PROJECT STATUS OF EXPO FORGINGS PVT. LTD.

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 PROJECT STATUS OF EXPO FORGINGS PVT. LTD.
ACTIVITY
DEFINE RED-TEG AREA & HOLD AREA IN YOUR PLANT
PREPARETION OF CFT( CROSS FUNCTIONAL TEAM).
ESTABLISH ORGANISATION CHART.
DEFINE QUALITY POLICY,OBJECTIVIES AND OTHERS POLICIES.
DEFINE KPI'S DEPARTMENT WISE.
PREPARE QUALITY MANUAL (INCLUDING RISK ASSESSMENT, CONTEXT OF ORGANISATION, INTERNAL &
EXTERNAL ISSUES, NEEDS &-EXPECTATIONS
LEVEL-2 DOCUMENTATION OF INTERSETED
ALL DEPARTMENT PARTIES)
WISE PROCEDURE.
PREPARATION OF ALL TYPES WORK INSTRUCTIONS
WORK INSTRUCTIONS DISPLAY ON THE MACHINES AND REQUIRED AREA.
IMPLEMENTATION OF DAILY MACHINE CHECK SHEET FOR EVERY MACHINE ON DAILY BASIS
MAKE MASTER LIST OF FORMATS REQUIRED FOR ALL DEPARTMENTS.
MAKE FROMATS READY AS PER IDENTIFIED LIST.
ALL THE DATA IS BEING FILED IN FORMATS
CHECK AND ENSURE ALL FORMATS ARE LINKED TO QMS SOP'S
RELEASE ALL QMS DOCUMENTS AND FORMATS TO PROCESS OWNERS FOR IMPLMENTATION.
GIVE ON-JOB TRAINING FOR IMPLEMENTATION OF FORMATS.
MAKE INTERNAL AUDIT PLAN COVERING ALL PROCESSES/FUNCTIONS.
CONDCUT INTERNAL AUDIT
MAKE SUMMARY OF NCR'S RAISED AND CLOSURE OF NCR'S.
MAKE MRM AGENDA
RELASE MRM DATES AND CONDUCT MRM INCLUDING ALL PROCESS OWNERS / DIRECORS/UNIT HEAD.
AWARNESS TRAINING ON 5S TO THE TEAM MEMBERS
DIVISION OF COMPANY PREMISIS IN DIFFERENT 5'S ZONES
IDENTIFICATION OF UNNECESSARY AND UNUSED ITEMS ACROSS THE PLANT W.R.T DEFINED ZONES
SHORTING OF DEAD ITEMS IN PLANT.(1'S)
IDENTIFY FIX LOCATION FOR TOOLS, JIGS, FIXTURES, MATERIALS, MACHINES, DOCUMENTS ETC.
IDENTIFICATION OF ALL SHOPS/WORKING AREA, TOOL,RACKS,MACHINES,BINS,SAFETY EQUIPMENTS ETC.
CLEANING OF FLOOR, MACHINES, BINS RACKS , ALMIRAH, WORK STATIONS, INSPECTION STRATIONS ETC.
PAINTING OF PLANT PREMISES, MACHINES,RACKS,BINS,WALLS AND IDENTIFICATION WITH MACHINE NOS.
FIFO IDENTIFICATION IN STORES FOR INVENTORY MANAGEMENT
DEFINE RED-TEG AREA & HOLD AREA IN YOUR PLANT
AREA IDENTIFICATION (E.G WORK STATIONS, ZONES ETC.)
TAGGING OF ALL RAW MATERIAL
IDENTIFICATION OF SAFETY MEASURES INCLUDING PPE'S, FIRE EXTINGUISHER, EVACUATION ZONES, EXIT GATES ETC.
PREPARE KAIZEN GALLEY / BOARDS
RED BIN ANALYSIS SYSTEM IMPLEMENTATION
MATERIAL IDENTIFICATION AT DIFFERENT STAGE OF MANUFACTURING AND AT DEFINED INVENTORY ARES
GANG WAYS AND FLOOR MARKING
INVENTORY RECORD EVERY ITEM.
CREATING OF FG STORE FOR RFD PARTS WITH PROPER IDENTIFICATION
LTD.
STATUS REMARK
DELAY ONLY HOLD AREA PREPARED.
DONE
DONE
DONE
DELAY
DONE
DONE
DONE
DONE
DONE
DONE
DONE
DELAY
WORK IN PROGRESS
DONE
DONE
DELAY
WORK IN PROGRESS
WORK IN PROGRESS
WORK IN PROGRESS
WORK IN PROGRESS
DONE
DONE
DELAY
DELAY
DONE
DONE
WORK IN PROGRESS
WORK IN PROGRESS
DELAY
DELAY
WORK IN PROGRESS
DONE
DELAY
DONE
DONE
WORK IN PROGRESS
WORK IN PROGRESS
DELAY
DELAY
S.NO.
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 CHALLENGES POINTS FROM EXPO FORGINGS
THE POINTS DISCUSSSED IN MOM MEETING WERE NEVER COMPLETED ACCORDING TO TARGAT DATE.
WE DON'T GET GOOD RESPONSE FROM THE TEAM
MANPOWER SHORTING ISSUE.
THE SUPPLIER IS BUSY DELIVERING HIS PRODUCTION
HR AND QMS HEAD POSITION IS VACENT
SERIOUSNESS ABOUT THIS PROJECT.
ISO 9001:2015 QUALITY MANAGEMENT SYSTEM
ROAD MAP OF ISO 9001:2015 QUALITY MANAGEMENT SY
Name of Company :- EXPO FORGINGS PVT LTD.

Road Map
Activity Approach

PLAN
A) PROJECT KICK OFF. P
ACTUAL

PLAN
P
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL B) CONDUCT GAP ASSESMENT WITH
RESPECT TO 5'S, VISUAL LIZATION AND
QUALITY MANAGEMENT SYSTEM
PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN Mile Stone

PLAN
P
ACTUAL

PLAN
D
 D
ACTUAL

PLAN
D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
D
ACTUAL

PLAN
C
ACTUAL

PLAN
C,A
ACTUAL
Mile Stone

PLAN
P,D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL
Mile Stone

PLAN
D
ACTUAL

PLAN
D
ACTUAL
PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
C,D
ACTUAL
Mile Stone

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL
Mile Stone

PLAN
D
ACTUAL

PLAN
C,A
ACTUAL
PLAN
C,A
ACTUAL

PLAN
WORK IN PROGRESS
DONE
ACTIVITY DELAY

Manpower Deployment Plan

QMS Engineer Qtrek 02 times/month

02 times /
Senior Consultant- Qtrek
month

Lead /Principal Consultant- Qtrek Once/45 days

EMENT SYSTEM
ALITY MANAGEMENT SYSTEM
LTD.

Feb'25

ad Map VISIT-1

Sub-Activity Resp. W1

A.1 ) SITE VISIT, CONDUCT OPENING MEETING & Qtrek + EXPO

SETTING THE CONTEXT OF IMPROVEMENTS Team

B.1 ) ASSESMENT OF PRESENT SITUATION OF 5'S

MAINTAINANCE IN THE PLANT THROUGH GEMBA WALK Qtrek + EXPO
AND ASSESMENT SHEET Team

Qtrek + EXPO
a. Verification of 1-S (Sorting) condituon in the plant
Team

Qtrek + EXPO
b. Verification of 2-S (Set in order) condition in the plant
Team

Qtrek + EXPO
c. Verification of 3-S (Cleanliness) condition in the plant
Team

Qtrek + EXPO
d. Verification of 4-S (Standardization) in plant
Team

Qtrek + EXPO
e. Verification of 5-S (Sustainance) of 5S in Plant
Team

B.2 ) 5'S IMPLEMENTATION JOURNEY

a. Awarness training on 5S to the team members QTREK

b. Division of Company premisis in different 5'S Zones EXPO Team

b. Division of Company premisis in different 5'S Zones EXPO Team

c. Cross Functional Team development Zones Wise for

EXPO Team
Implementation of 5'S

B.3) 1S (Sorting) Implementation at Supplier Site

a. Identification of unnecessary and unused items across the Qtrek + EXPO

plant w.r.t defined zones Team

b. Tagging of the identified items for disposition e.g either to Qtrek + EXPO
scrap or offer to other for relevant use creating Red Tag Area Team

c. After discussion disposition action to be taken accordingly EXPO Team

d. The activity of 1S to be done on weekly basis EXPO Team

1S Audit at Supplier Site

B.4) 2S (Set In Order) Implementation at Supplier Site EXPO Team

a. Identify Fix Location for Tools, Jigs, Fixtures, Materials,

EXPO Team
Machines, Documents etc.

b. Fix Location marking for Tools, Jigs, Fixtures, Materials,

EXPO Team
Bins, Shadow Boards for tools etc.

c. Cretion of Shdow board for tool hang tool management and

EXPO Team
keeping

2S Audit at Supplier Site

B.5) 3S (Cleanliness) Implementation at Supplier Site EXPO Team

a. Cleaning of Floor, Machines, Bins Racks , Almirah, Work

EXPO Team
stations, Inspection Strations etc.
b.Identification of Hard to Clean Areas EXPO Team

c. Implementation of CLITA check sheet for every machine

EXPO Team
on daily basis

d. Development of Cleaning tools for the areas which are hard

EXPO Team
to clean

e. Identification and monitoring of abnormalities on machines EXPO Team

3S Audit at Supplier Site

B.6) 4S (Cleanliness) Implementation at Supplier Site EXPO Team

a. Painting of Plant Premises, Machines and Identification

EXPO Team
with Machine Nos.

b. Identification of 5'S zones along with the defined teams EXPO Team

c. Tools, Dies, Fixture, Jig identification EXPO Team

d. Identification of Fixtures based on the Parts Nos. of models EXPO Team

e. Inventory management by Identification of FIFO in Stores

EXPO Team
and at Shop Floor by defining levels

4S Audit at Supplier Site

B.7) 5S (Sustainance) Implementation at Supplier Site EXPO Team

a. Auditing of defined 5S zones based on the Checksheets by Qtrek + EXPO

the supplier team on regular basis Team
 b.Audit Scoring to be shared on Regular basis with the Swaraj Qtrek + EXPO
Team Team

Manpower Deployment Plan

Responsibility : Support in preperation of Level 1,2,3,4

documentation
Responsibility : Lead Project in preperation of Level 1,2,3,4
documentation, Visual Management improvements & on-job
training. Escalate any activity delays on timely basis.
Responsibility : Track on-time project completion of activities /
have phased review meetings with Unit Owners for any necessary
support.
 Feb'25 Mar'25 Apr'25
VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1

W2 W3 W4 W1 W2 W3 W4 W1
 Apr'25 May'25 Jun'25
VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1

W2 W3 W4 W1 W2 W3 W4 W1
 Jun'25 July'25
VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4

W2 W3 W4 W1 W2 W3 W4
ROAD MAP OF ISO 9001:2015 QUALITY MANAGEMENT SYSTEM
Name of Company :- EXPO FORGINGS PVT LTD.

Feb'25 Mar'25 Apr'25 May'25 Jun'25 July'25

Road Map VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4

Activity Approach Sub-Activity Resp. W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

PLAN A.1 ) SITE VISIT, CONDUCT OPENING MEETING & SETTING THE Qtrek + EXPO
A) PROJECT KICK OFF. P
CONTEXT. Team
ACTUAL
B.1 ) ASSESMENT OF BUSINESS PROCESSES INCLUDING
PLAN I.TOP MANAGEMENT
II. MANAGEMENT REPRESENTATIVE
III.STORE
IV. PRODUCTION PLANNING
AND CONTROL
V. PRODUCTION Qtrek + EXPO
P,D VI. QUALITY ASSURANCE Team
VII. HUMAN RESOURCE
VIII. FINISHED
GOODS AND DISPATCH
IX. MAINTENANCE
X. PURCHASE
ACTUAL B) CONDUCT GAP ASSESMENT WITH XI. OTHER TECHNICAL
RESPECT QUALITY MANAGEMENT B.2) ASSESMENT OF CURRENT STATUS OF QUALITY
SYSTEM REQUIREMENTS (ISO MANAGEMENT SYSTEM DOCUMENTATION INCLUDING
9001:2015) I.
QUALITY POLICY
P,D II. QUALITY MANUAL
III. QUALITY OBJECTIVIES
PLAN IV. FORMATS FOLLOWED
V. MASTER LIST OF DOCUMENTS
ACTUAL
B.3) ACTION PLAN DEVELOPMENT WITH TARGET DATES
PLAN BASED ON THE GAP ASSESMENT CONDUCTED FOR QUALITY Qtrek + EXPO
P,D
MANGEMENT SYSTEM Team
ACTUAL

PLAN B.5) DEFINE RED-TEG AREA & HOLD AREA IN YOUR PLANT Qtrek + EXPO
P,D
AND TO BE MAINTAN IT. Team
ACTUAL
C.1) AWARENESS TRAINING TO PROCESS OWNERS ON
PLAN ISO 9001:2015 REQUIREMNENTS AND OTHER USEFUL
C) ISO 9001:2015 STD CLAUSES
D CONCEPTS (COPQ, MTTR,MTBF, OTIF, EFFEICEINCY & OTHER Deepak Bhardwaj
AWARENESS.
KEY PERFORMANCE INDICATORS)
ACTUAL

PLAN D.1) FORMATION OF CFT & SIPOC (SYSTEM CO-ORDINATOR) Qtrek + EXPO
P
FROM SUPLIERS. Team
ACTUAL
D) CFT FORMATION
PLAN Qtrek + EXPO
P,D D.2) ESTABLISH ORGANISATION CHART.
Team
ACTUAL

PLAN E.1) DEFINE QUALITY POLICY & GET APPROVED BY TOP

D EXPO Team
MANAGEMENT.
ACTUAL

PLAN E.2) DEFINE QUALITY OBJECTIVES & TARGETS (KEY

D EXPO Team
E) QMS LEVEL 1 DOCUMNETATION PERFORMANCE INDICATORS)
ACTUAL
E.3) PREPARE QUALITY MANUAL (INCLUDING RISK
PLAN ASSESSMENT, CONTEXT OF ORGANISATION, INTERNAL &
D EXTERNAL ISSUES, NEEDS & EXPECTATIONS OF INTERSETED EXPO Team
PARTIES)
ACTUAL

P F1) BUSINESS PROCESSES- SALES & MARKETING

PLAN
F) MAPPING OF BUSINESS D a. Procedure for Contract Review EXPO Team
ACTUAL PROCESSES- L2 DOCUMENTATION

PLAN
D b. Procedure for Customer satisfaction EXPO Team
ACTUAL
P F2) BUSINESS PROCESSES- NEW PRODUCT DEVELOPMENT

PLAN
D a. Procedure for Planning of Product Realization EXPO Team
ACTUAL

PLAN
D b. Procedure for PPAP (Production Part Approval Process) EXPO Team
ACTUAL

PLAN
D c. Procedure for Initial Supply Control EXPO Team
ACTUAL

PLAN
D d. Procedure for Handling of Engineering Change EXPO Team
ACTUAL
P F3) BUSINESS PROCESSES- PURCHASE

PLAN
D a. Procedure for New Supplier Selection EXPO Team
ACTUAL

PLAN
D b. Procedure for Purchasing EXPO Team
ACTUAL

PLAN
D c. Procedure for Supplier Performance Assesment EXPO Team
ACTUAL
P F4) BUSINESS PROCESSES- RECEIPT STORE

PLAN
D a. Procedure for Material Receipt EXPO Team
ACTUAL
P F5) BUSINESS PROCESSES- QUALITY
 PLAN
D a. Procedure for Receipt Quality Control EXPO Team
ACTUAL

PLAN
D b. Procedure for Inprocess Quality Control EXPO Team
ACTUAL

PLAN
D c. Procedure for Control of Measuring and Monitoring Devices EXPO Team
ACTUAL

PLAN
D d. Procedure for Control of Non Confirming Products EXPO Team
ACTUAL

PLAN
D e. Procedure For Process & Product Audit EXPO Team
ACTUAL

PLAN
D f. Procedure For Corrective and Preventive Action EXPO Team
ACTUAL

PLAN
D g. Procedure for Customer Complaint Handling EXPO Team
ACTUAL
P F6) BUSINESS PROCESSES- PPC
QUALITY MANAGEMENT SYSTEM

PLAN
D a. Procedure for Production Planning and Control EXPO Team
ACTUAL
P F7) BUSINESS PROCESSES- PRODUCTION PROCESS

PLAN
D a. Procedure for Production Process EXPO Team
ACTUAL

PLAN
D b. Procedure for Tooling manitenance EXPO Team
ACTUAL
P F8) BUSINESS PROCESSES- MAINTENANCE

PLAN EXPO Team

D a. Procedure for Breakdown maintenence
ACTUAL

PLAN EXPO Team

D b. Procesure for Preventive maintenence
ACTUAL
P F9) BUSINESS PROCESS- SYSTEM COORDINATOR

PLAN
D a. Procedure for Control of Documents EXPO Team
ACTUAL

PLAN
D b. Procedure for Control of Records EXPO Team
ACTUAL

PLAN
D c. Procedure for Internal System Audit EXPO Team
ACTUAL

PLAN
D d. Procedure for MRM EXPO Team
ACTUAL

PLAN
D e. Procedure For Business Planning EXPO Team
ACTUAL

PLAN
D f. Procedure For Risk and Opportunity Assesment EXPO Team
ACTUAL

PLAN
D g. Procedure for Continual Improvements EXPO Team
ACTUAL
P F10) BUSINESS PROCESS- HUMAN RESOURCE

PLAN EXPO Team

D a. Procedure For Recruitment (where ever applicable)
ACTUAL

PLAN EXPO Team

D b. Procedure for Training and Development
ACTUAL

PLAN EXPO Team

D BUSINESS PROCESS- PACKAGING AND DISPATCH
ACTUAL

PLAN EXPO Team

D a. Procedure for Packaging and Dispatch
ACTUAL

PLAN G) QMS LEVEL 3 DOCUMENTS P,D G.1) PREPARATION OF ALL TYPES WORK INSTRUCTIONS

PLAN Qtrek + EXPO

D G.2) PREPARE LIST OF WORK INSTRUCTIONS REQUIRED.
Team
ACTUAL

PLAN Qtrek + EXPO

D G.3) MAKE WORK INSTRUCTION AS PER IDENTIFIED LIST.
Team
ACTUAL

PLAN G.4) CHECK IF ALL WORK INSTRUCTIONS ARE LINKED WITH Qtrek + EXPO
C
QMS SOP'S. Team
ACTUAL

PLAN H.1) MAKE MASTER LIST OF FORMATS REQUIRED FOR ALL

H) QMS LEVEL 4 DOCUMENTS D EXPO Team
DEPARTMENTS.
ACTUAL

PLAN
P,D H.2) MAKE FROMATS READY AS PER IDENTIFIED LIST. EXPO Team
ACTUAL

PLAN H.3) CHECK AND ENSURE ALL FORMATS ARE LINKED TO QMS
C,A EXPO Team
SOP'S.
 H.3) CHECK AND ENSURE ALL FORMATS ARE LINKED TO QMS
C,A EXPO Team
SOP'S.
ACTUAL

PLAN I) QMS LEVEL 1,2,3 & 4 DOCUMENTS I.1) RELEASE ALL QMS DOCUMENTS AND FORMATS TO
D EXPO Team
DISTRIBUTION & RELEASE. PROCESS OWNERS FOR IMPLMENTATION.
ACTUAL

PLAN I.2) GIVE ON-JOB TRAINING FOR IMPLEMENTATION OF

D EXPO Team
FORMATS.
ACTUAL

PLAN J.1) MAKE LIST OF PARTICIPANTS FOR ATENDING 02 DAYS Qtrek + EXPO
J) INTERNAL AUDITOR TRAINING P
INTERNAL AUDITOR TRAINING/COURSE. Team
ACTUAL

PLAN J.2) ANNOUCE TRAING DATES & ARRNAGE/BOOK FOR Qtrek + EXPO
P
LOGISTICS. Team
ACTUAL

PLAN J.3) CONDUCT 02 DAYS INTERNAL AUDITOR TRAINING AS PER

D EXPO Team
PLAN & QUALIFY THE SUCCESFUL CANDIDATES.
ACTUAL

PLAN K.1) MAKE INTERNAL AUDIT PLAN COVERING ALL Qtrek + JMD
K) INTERNAL AUDIT P
PROCESSES/FUNCTIONS. Team
ACTUAL

PLAN
D K.2) CONDCUT INTERNAL AUDIT . EXPO Team
ACTUAL

PLAN K.3) MAKE SUMMARY OF NCR'S RAISED AND CLOSURE OF

D EXPO Team
NCR'S.
ACTUAL

PLAN Qtrek + EXPO

L) MANAGEMENT REVIEW MEETING P L.1) MAKE MRM AGENDA
Team
ACTUAL

PLAN L.2) RELASE MRM DATES AND CONDUCT MRM INCLUDING

D EXPO Team
ALL PROCESS OWNERS / DIRECORS/UNIT HEAD.
ACTUAL

PLAN M) STAGE 1 CERTIFICATION AUDIT Qtrek + EXPO

P M.1) PLAN & FINALISE DATES FOR STAGE 1 AUDIT.
BY CERTIFICATION BODY Team
ACTUAL

PLAN
D M.2) STAGE 1 AUDIT CB
ACTUAL

PLAN M.3) MAKE /ACTION PLAN & CLOSURE OF ANY Qtrek Managemet
A
NC'S/RECOMMENDATIONS IN STAGE 1 AUDIT. Solution
ACTUAL

PLAN N) STAGE 2 CERTIFICATION AUDIT Qtrek + JMD

P N.1) PLAN & FINALISE DATES FOR STAGE 2 AUDIT.
BY CERTIFICATION BODY Team
ACTUAL

PLAN
D N.2) STAGE 2 AUDIT EXPO Team
ACTUAL

PLAN N.3) MAKE /ACTION PLAN & CLOSURE OF ANY

A CB
NC'S/RECOMMENDATIONS IN STAGE 2 AUDIT.
ACTUAL

PLAN
O) CERTIFICATION AWARDED D O.1) CERTIFICAE RECOMMEND BY CB. CB
ACTUAL

PLAN P) CONGRATULATE THE TEAM/

D P.1) END OF PROJECT All
CLOSURE OF THE PROJECT.
ACTUAL

PLAN
WORK IN PROGRESS
DONE
ACTIVITY DELAY

Manpower Deployment Plan

QMS Engineer Qtrek 02 times/month Responsibility : Support in preperation of Level 1,2,3,4 documentation

Responsibility : Lead Project in preperation of Level 1,2,3,4 documentation,

Senior Consultant- Qtrek 02 times / month Visual Management improvements & on-job training. Escalate any activity
delays on timely basis.
Responsibility : Track on-time project completion of activities / have phased
Lead /Principal Consultant- Qtrek Once/45 days
review meetings with Unit Owners for any necessary support.
ROAD MAP OF ISO 9001:2015 QUALITY MANAGEMENT SY
Name of Company :- EXPO FORGINGS PVT LTD.

Road Map
Activity Approach
PLAN
ACTUAL A) CONDUCT GAP P
ASSESMENT WITH RESPECT TO
5'S, VISUAL LIZATION AND QUALITY
PLAN MANAGEMENT SYSTEM P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL

PLAN
P,D
ACTUAL
PLAN
P,D
ACTUAL
B ) Visualization Improvement and
PLAN Best Practices Implementation
PLAN
Mile Stone
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

C) Manufacturing Process Layout

PLAN Improvement and Optimization
D
ACTUAL

PLAN
C,A
 C,A
ACTUAL

PLAN
D
ACTUAL

PLAN
D
ACTUAL

PLAN
WORK IN PROGRESS
DONE
ACTIVITY DELAY

Manpower Deployment Plan

QMS Engineer Qtrek 02 times/month

02 times /
Senior Consultant- Qtrek
month

Lead /Principal Consultant- Qtrek Once/45 days

LITY MANAGEMENT SYSTEM
TD.

oad Map
Sub-Activity Resp.
Qtrek + EXPO
A.1 ) Plant Visualization at different zones including
Team
Qtrek + EXPO
a.5'S Imlementation at Shop Floor and other Work Areas
Team

Qtrek + EXPO
b. Red Bin Area (Quarentine Area) Lock and Key
Team

Qtrek + EXPO
c. Area Identification (e.g Work Stations, Zones etc.)
Team

d. Materail Identification on Shop Floor through Identification Tag / Qtrek + EXPO

Labeling Team

e. Implementation of Work Instructions, Operational Standards,

Perforfmance Boards, DWM Board, Red Bin Analysis Area, Qtrek + EXPO
Tagging of Materails based on Stage of Manufacturing Team

f. Identification of Plant Pipe Lines (eg. Gas, Water, Air with colour Qtrek + EXPO
coding etc.) Team

g. Identification of Safety Measures including PPE's, Fire Qtrek + EXPO

Extenguisher, Evacuation Zones, Exit gates etc. Team

Qtrek + EXPO
h. kaizen Galley / Boards (Continual Improvement Practices)
Team

Qtrek + EXPO
i. Manufacturing Layout Compatibility
Team
 Qtrek + EXPO
j. FIFO Identification in Stores for Inventory Management
Team

B.1) Visualization Improvement and Best Practices Implementation

a. Implementation of Work Ares incuding different Work Shops (e.g

EXPO Team
Assembly Line, Press Shop, Weld Shop etc.)

b. Implementation of Daily Work maangement System including

EXPO Team
DWM Boards and DWM Checksheets

c. Plant Performance System Implementation based on PQCDSM Qtrek + EXPO

parameters and Implementation of Performance Board Team

d. Daily Rejection and Rework Monitoring through Red Bin

Analysis System Implementation EXPO Team

e. Material Identification at different stage of manufacturing and at

defined Inventory ares (Super Market etc.) Qtrek + EXPO
Team

f.. Implementation of Inventory norms and Levels based on

Production Planning for Bins and Super Market araes Qtrek + EXPO
Team

g. Layout Optimization for efficiency Improvement

Qtrek + EXPO
Team

h. Gang Ways and Floor Marking , Kaizen Board etc.

Qtrek + EXPO
Team

i. Implementation of FIFO in Stores along with the tagging and

Identification of Materials at Shop Floor Qtrek + EXPO
Team

C) Manufacturing Process Layout Improvement and

Optimization

a. Improvement of Materail flow by doing Re layouting of Qtrek + EXPO

manufactring Processes Team

Qtrek + EXPO
b.Line Balancing of Manufacturing Process
Team
 Qtrek + EXPO
b.Line Balancing of Manufacturing Process
Team

c. Development of New work stations and Inspection tables with Qtrek + EXPO
defined Lux Level through (if required) Team

d. Identification of Input and Output of Material on manufacturing

EXPO Team
stations

Manpower Deployment Plan

Responsibility : Support in preperation of Level 1,2,3,4 documentation

Responsibility : Lead Project in preperation of Level 1,2,3,4

documentation, Visual Management improvements & on-job training.
Escalate any activity delays on timely basis.
Responsibility : Track on-time project completion of activities / have
phased review meetings with Unit Owners for any necessary support.
 Feb'25 Mar'25
VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2

W1 W2 W3 W4 W1 W2
Mar'25 Apr'25
VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4

W3 W4 W1 W2 W3 W4
 May'25 Jun'25
VISIT-1 VISIT-2 VISIT-3 VISIT-4 VISIT-1 VISIT-2

W1 W2 W3 W4 W1 W2
Jun'25 July'25
VISIT-3 VISIT-4 VISIT-1 VISIT-2 VISIT-3 VISIT-4

W3 W4 W1 W2 W3 W4