VIJAY ENGINEERING

WORKS

PRODUCTION PROCEDURE

As Per IATF 16949:2016

VEW VIJAY ENGINEERING WORKS
Index
DEPARTMENT: PRODUCTION

SL. NO. Subject Document No.

1 Index

2 Production Process Procedure VEW-PRD-P-01

Procedure for Temparary Changes of process

3 VEW-PRD-P-02
Controls

4 Procedure for Rework VEW-PRD-P-03

5 Procedure for Repaire VEW-PRD-P-04

6 Introduction, Process Measurements & VEW-PRD-P-A

Objectives

7 Responsibility, Authority & Communication VEW-PRD-P-B

8 Abbrevations VEW-PRD-P-C

9 Ammendment Record Sheet VEW-PRD-P-D

List of Documented information for Production

10 VEW-PRD-L-02
 Ref No: VEW-PRD-P-A
Rev No:00
VEW VIJAY ENGINEERING WORKS Eff Dt :01/04/2018
Page No: 1 of 1

Production Department Procedures

Subject : Introduction, Processes Measurements & Objectives

1.0 Introduction

Production planning is done based on the customer schedule/Requirements

2.0 Process Measurement & Objectives

To monitor and measure department processes, following measures and objectives
are established.

Effectiveness/
Sl No Description Unit
Efficiency
1 Manufacturing planned vs actual % Effectiveness
2 Customer Schedule Vs Dispatch % Effectiveness
3 Production outputs-Door Assly Nos Efficiency
4 Inhouse Rejection Performance % Efficiency

5 Inhouse Rework Performance % Efficiency

Prepared By Approved By
Designation Prod In charge MP

Signature
Ref No: VEW-PRD-P-A
Rev No:00
Eff Dt :01/04/2018
Page No: 1 of 1

Evaluation
Period
Monthly

Monthly

Monthly

Monthly

Monthly

Approved By
MP
VEW VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-B
Rev No:00
Production Department Procedure Eff Dt :01.04.2018
Page No: 1 of 1
Subject : Roles, Responsibilty, Authority & Communication

Objective:
To establish an organisation structure that will ensure proper communication and control within the Department and also
clearly define the responsibility and authorities of department personnel to achieve the organisation's objective.

Scope:
All personels of Production

Responsibility:
Details:
1.0 Organisation structure of Production Department

PRODUCTION IN CHARGE

Operator

2.0 Role, Responsibility and Authority

2.1 Role : Production I/c
Responsibility:
1. Allocate work to all operators as per production plan.
2. Monitor Day-to-Day Production Activities.
3. Maintain Production Records.
4. Participate in Management Review meetings
5. Maintain daily production plan and review its effectiveness
6. Ensure identification and traceability at various stages of product realization.
7. Ensure compliance with laid down systems and procedures, as per IATF 16949 quality
Management System.
8. Maintain good 5S standards in the organization.
9. Allocate Identification Marks to all Process Equipments.
10. Discuss corrective actions for any rejection or defects with other staff in production and quality
Incharge and ensure implementation of the same.

11.On job traing records,trainings to be conducted as per the training plan & records are to be maintained in training register.
12. Error Proffing devicess monitoring & controls
13. Control of Temparary changes of process controls as per procedure
14. First Pieces Inspection / Verification after product shutdown ( Power failure, Machine B/d)
15. Control of Inhouse Rejection & Rework
16. Monthly Monitoring of KPI / Objective Target status , if target not achieved analysis and corrective action to reduce the
Rejection & Reowrk
17.Carry out Validation of welding process as per frquency defined and maintain the same records
19. Carry out all process validation once in a year
Authority:
1) Preparation of production schedule as per planning
2) Responsible for all activities relating to production.
3) Interaction with external agencies like customer/client and with internal QC dept.
4) Interact with production & stores on a day to day basis.

2.2 Sr. Operator

Responsibility:
1) Responsible for carrying out the planning as per in charge.
2)
3) Responsible
Fulfillment of for product
duties qualitybyatProduction
allocated all time. in charge in time.

Prepared By Approved By
Designation Prod In charge MP

Signature
 Ref No: VEW-PRD-P-C
Rev No:00
VEW VIJAY ENGINEERING WORKS Eff Dt :01/04/2018
Page No: 1 of 1

Production Department Procedures

Subject : Abbreviations

ASST - ASSISTANT
B/D - BREAKDOWN
BDR - BREAKDOWN REPORT
DG SET - DIESEL GENERATOR SETS
F - FORMAT
M/C - MACHINE
MNT - MAINTENANCE
MTBF - MEAN TIME BETWEEN FAILURE
MTTR - MEAN TIME TAKEN FOR REPAIR
PM - PREVENTIVE MAINTENANCE
PRD - PRODUCTION
QAD - QUALITY ASSURANCE DEPARTMENT
R - REGISTER
REF NO. - REFERENCE NUMBER
STR - STORES
PUR - PURCHASE
IATF INTERNATION AUTOMOTIVE TASK FORCE
QMS QUALITY MANAGEMENT SYSTEM
TRG TRAINING
LIR LINE INSPECTION REPORT
FMEA FAILURE MODE EFFECT ANALYSIS
MSA MEASURMENT SYSTEM ANALYSIS
PPAP PARODUCTION PART APPROVAL PROCESS
APQP ADVANCE PRODUCT QUALITY PLANNING

Prepared By Approved By
Designation Production In charge MP

Signature
Ref No: VEW-PRD-P-C
Rev No:00
Eff Dt :01/04/2018
Page No: 1 of 1

Approved By
MP
 Ref No: VEW-PRD-P-D
Rev No: 00
VEW VIJAY ENGINEERING WORKS Eff Dt : 01/04/2018
Page No: 1 of 1

Production Procedure
Subject : Dcoumented Information Amendment Record Sheet
Sl. Existing Document Effective
Ref. No Rev. No Details of Changes Bases of Changes Reviewed By Approved By
No. Name. Date

APPROVED BY APPROVED BY
DESIGNATION PRODUCTION INCHAGE MP
SIGNATURE
VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 1 of 8
Subject : Cutting Process

Process
Flow Chart Resp Documents referred Records Generated

Start

Receipt of Daily
Production Plan Customer Schedule

Production planning
(As per the availblity of the Daily Production planning Production LIR cum Job card
R/M etc)

Daily Production planning Production LIR cum Job card

Receipt of material as VEW/PRD/F/02
per requirement

Preparation of Jigs & Work Instruction/Process

control plan
Production LIR cum Job card
Fixtures Production Incharge
CUTTING PROCESS

Work Instruction/Process Production LIR cum Job card

Assembly of Jigs & fixtures control plan

Work Instruction/Process Production LIR cum Job card

Cleaning of machine control plan

Work Instruction/Process Daily Production report

cutting of raw material control plan

rework the component

if length is varied Work Instruction/Process Daily Production report
store as per the required sizes
control plan

Hand over the component for

Drilling

Compeleted

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 2 of 8
Subject : Drilling Process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Receipt of Component from Cutting

Production LIR cum Job card

Jigs & template Work Instruction & process Production LIR cum Job card
control plan

Work Instruction & process Production LIR cum Job card

control plan
selection of drill bit

Checking of dimension
Work Instruction & process Production LIR cum Job card
control plan

rework the
component Work Instruction & process Production LIR cum Job card
Not Ok
control plan
DRILLING PROCESS

Verification of
Production Incharge

dimension

Ok Work Instruction & process Production LIR cum Job card

control plan

Removal of Burrs

Next operation to Welding

Work Instruction & process Production LIR cum Job card
control plan

Compeleted

Work Instruction & process Production LIR cum Job card

control plan

Prepared By Approved By

Designation PROD IN CHARGE MP

 Signature

VEW VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01

Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 3 of 8
Subject : Rolling Process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Reciept of component from Production LIR cum Job card

cutting

roller setting in rolling machine Work Instruction/ Stage Production LIR cum Job card
control plan

production In charge
ROLLING PROCESS

Inspection/radius Work Instruction/ Stage

verification with the First piece approval from QA
control plan
template

Work Instruction/ Stage Production LIR cum Job card

Next operation to control plan
assembly & welding

Work Instruction/ Stage Production LIR cum Job card

control plan

Compeleted

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
VEW VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 4 of 8
Subject : Assembly & welding Process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Welder qualification done through third

Production HOD Welder certicaate & WPS & PQRS
party agency

Welding process validation done for

defferent thickness once in a year for Welding process validation report
process & Product parameters and Control Plan & Welding work
personal validation through exam Production HOD instruction

Reciept of component from Production LIR cum Job card

rolling & drilling
WELDING PROCESS

Assemble the child parts in welding fixture Work Instruction/ Stage Production LIR cum Job card
control plan
Qualified Welders

welding
Work Instruction/ Stage Production LIR cum Job card
control plan

Inspection/dimension Work Instruction/ Stage Production LIR cum Job card

verification control plan

Next operation to grinding Work Instruction/ Stage Production LIR cum Job card
control plan

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
VEW VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No:: 5 of 8
Subject : Grinding & primer application Process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Reciept of component from

welding Production LIR cum Job card
Grinding & primer application Process process

Grinding on welding area Work Instruction/ Stage Production LIR cum Job card
control plan

Production In charge
Red oxide primer Work Instruction/ Stage Production LIR cum Job card
application on grind area control plan

Inspection of component
Work Instruction/ Stage Production LIR cum Job card
control plan

Compeleted

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 6 of 8
Subject : Panelig Process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Production LIR cum Job card

Reciept of component from
grinding process

Work Instruction/ Stage Production LIR cum Job card

Application of simsom control plan
IR7005 adhesive on door
frame

Production In charge
Panelig Process

Work Instruction/ Process Production LIR cum Job card

Assembly of external panel Parameter
& door frame

clamping Work Instruction/ Stage Production LIR cum Job card

control plan

Inspection of component Work Instruction/ Stage Production LIR cum Job card
control plan

Compeleted

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 7 of 8
Subject : Finishing and primer application process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Production LIR cum Job Card

Reciept of component from
panelling
Finishing and primer application process

Work Instruction/ Stage

control plan Production LIR cum Job Card

Grinding of sharp edges

Production In charge
Work Instruction/ Stage
control plan Production LIR cum Job Card

Primer application

Work Instruction/ Stage

control plan Production LIR cum Job Card

Inspection of component

Compeleted

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
VIJAY ENGINEERING WORKS Ref No: VEW-PRD-P-01
Rev No:01
Production Department Procedure Eff Dt :01.10.2019
Page No: 8 of 8
Subject : Lock fitting process

Process
Flow Responsibility Documents referred Records Generated
No.

Start

Reciept of component from Work Instruction/ Stage

finishing process control plan Production LIR cum Job Card

Work Instruction/ Stage

Lock fitting control plan Production LIR cum Job Card

Production In charge
Lock fitting process

Work Instruction/ Process

Inspection of component Drawing Production LIR cum Job Card

Compeleted

Prepared By Approved By

Designation PROD IN CHARGE MP

Signature
 Ref No: VEW-PRD-L-02
VEW VIJAY ENGINEERING WORKS Rev No: 00
Eff Dt : 01/04/2018

TITLE: MASTER LIST OF DOCUMENTED INFORMATION

SUBJECT: LIST OF DOCUMENTED INFORMATION FOR PRODUCTION DEPARTMENT

Form of Record Retention File No./ Storage

Sl. No. Record Description Record Ref. No.
0 1 2 3 4 5 (Hard/ Soft) Period Folder No. Location

Office
1 Procedure for Production VEW-PRD-P-01 Soft ---------- Production
Computer
Procedure for Temparary Changes of Office
2 process controls
VEW-PRD-P-02 Soft ---------- Production
Computer
Office
3 Procedure for Rework VEW-PRD-P-03 Soft ---------- Production
Computer
Office
4 Procedure for Repaire VEW-PRD-P-04 Soft ---------- Production
Computer
Office
5 Process Mapping VEW-QMS-F-02 Soft ---------- Production
Computer
Office
6 Contigency Plan VEW-PPRD-L-01 Soft ---------- Production
Computer
Office
7 List of Documented Information VEW-PRD-L-02 Soft ---------- Production
Computer
Office
8 Process Turtles ------------ Soft ---------- Production
Computer
Introduction, Processes Office
9 Measurements & Objectives
VEW-PRD-DP-A Soft ---------- Production
Computer
Roles, Responsibilty, Authority & Office
10 Communication
VEW-PRD-DP-B Soft ---------- Production
Computer
Office
11 Abbreviations VEW-PRD-DP-C Soft ---------- Production
Computer
Dcoumented Information Office
12 Amendment Record Sheet
VEW-PRD-DP-D Soft ---------- Production
Computer
Office
13 KPI Tend Chart ------------ Soft ---------- Production
Computer

14 Work instruction for Shearing VEW-PRD-WI-01 Hard ---------- Display Shop Floor

15 Work instruction for tube cutting VEW-PRD-WI-02 Hard ---------- Display Shop Floor

16 Work instruction for drilling VEW-PRD-WI-03 Hard ---------- Display Shop Floor
17 Work instruction for bending VEW-PRD-WI-04 Hard ---------- Display Shop Floor

18 Work instruction for rolling VEW-PRD-WI-05 Hard ---------- Display Shop Floor

19 Work instruction for bending VEW-PRD-WI-06 Hard ---------- Display Shop Floor

20 Work instruction for mig welding VEW-PRD-WI-07 Hard ---------- Display Shop Floor

21 Work instruction for handling of NC VEW-PRD-WI-08 Hard ---------- Display Shop Floor

22 Work instruction for grinding VEW-PRD-WI-09 Hard ---------- Display Shop Floor

23 Work instruction for using pasting gun VEW-PRD-WI-10 Hard ---------- Display Shop Floor

24 Work instruction for die setting VEW-PRD-WI-11 Hard ---------- Display Shop Floor

Work instruction for in process

25 inspection
VEW-PRD-WI-12 Hard ---------- Display Shop Floor

Work instruction for loading &

26 unloading
VEW-PRD-WI-13 Hard ---------- Display Shop Floor

27 Work instruction for final inspection VEW-PRD-WI-14 Hard ---------- Display Shop Floor

28 Work instruction for blanking,piercing VEW-PRD-WI-15 Hard ---------- Display Shop Floor

Work instruction for tool

29 management
VEW-PRD-WI-16 Hard ---------- Display Shop Floor

30 Stage Control plan for cutting VEW-PRD-CP-01 Hard ---------- Display Shop Floor

31 Stage Control plan for shearing VEW-PRD-CP-02 Hard ---------- Display Shop Floor

32 Stage Control plan for Drilling VEW-PRD-CP-03 Hard ---------- Display Shop Floor

33 Stage Control plan for Rolling VEW-PRD-CP-04 Hard ---------- Display Shop Floor

34 Stage Control plan for Bending VEW-PRD-CP-05 Hard ---------- Display Shop Floor

Stage Control plan for assembly &

35 Welding
VEW-PRD-CP-06 Hard ---------- Display Shop Floor

Stage Control plan for

36 piercing,blanking
VEW-PRD-CP-07 Hard ---------- Display Shop Floor
 37 Stage Control plan for panelling VEW-PRD-CP-08 Hard ---------- Display Shop Floor

Stage Control plan for finishing

38 process
VEW-PRD-CP-09 Hard ---------- Display Shop Floor

Stage control plan for grinding &

39 primer application
VEW-PRD-CP-10 Hard ---------- Display Shop Floor

40 Monthly-Daily Production Plan VEW-PRD-F-01 Hard 2 Months PRD-01 Shop Floor

41 ProductionLIR cum Job card VEW-PRD-F-02 Hard 1 Year PRD-02 Shop Floor

Objective achievement Planning

42 report
VEW-PRD-F-03 Hard 1 Year PRD-03 Shop Floor

43 Process Validation report VEW-PRD-F-04 Hard 3 Years PRD-04 Shop Floor

44 Process validation plan VEW-PRD-F-05 Hard 1 Year PRD-04 Shop Floor

45 Welding Process Validation Report VEW-PRD-F-06 Hard 2 Years PRD-04 Shop Floor

DEVIATION PERMIT/ TEMPORARY

46 PROCESS DEVIATION REPORT
VEW-ENGG-F-09 Hard 1 Year PRD-04 Shop Floor

Prepared By Approved By

DESIGNATION PRODUCTION INCHAGE MP

SIGNATURE