t
*nitinuinthuiin
. A u%tin in th %$)+ity )u%t &u ity ) nnin th
%ut$ nu))i.
. A $ n u))i t iy %$$uni% t )u%t &u ity ) nnin
&ui$nttu*%nt %t.
FUNDAMENTALS OF ADVANCED PRODUCT QUALITY
PLANNING
Av n% cu%t0u ityc nnin i tu%tu $th inin n
t *ihin th t) n% y t u th t )u%t tii th
%ut$. Th v n% )u%t &u ity ) nnin i t %iit t
%$$uni% tin'ithvyninvvt uth t &uit)
%$)tnti$.%tiv v n%)u%t&u ity) nnin)nn
%$) ny¶ t) $ n $nt %$$it$nt t th t &ui in
%hivin %ut$ ti %tin. S$ th *nit v n% )u%t
&u ity) nnin
c
.Ti%tu%t tiyth%ut$.
.T)$t yintii% tin&ui%h n.
.T vi t%h n.
.T)vi &u ity)u%tnti$ tth't%t.
Th'() %ti%t n n yti% t%hni&u%i* inthi
)t itin i% &un%t$ (it yt'. %h v n%
)u%t&u ity) niuni&u.Th %tu ti$in n&un%+%utin
i )nnt n %ut$ n n +)%t tin n th ) %ti%
$ tt.
c
th %ut$ in $in )viin *tt )u%t n vi% th n th
%$)titin. Th y t th )u%t &u ity ) nnin )% i
in t u th t %ut$ n n +)%t tin % y
unt.
Thin)ut nut)ut ))i% *tth)% $ yv y %%in
t th )u%t )% n %ut$ n n +)%t tin. S$
%$$n tini%uinthi%tin '
Inputs
ÿ Vi%th%ut$
Y. M (tR %h
. Hiti% nty n0u ityIn$ tin
3. T $+)in%
ÿ uinc nM (tinSt ty
ÿ cu%tc%n%h$ (D t
ÿ cu%tc%Au$)tin
ÿ cu%tRi *iityStui
ÿ Cut$In)ut
Outputs
ÿ Din
ÿ Ri *iity n0u ity
ÿ ci$in yiM ti
ÿ ci$in yc%'Ch t
ÿ ci$in yLitinS)%i cu%t nc%Ch %titi%
ÿ cu%tAu n%c n
ÿ M n $ntSu))t
c
. PRODUCT DESIGN AND DEVELOPMENT
Thi %tin i%u th $nt th ) nnin )% uin
'hi%h in tu n %h %titi% v) int n in
$. Th cu%t 0u ity c nnin T $ hu %ni in
%tinth) nnin)%vnithini'n*yth%ut$
h . Th t) in%u )tty) *ui t viy th t th )u%t
vi%$tth*-%tivthVi%thCut$.A i*in
$ut)$it $tin)u%tin vu$ n%hu n*%nitnt
'ith *iity t $t ninin &ui$nt n 'ith &u ity
i *iity invt$nt %t 'iht unit %t n ti$in *-%tiv.
Athuh i*iity tui n %nt ) n )i$ iy * n
ninin 'in n)%ii% tin &ui$nt v u * in$ tin
% n*iv$th n yti% t%i*inthi%tintuth
in n )iitiz th %h %titi% th t $ y n )%i )u%t n
)%%nt.
Inputs
ÿ Din
ÿ Ri *iity n0u ity
ÿ ci$in yiM ti
ÿ ci$in yc%'Ch t
ÿ ci$in yLitinS)%i cu%t nc%Ch %titi%
ÿ cu%tAu n%c n
ÿ M n $ntSu))t
c
Outputs
ÿ Din iuM n%tAn yi!DMA)
ÿ DinM nu %tu *iity nA$*y
ÿ DinVii% tin
ÿ DinRvi'
ÿ ctty)uiCntc n
ÿ nininD 'in!in%uin$ th t )
ÿ nininS)%ii% tin
3. PROCESS DESIGN AND DEVELOPMENT
Thi %tin i%u th $ - tu v)in
$ nu %tuin yt$ n it t %nt ) n t %hiv &u ity
)u%t. Th t ( t * %%$)ih t thi t) th )u%t &u ity
) nnin)%)nu)nthu%%u%$)tinth)it
%nt in inth itt'%tin.Thi n+tt) iintnuth
%$)hniv v)$nt n %tiv $ nu %tuin yt$. Th
$ nu %tuin yt$ $ut u th t %ut$ &ui$nt n n
+)%t tin $t.
Inputs
ÿ Din iuM n%tAn yi!DMA)
ÿ DinM nu %tu *iity nA$*y
ÿ DinVii% tin
ÿ DinRvi'
ÿ ctty)uiCntc n
c
ÿ nininD 'in!in%uin$ th t )
ÿ nininS)%ii% tin
ÿ M ti S)%ii% tin
ÿ D 'in nS)%ii% tinCh n
ÿ '&ui)$ntTin n %iitiR&ui$nt
ÿ S)%i cu%t nc%Ch %titi%
ÿ Ttin&ui)$ntR&ui$nt
ÿ T $ i*iityC$$it$nt nM n $ntSu))t
Outputs
ÿ c %( inSt n
ÿ cu%tc%0u itySyt$Rvi'
ÿ c%'Ch t
ÿ c nL yut
ÿ Ch %titi%M ti+
ÿ c% iuM n%tAn yi!cMA)
ÿ cL un%hCntc n
ÿ c%Intu%tin
4. PRODUCT AND PROCESS VALIDATION
Thi %tin i%u th $ - tu v i tin th
$ nu %tuin )% thuh n v u tin )u%tin ti un.
Duin )u%tin ti un th cu%t 0u ity c nnin T $ hu
v i tth tth%nt) n n)%'%h t *in' n
th )u%t $t %ut$ &ui$nt. Aitin %n%n hu *
intiiinvti tin nutin)itu )u%tinun.
c
Inputs
ÿ c %( inSt n
ÿ cu%tc%0u itySyt$Rvi'
ÿ c%'Ch t
ÿ c nL yut
ÿ Ch %titi%M ti+
ÿ c% iuM n%tAn yi!cMA)
ÿ cL un%hCntc n
ÿ c%Intu%tin
ÿ M u$ntSyt$An yic n
ÿ ci$in yc%C ) *iityStuyc n
ÿ c %( inS)%ii% tin
ÿ M n $ntSu))t
Outputs
ÿ cu%tinTi Run
ÿ M u$ntSyt$v u tin
ÿ ci$in yc%C ) *iityStuy
ÿ cu%tinc tA))v
ÿ cu%tinV i tinTtin
ÿ c %( inv u tin
ÿ cu%tinCntc n
ÿ 0u ityc nninSin nM n $ntSu))t
c
V. FEEDBACK, ASSESSMENT AND CORRECTIVE
ACTION
0u ity) nninntn'ith)%v i tin nint tin.
It i th %$)nnt $ nu %tuin t 'h ut)ut % n * v u t
'hn )%i n%$$n% uv i tin )nt.Thii th
ti$tv u tth%tivnth)u%t&u ity) nnint.Th
)u%tin%nt) nith* iv u tin)u%tvi% tthi
t .V i * n tti*ut t $ut*v u t.Itith*i tin
u))i t $t %ut$ &ui$nt n %h %titi%. S)%i
%h %titi%$ut$tthini%)%ii*yth%ut$.
Inputs
ÿ cu%tinTi Run
ÿ M u$ntSyt$v u tin
ÿ ci$in yc%C ) *iityStuy
ÿ cu%tinc tA))v
ÿ cu%tinV i tinTtin
ÿ c %( inv u tin
ÿ cu%tinCntc n
ÿ 0u ityc nninSin nM n $ntSu))t
Outputs
ÿ Ru%V i tin
ÿ Cut$S ti %tin
ÿ Divy nSvi%
c
A. CONTROL PLAN
Th )u) thi Cnt c n $thy i t i in th
$ nu %tu&u ity)u%t %%int%ut$&ui$nt.It
thi *y )viin tu%tu )) %h th in %tin n
i$)$nt tinv u %nt$ththtt yt$.Cnt
c n )vi 'ittn u$$ y %i)tin th yt$ u in
$ini$izin)% n)u%tv i tin.ThCntc nnt) %
th in$ tin %nt in in t i ) t intu%tin. Thi
$thy i ))i% *t 'i n $ nu %tuin)% n
t%hni. Th Cnt c n i n int ) t n v &u ntity
)% nit*utiiz ivin%u$nt.
An i$)t nt )h th )% &u ity ) nnin i th
v)$nt Cntc n.ACntc ni 'ittn%i)tinth
yt$%ntin) t n)%.AinCntc n$ y ))y
t u) $iy)u%tth t )u%*yth $)% tth
$u%.S(t%h n% y$ y* tt %htthCntc n
iut tin )u). In u))t Cnt c n )% $nitin
intu%tinhu*in nu%ntinu y.
In %t th Cnt c n %i* th %tin th t &ui t
%h )h th )% in%uin %ivin in)% utin n
)ii%&ui$ntt uth t )%ut)ut'i*in t t
%nt. Duin u )u%tin un th Cnt c n )vi th
)% $nitin n %nt $th th t 'i * u t %nt
%h %titi%. Sin% )% +)%t t * %ntinu y u) t n
i$)v th Cnt c n %t t ty th t i )niv t th
%h nin)%%nitin.
c
ThCntc n i $ int in n uthuhutth)u%t i
%y%. yinth)u%ti%y%it)i$ y)u)it%u$nt n
%$$uni% t th initi ) n )% %nt. Su*&unty it ui
$ nu %tuin in h' t %nt th )% n nu )u%t &u ity.
Uti$ ty th Cnt c n $ in ivin %u$nt %tin th
%unt $th %nt n $ u$nt yt$ u. Th Cnt
c niu) t $ u$ntyt$ n%nt$th v u t
ni$)v.
)% %nt n i$)v$nt t * %tiv * i%
unt ninth)% $ut**t in. A $utii%i)int $ i
t *ih t v) th Cnt c n *y utiizin th v i *
in$ tint in *ttunt ninth)%u%h
ÿ c%'Di $
ÿ Syt$Dinc% iuM n%tAn yi
ÿ S)%i Ch %titi%
ÿ LnL n$Si$i c t
ÿ T $¶
n'thc%
ÿ DinRvi'
ÿ )ti$iz tinMth
Th*nitv)in ni$)$ntin Cntc nin%u
.0u ityti$)v.
.Cut$tuy tii.
. C$$uni% tin ny %h n in )u%t )% n %nt $th
t*tt.
c
c
INTRODUCTION
Purpose:
cu%tin c t A))v c% !ccAc) in ni%
&ui$nt )u%tin ) t ))v in%uin )u%tin n *u(
$ ti .Th)u)ccAcitt$ini %ut$ninin
in% n)%ii% tin&ui$nt ))yunt*yth
u))i n th t )% h th )tnti t )u% )u%t %nitnty
$tin th &ui$nt uin n %tu )u%tin un t th &ut
)u%tin t.
Applicability:
ccAc h ))y t intn n +tn u))i it *u(
$ ti )u%tin $ ti n )u%tin vi% ) t. *u(
$ ti ccAc i nt &ui un &ut *y yu %ut$. A
u))it n % t u)u%tinvi%) th %$)y'ith
ccAcun$ y' iv*yth%ut$.Tinh *$ int in
t n % t u it$ n th it$ t t
*in v i *.
Y. GENERAL
Thu))ih *t in u ))v $ th%ut$)u%t ))v
%tivity
) An') t)u%t
*) C%tin i%) n%yn )viuyu*$itt) t
%) cu%t $ii *y n ninin %h n t in %
)%ii% tin$ ti .
c
. PPAP PROCESS REQUIREMENTS
Significant Production Run
)u%tin ) t )u%t ccAc h * t (n $
inii% nt )u%tin un. Thi )u%tin un h * $ n hu t
ihthu)u%tin n'ithth)%ii%&u ntityttt $ini$u$
%n%utiv ) t un th'i )%ii *y th uthiz
%ut$&u ity)nt tiv.
Thi un h * $ nu %tu t th )u%tin it uin th
tin uin )% $ ti n ) t $ th )u%tin
nvin$nt. c t $ %h uni&u )u%tin )% .. u)i% t
$*yin n'(% %h)itin $uti)% vityi$
t) ttnh *$ u n)nt tiv) ttt.
*u($ ti n)%ii%n.4) t5i&ui.I $)i
&ui t * u*$itt it h * t (n in $ nn t u th t it
)nt4t yt t5) tinth)%.
PPAP Requirements
Th u))i h $t )%ii &ui$nt .. in %
)%ii% tin n *u( $ ti th u( M ti R&ui$nt
Ch%(it. Any ut th t uti )%ii% tin % u th
u))inttu*$itth) t%u$nt tin n%.vyt
h * $ t %%t th )% th t in % &ui$nt
$t. I th u))i i un * t $t ny th &ui$nt th
%ut$ h * %nt %t t$in tin )))i t %%tiv
%tin.
c
In)%tin n ttin ccAc h * )$ *y &u ii
* ty. C$$%i in)nnt tt * ti u h *
%%it %iiti. hn %$$%i * ty i u th u))i
h u*$it th tt ut n th * ty tth th n$
* ty )t $ t. Th n $ th * ty th t )$ th
tt nth t!)thtt ntht n utunthtth
* ini% t. Blanket statements of conformance are unacceptable for
any test results.
Th u))i h h v th ))i% * it$ n % it *'
%h) t $iy) t th) tu*$iinv.Th
%h *in PPAP) tin%inu%hi n* iy
v i *. Th it$ *' h * iy v i * %ut$ u in
ccAc. Th u))i h *t in )i ))v $ th %ut$ )u%t
))v %tivity+%)tinvi tintccAc&ui$nt.
Various Records in PPAP File
)DinR%
*)Any uthiznininCh n%u$nt
%)nininA))v 'hn&ui
)Din iuM n%tAn yiiu))iiin
)ni*.
)c%'i $
)c% iuM n%tAn yi
)Di$nin Rut
h)R%$ ti )$ n%ttut
i)Initi )%tui
c
)n
)0u ityIni%
)A%%)t n%%iti initi tuy
)Unt *)%
)c%'ithnSiS)%ii% tinn$
Diti*utin
)St tyhnA%%)t n%Citi AtS tii
-)M u$ntSyt$An yiStui
()0u iiL * tyD%u$nt tin
)Cntc n
$)c tSu*$iin nt!cS)
n)A)) n%A))v R)t!AAR)
)u(M ti R&ui$ntCh%(it
))S $)cu%tinc t
&)M tS $)
)Ch%(inAi
)Cut$S)%ii%R&ui$nt
c
Submission to Customer
Th u))i h u*$it ccAc ))v )i t th it )u%tin
hi)$ntinth'initu tinunth)ni*)u%t ))v
%tivityh ' ivthi&ui$nt.
Th u))i h vi' n u) t n% y ))i% * it$ in
thccAcit%tth)u%tin)% 'hthnt
th%ut$&ut $ u*$iin.ThccAcih %nt inth
n $th)ni*%ut$)u%t ))v %tivity)n ntin
th' iv nth t.
4. SUBMISSION TO CUSTOMER- LEVELS OF
EVIDENCE
Submission Levels
Thu))ih u*$itthit$ n%)%ii*ythv
&ut*yth%ut$
Lv / nt ny ! n in t )) n% it$ n
A)) n%A))v R)t)u*$itttth%ut$.
Lv / nt 'ith )u%t $) n i$it u))tin t
u*$itttth%ut$.
Lv
/ nt 'ith )u%t $) n %$)t u))tin t
u*$itttth%ut$.
Lv/ nt nth&ui$nt in*yth%ut$.
Lv / nt 'ith )u%t $) n %$)t u))tin t
v i *vi' tthu))i¶$ nu %tuin% tin.
c
Thu))ih u v
th ut v u*$iin
un )%ii th'i *y th )ni* %ut$ )u%t ))v
%tivity.Au))i*u($ ti nyh uv th utv
*u( $ ti ccAc u*$iin un )%ii th'i *y th
)ni*%ut$)u%t ))v %tivity.
c
M ti %v *y n inti$ ))v th t i t $t th
u)n %tin ) n ith *y th +)i tin t th hi)$nt th
uthiz&u ntity'i*-%t. itin hi)$nt uthiz
un n+tninthinti$ ))v i nt.
*u( $ ti th u))i h u th 4u( M ti Inti$
A))v 5$it&uiv nt.
Rejected $ n th t th u*$iin th )u%tin t $ 'hi%h it
' t (n n %%$) nyin %u$nt tin nt $t %ut$
&ui$nt.C%t)u%t n %u$nt tinh *u*$itt n
))v*)u%tin&u ntiti$ y*hi)).
A. RECORD RETENTION
cu%tin ) t ))v % u*$iin v h *
$ int in th nth ti$ th t th ) t i %tiv )u n % n
y .
Th u))i h nu th t th )))i t ccAc % $
u)) tccAci in%un%inthn') tccAc
i.
c