Unit: 68
Zone / Area: Brakes India - SEZ
STANDARD OPERATING PROCEDURE Brakes India Private Limited
CUSTOMER MODEL PROCESS DESCRIPTION PART NUMBER SEQ. NO SOP NO. SOP ISSUE NO. DATE AMENDMENT HISTORY
FUSO LIFT VISUAL INSPECTION VARIOUS 15 68/WI/PBP/001
1 2/16/2017 NEW RELEASE
RED REJECTION (RED COLOUR) YELLOW REVIEW (YELLOW COLOUR) Blue
Ble REWORK (BLUE COLOUR)
BY INSPECTOR BY SUPERVISOR OF QC. BY SUPERVISOR OF MFG
Start Up: 1. Calibrate facility. 2. Verify Mistake-Proofs 3. Review Boundary Samples. 4. Perform all In Process Checks
JUDGMENT FOR
METHOD OF TRAY
OK NOT OK INSPECTION POINTS FREQUENCY SURFACE & DISPOSITION RECORD
INSPECTION COLOUR
VISUAL DEFECTS
VIEW-1 PART NAME: CUPWASHER: 291140109
1. ENSURE PLATING IS OK 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
2, CHECK FOR THE FOLLOWING 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
YELLOW
a. PRESENCE OF BEND./DAMAGE IN THE COMPONENT 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
b. PRESENCE OF RUST 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
c. PRESENCE OF PROPER FEATURES IN COMPONENT
PART NAME: SCREW M12: 29110052
1. ENSURE THE FOLLOWI N G:
a. PLATING IS OK 100% VISUAL REVIEW YELLOW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
b. ABSENCE OF RUST/ THREAD DAMAGE & HEAD DAMAGE 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
c. ABSENCE OF BURR MARK 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
d. PROPER PART NUMBER AND PROPER SIZE OF COMPONENTS
PART NAME: SHOE HOLD ON PIN: 29193943/29113737
1. ENSURE THE FOLLOWI N G: 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
a. PLATING IS OK 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
b. PROPER LENGTH OF SHOE HOLD ON PIN 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
c. ABSENCE OF ANY DAMAGE LIKE BEND, DENT MARK 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
YELLOW
100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
d. PROPER PART NUMBER AND PROPER SIZE OF COMPONENTS
100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - QC REJECTION / REWORK ENTRY NOTE
Needed calibrated Number of Number of Numebr of Work in Change
SPECIAL CHARACTERISTICS
Operator Skill
Level Reqd. devices 0 mistake NA master process progress 1 first / last SC NA
proofings samples controls part
CC NA
ALL REJECT / SUSPECT PARTS TO BE IDENTIFIED AND SEGREGATED! IF IN DOUBT ASK!
PREPARED BY VERIFIED BY APPROVED BY y KEEP HANDS AWAY FROM MACHINE WHILE IT IS WORKING! SHEET NUMBER
t
OTHERS
EAR
A.SHANKAR B.BALAJI B.BALAJI
e
GLOVES SHOES HEAD CAP GOGGLES (SPECIF
PLUG 1 OF 3
f Y)
a
S P P - - - -
Unit: 68
Zone / Area: Brakes India - SEZ
STANDARD OPERATING PROCEDURE Brakes India Private Limited
CUSTOMER MODEL PROCESS DESCRIPTION PART NUMBER SEQ. NO SOP NO. SOP ISSUE NO. DATE AMENDMENT HISTORY
FUSO LIFT VISUAL INSPECTION VARIOUS 15 68/WI/PBP/001
1 2/16/2017 NEW RELEASE
RED REJECTION (RED COLOUR) YELLOW REVIEW (YELLOW COLOUR) Blue
Ble REWORK (BLUE COLOUR)
BY INSPECTOR BY SUPERVISOR OF QC. BY SUPERVISOR OF MFG
Start Up: 1. Calibrate facility. 2. Verify Mistake-Proofs 3. Review Boundary Samples. 4. Perform all In Process Checks
JUDGMENT FOR
METHOD OF TRAY
OK NOT OK INSPECTION POINTS FREQUENCY SURFACE & DISPOSITION RECORD
INSPECTION COLOUR
VISUAL DEFECTS
PART NAME: SHOE RETURN SPRING: 29111118
ENSURE THE FOLLOWING
a. PRESENCE OF CORRECT COMPONENT FOR CORRECT PART NO 100% VISUAL REVIEW AT SHIFT END TO BE REVIEWED BY SUP - VQ
YELLOW REJECTION / REWORK ENTRY NOTE
b. NO PAINT PEEL OFF 100% VISUAL REVIEW
PART NAME: SHOE HOLD ON SPRING: 29111888
1. ENSURE THE FOLLOWI N G:
a. PAINTING IS OK 100% VISUAL REVIEW REJECTION / REWORK ENTRY NOTE
YELLOW
b. ABSENCE OF RUST/ THREAD DAMAGE & HEAD DAMAGE 100% VISUAL REVIEW REJECTION / REWORK ENTRY NOTE
AT SHIFT END TO BE REVIEWED BY SUP - VQ
PART NAME: SCREW: 29110049
1. ENSURE THE FOLLOWI N G: 100% VISUAL REVIEW
a.NO RUST 100% VISUAL REVIEW
b. PROPER THREAD FORMATION 100% VISUAL REVIEW
YELLOW AT SHIFT END TO BE REVIEWED BY SUP - QC
c. PROPER LENGTH, HEAD FORMATION 100% VISUAL REVIEW REJECTION / REWORK ENTRY NOTE
100% VISUAL REVIEW
d. ABSENCE OF BURR MARK
100% VISUAL REVIEW
Operator Skill Needed calibrated Number of Number of Numebr of Work in Change
SPECIAL CHARACTERISTICS
Level Reqd. devices
0 mistake NA master
samples
process progress 1 first / last SC NA
proofings controls part
CC NA
ALL REJECT / SUSPECT PARTS TO BE IDENTIFIED AND SEGREGATED! IF IN DOUBT ASK!
PREPARED BY VERIFIED BY APPROVED BY y KEEP HANDS AWAY FROM MACHINE WHILE IT IS WORKING! SHEET NUMBER
t
OTHERS
EAR
A.SHANKAR B.BALAJI B.BALAJI
e
GLOVES SHOES HEAD CAP GOGGLES (SPECIF
PLUG 2 OF 3
Y)
f
a
S P P - - - -
Unit: 68
Zone / Area: Brakes India - SEZ
STANDARD OPERATING PROCEDURE Brakes India Private Limited
CUSTOMER MODEL PROCESS DESCRIPTION PART NUMBER SEQ. NO SOP NO. SOP ISSUE NO. DATE AMENDMENT HISTORY
FUSO VARIOUS VISUAL INSPECTION VARIOUS 15 68/WI/PBP/001
1 2/16/2017 NEW RELEASE
RED REJECTION (RED COLOUR) YELLOW REVIEW (YELLOW COLOUR) Blue
Ble REWORK (BLUE COLOUR)
BY INSPECTOR BY SUPERVISOR OF QC. BY SUPERVISOR OF MFG
Start Up: 1. Calibrate facility. 2. Verify Mistake-Proofs 3. Review Boundary Samples. 4. Perform all In Process Checks
JUDGMENT FOR
METHOD OF TRAY
OK NOT OK INSPECTION POINTS FREQUENCY SURFACE & DISPOSITION RECORD
INSPECTION COLOUR
VISUAL DEFECTS
VIEW-1 PART NAME: WASHER: 64140327
1. ENSURE COMPONENT IS OF CORRECT MODEL 100% VISUAL REVIEW
2, CHECK FOR THE FOLLOWING 100% VISUAL REVIEW
YELLOW AT SHIFT END TO BE REVIEWED BY SUP - VQ REJECTION / REWORK ENTRY NOTE
a. ABSENCE OF RUST AND DAMAGE 100% VISUAL REVIEW
b. ABSENCE OF OVER GAP/ OVERLAP 100% VISUAL REVIEW
c. PROPER SIZE OF COMPONENT
PART NAME: WASHER: 29191071
1. ENSURE COMPONENT IS OF CORRECT MODEL 100% VISUAL REVIEW
2, CHECK FOR THE FOLLOWING 100% VISUAL REVIEW
a. ABSENCE OF RUST AND DAMAGE 100% VISUAL REVIEW YELLOW AT SHIFT END TO BE REVIEWED BY SUP - VQ AT SHIFT END TO BE REVIEWED BY SUP
b. ABSENCE OF OVER GAP/ OVERLAP 100% VISUAL REVIEW - VQ
c. PROPER SIZE OF COMPONENT 100% VISUAL REVIEW
Operator Skill Needed calibrated Number of Number of Numebr of Work in Change
SPECIAL CHARACTERISTICS
Level Reqd. devices
0 mistake NA master
samples
process progress 1 first / last SC NA
proofings controls part
CC NA
ALL REJECT / SUSPECT PARTS TO BE IDENTIFIED AND SEGREGATED! IF IN DOUBT ASK!
PREPARED BY VERIFIED BY APPROVED BY y KEEP HANDS AWAY FROM MACHINE WHILE IT IS WORKING! SHEET NUMBER
t
OTHERS
EAR
A.SHANKAR B.BALAJI B.BALAJI
e
GLOVES SHOES HEAD CAP GOGGLES (SPECIF
PLUG 3 OF 3
Y)
f
a
S P P
ANNEXURE-1: PART MATRIX
S.NO PART NUMBER PART NAME
1 29140109 CUP WASHER
2 29465192 BUNDY PIPE ASSY
3 29465193 BUNDY PIPE ASSY
4 29465017 BRIDGE PIPE ASSY
5 29465084 BUNDY PIPE ASSY
6 29465082 BUNDY PIPE ASSY
7 29465083 BUNDY PIPE ASSY
8 29193737 PIN
9 29193943 PIN
10 29465138 BUNDY PROTECTOR
11 29465237 BUNDY PROTECTOR
12 29465002 BUNDY PROTECTOR
13 29465231 BUNDY PROTECTOR
14 29465140 BUNDY CLIP
15 29465236 BUNDY CLIP
16 29465003 BUNDY CLIP
17 29465178 BUNDY CLIP
18 29465179 BUNDY CLIP
20 29110052 SCREW
21 29193306 GROMMET
22 29191001 GROMMET- LINING INSPECTIONWIND
23 29371118 SPRING SHOE RETURN
24 29465137 BUNDY PROTECTOR
25 29110049 SCREW
26 29140171 WASHER
27 29191888 SPRING SHOE HOLD DOWN
28 64140327 SPRING WASHER M4
