Daily Work Management

NAME
Month- SHIFT
TIME- DATE Freq. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
sn SHIFTWISE Contents M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T
Shift start Meeting DAILY
Manpower deployment on m/c DAILY
1 7.00 -8.00am
First piece checked on every m/c DAILY
3.30-4.30pm
12.00-1.00am Previous Shift rejections /problems DAILY

Cycle time check die casting machine DAILY

2 8.00-9.00 am Audit of Use of PPE on shop floor MONDAY

4.30-5.45pm
1.00-2.00am Oil/Air leakage on Machine DAILY

9.15-10.15 am 5 S & EHS Audit on shop floor DAILY

3 5.45-6.45pm
2.15-3.15am Verify check sheet/ W I on m/c's DAILY

Gap analysis(Plan vs Actual) DAILY

4 10.30-11.30AM meeting with die maint with report DAILY
7.00pm-8.00pm
3.15-4.15 am Material in trolly with identification MONDAY

Action on NG points in Check sheets TUESDAY

11.30am-1.00pm
5 8.30pm-10.00pm Shop Floor Improvement & kaizen DAILY
4.30-5.00am activity
Cleaning of machines
SATURDAY
1.30 pm -2.30pm (Jishu hozen activity)
6 10.00pm-11.00pm
5.00am-6.00am Shift schedule & Training SATURDAY

2.30-3.00pm Red bin activity

7 11.00-11.30pm Clearance of rework/hold/ rejection
DAILY
6.00-6.30 am
Break Downs/Problems Solving on DAILY
1.DIE CASTING M/C NO. 1,2 & 3 DAILY
8 2.FETLING AREA DAILY
7.00-3.30pm
Cycle time verification DAILY
3.30-12.00am
12.00-7.00am Despatch of castings & SAP entry DAILY

signature
For Filling up- Put O For Ok, X for NG, for NG if corrected/repaired
`
If On Leave then mark ' L" for that date
 Code Of Conduct (Team leader) PDC Ravindra Kumar
When Time Where To Whom Action Written Form Check Point

1)Check for 2S condition on shop floor line

Shop floor Patroling Worksite
2)M/c status for stoppage/breakdown as observation
06.50 AM
Come to Work
07.00 AM
1)Face to Face meeting with previous shift Incharge
Previous shift production Report,Log
Self Desk Share Information
incharge Book
2)Check for any abnormalities in previous shift related to PQCDSHE(Rejection,Change point,shortage,B/D etc

Morning greetings 1)Check associates body language,if possible talk to them whose body language not good

Attendence checking Shift schedule form 1)Check absenteesm and allocate associates for machine. if more,call to plant head & discuss
1)Check the attention of all associates during sharing information on major defects,breakdowns,safety related issues &
Prod
07.00 AM log book,communication change points.
Morning meeting Shopfloor All Associates Information sharing
07.15 AM board, 5M 1E board
DWM area 2)Share special information on audits/visits and write on communication board

Say quality points in chorus 20 rules of quality Explain the contenet of one rules everyday and with example

Touch and call ----- Speak loudly by standing in circle & with good cheer(zero defects & zero accidents)

1)Check associates are using PPE's(Gemba) at work site

2)Check all m/c is started for production (Gemba),Discuss with maint/Die maint if any B/D
07.15 AM Production
Work Start All Associates Patroling on Line -----
07.45 AM shop floor
3)Observe the working till smooth flow and take care of 2S.

4)Bring store key from Pl -2 security(For A shift Incharge)

1) Check 2~3 shots on DCM & 2~3 pcs each cavity on fetling m/c by picking up in hand

Work Instruction 2) Check each sheet in good condition & properly filled and displayed & then sign
M/C checksheet
Parameter Check sheet 3) Check cycle time of critical machine(Die casting m/c,Shot blasting m/c)
During production 07.45 AM Production Check at eack work Furnace checksheet
running Working station
08.45 AM shop floor station(Die casting & Fetling) Production Report(Hrly.)
Die loading/Unloading 4) Share defect with 2 operators with limit samples in fetling area(Specially with less skill operators)
sheet
Identification tag 5) Ask min. 2 persons daily for filing check sheet due to frequent change in operator

6)Check & record WIP status & NG points in check sheets

1) Check all DCM are running

Production Before break Shopfloor ----- Patrolling Worksite 2) Check at least one operator on shop floor for DCM monitoring & rest will go for tea(Staggered tea break)

3) Check all lightes ,Fans & m/c are in OFF position in fetling lines

Tea Break Break Tea Point ----- Communication 1)Check personal discussion is going on & involve in their discussion

1)Check associates are using PPE's(Gemba) at work site

Production After break Shop Floor All Patrolling Worksite
2)Observe the working till smooth flow and take care of 2S.

Mail Check Email 1)Check Emails

Production summary
2)Send Production summary sheet to seniors & concerned deptt thr. mail
report
Gap Analysis board 3)Fillup DWM board in office & DWM area
09.10 AM
In operation Office Desk
09.45 AM
MIS Sheet OEE sheet 4)Check current status & all data entered properly

SAP Status 5)Check SAP entry of previous day & if any problem correct entry

PPC Report 6) check casting stocks for FG & WIP status

1)Check defects in red bins at each station. Observe any abnormalities (high rejection/zero rejection) check process &
Production report fetlling
machine operation & operator skill & behaviour
09.45 AM
In Operation Shop Floor Patrolling Worksite
10.30 AM 5M1E board 2)Check 5M1E board status

2)Check 5M1E board status

Gap Analysis board 1)Check all major abnormalities discussed and CAPA decided and recorded
10.30 AM
In Operation Office All section Heads Daily Gap Analysis
11.00 AM
CAPA Sheet 2)Check die loading/unloading plan decided as per stock on communication board & updated in shop floor

1)Check the status of previous action arein place

11.00 AM
In operation Shop Floor TEAM DD20 Activity Recording sheet
11.20 AM
2)Check all members involve in finding abnormalities & suggesting countermeasures at worksite

Discussion on major issues Defect summary 1)Check the status on action decided for top three defects with die maint/quality /production supervisor
11.20AM Concerned section
In operation Shop floor /urgency for quality
12.00 AM incharge
/production PR 2)Check the status of PR items

1) Check all DCM are running

Production Before break Shopfloor ----- Patrolling Worksite 2) Check at least one operator on shop floor for DCM monitoring & rest go for lunch(Staggered lunch break)

3) Check all lightes ,Fans & m/c are in OFF position in fetling lines
12.00 PM
Lunch Break Canteen ----- Communication 1)Check personal discussion is going on & involve in their discussion
12.30 PM
1)Check associates are using PPE's(Gemba) at work site
Production After break Shop Floor All Patrolling Worksite
2)Observe the working till smooth flow and take care of 2S.

Red bin 1)Check available rejected castings are properly marked

2)Check CAPA is filled up by PDC

12.30 PM Compr plant
In operation internal Customers Defect analysis
01.00 PM DWM area
Top defect analysis sheet 3)Check improvement after action to reduce the rejections

4)Discuss for any potential defects

1)Check hrly production report for hrly production,stoppages during running,abnormalities related to defects,dies ,
Hrly prod report
machine and man at worksite

Suggestion form 1)Discuss with associates for current abnormalities & include in kaizen plan sheet for improvement.
01.00 PM
In operation Shop floor All associates Petrol worksite
02.20 PM 1)Check control plan audit status & action on improvement
Control plan
2)Check m/c parameter for top defect components during m/c operations

QRM presentation 1)Ensure final presentation on Thursday for Friday presentation

1)Check associates involvement in reduction of defects

Defect summary board
02.30 PM
In operation Shop floor All associates Red Bin activity 2)Ensure communication on current rejection status & show defects to all persons
02.50 PM
CAPA Sheet 1)Discuss for countermeasure for reducing top three defects & record & give responsibility for actions

1)Ensure material availability For next shift at storage area

02.50 PM
In operation Shop floor ----- Patrolling Worksite
03.15 Pm
2)Check casting visually at each station by picking up in hand

1)Check log book is written as per shift activity(Die running status,m/c & die b/d,defect issue,change points)
Log Book
Production Report
All 2) production report & log book properly filled & readable and kept at proper place
03.15 PM to
End of the shift
03.35 PM
Greeting 1)Say thanks to all for good work done

Shop floor Next shift incharge Meeting Logbook 1)Face to face meeting with next shift incharge & hand over shift

2)Communication special instruction (any change points,visits,important issues.