Page 1

Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
LEADERSHIP, BUSINESS PLANNING & RESOURCE MANAGEMENT
Material Resources Human Resources/ Competency
Market Analysis Process Risks for Company, System, Product, Management Skills
Data Analysis tools Interfaces Risk Leadership Skills
Communication tools Leadership Business Knowledge
Market value Experience
Low load from customer Market Knowledgeable
Delay in new customer development
Finanical issue
System failure
Inputs Shortage of manpower Outputs
Industry scenario, Productivity failure Increased Market share,
Opportunities, Business Decisions,
Customer information, Lack of equipement, raw material & manpower Business Plan,
Inventory, Sales, Power failure from resources Corrective Actions,
Cost of Quality, Process & Performance Monitoring,
Internal Data Analysis Results, Stand by power unit failure Improvement actions
Audit results Productivity failure
Latest Trends in the industry Lack of planning
Errors in drawing, Insufficient resources to meet the
specific customer requirements
Process, Effectiveness, Efficiency Indicators Low market price Documentation, Records, Tools
Quality objectives Shortage of manpower Quality Manual
Sales Trend Quality objectives monitoring records.
MRM Report
Account & Balancesheet
Business plan

DESIGNATION Prepared by MR Approved by COO

SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
Material Resources Process Risks for Human Resources/ Competency
Computer Network Company, System, Product, Interfaces Marketing skills
Communication Channel with customer email, telephone etc.
NEW DEVELOPMENT PROCESS Communication Skills
Customer Drawing Variable Presentation Skills
Specification Variable Negotiation Skills
Dimensional Variation Product & process Knowledge,
Out of Process Scope
Quantity Variable
Lack of Machine
Less Capacity
Cost too high
Inputs Delay in development Outputs
Market analysis report Cost of material high New Orders
Customer new enquiry / Quotation / Purchase Order Non availability of material Manufacturing plan,
Customer specific requirements Non Calibrated Gauges Increased demand
Customer schedules Over Priced Dispatch plans,
Ensure adherence to customer specific requirement Defected toolings & Gauges Approval for acceptance of PO
Process, Effectiveness, Efficiency Indicators Unproper Packing Documentation, Records, Tools
New Product Development on time with right job ( DR & QR) Delivery not on time Customer Quality Manual
Continual Improvement projects/ Kiezen APQP time plan
APQP Planning adherance
Engineering changes implementation
Cpk Value

DESIGNATION Prepared by DEVELOPMENT I/C Approved by COO

SIGNATURE
 Ref. No
PROCESS TURTLES Rev. No
Rev. Date
CONTINUAL IMPROVEMENT
Material Resources Process Risks for Human Resources / Competency
Reference material required Company, System, Product, Interfaces Creative mind ,Positive approach, Initiation
Data Analysis Tools, Data processing skills,
Statistical Tools
Continual Improvement Statistical analysis skills
Computer Incompetency in staf Analytical skills
Wrong Decisions,
Dissatisfied Customer,
Inputs Increase in quality cost, Outputs
Freedom of experimentation for some extend unsatisfactory customer ratings Savings
Customer information, Delay in delivery Management Decisions in Management
Competitor information, Lack of space Reduction in cost,
Suggestion Schemes, Productivity improvement
Data Analysis Results Quality improvement
Productivity and quality issues Reduction inrejection

Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools

Kaizen monthly 20 Quality Manual
Continual Improvement project report
MRM report

DESIGNATION Prepared by MR Approved by COO

SIGNATURE
 RGF.QMS.F.01
00
01.06.2019

n Resources / Competency
Positive approach, Initiation
skills,
sis skills

Outputs

ecisions in Management
st,
provement
ement
ection

umentation, Records, Tools

ovement project report

Approved by COO
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
MARKETING PROCESS
Material Resources Process Risks for Human Resources/ Competency
Communication Channel with customer email,
telephone etc. Company, System, Product, Interfaces Product & process Knowledge,
Computer Network Marketing Process Marketing skills
Product Catalogue Instrument and Equipment Failure Communication Skills
Failure of network, Presentation Skills
wrong analysis, failure of communication channel, Negotiation Skills

lack of knowledge about customer Spec. Requirement,

Training inefectiveness,
Dissatisfied customer,
Increase in quality cost,
Increased response time,
unsatisfied customer ratings
Inputs Number of repeted issues. Outputs
Market analysis report Delay in delivery New Orders & OA
Customer new enquiry / Quotation / Purchase Order failure in previous revision status Manufacturing plan,
Customer specific requirements No corrective action plan Increased demand
Customer schedules No proper communication Dispatch plans,
Ensure adherence to customer specific requirement Approval for acceptance of PO
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
Customer Satisfaction Survey Product Specification
Sales trend New Enquiry feasibility
Enquiry Convertion Ratio Product catalogue

DESIGNATION Prepared by MARKETING Approved by COO

SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
CUSTOMER COMPLAINT HANDLING
Material Resources Process Risks for Human Resources/ Competency

Correspondence Company, System, Product, Interfaces Skill matrix of personnel

Computer network, Communication skills
Customer complaint handling
Data Analysis Tools, Product & Process knowledge
Communication chanel eg: E-mail, Phone Call, unsatisfactory customer ratings
Failure of network,
Wrong analysis, failure of communication channel, lack
of knowledge about customer Spec
Requirement
training inefectiveness
Dissatisfied customer
Increase in quality cost
Inputs Increase response time Outputs
Defective parts, Management decisions
Customercomplaint /rejection & analysis record, Review records,
Ratings from customer Corrective action reports,

Corrected documents, counter measure

report,
Customer delight

Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools

Customer specification
Customer complaints Procedure for customer complaint handling
Control NC product procedure
CA procedure
Product calalogue
DESIGNATION Prepared by MARKETING Approved by COO

SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
CUSTOMER SATISFACTION
Material Resources Process Risks for Human Resources/ Competency
Data Analysis Tools Company, System, Product, Interfaces Product & process knowledge
Computer, Communication Channel Communication channel
Customer Satisfaction
Failure of network,
wrong analysis, failure of communication channel,

lack of knowledge about customer Spec. Requirement,

Training inefectiveness,
Dissatisfied customer,
Increase in quality cost,
Inputs Increased response time, Outputs
Competitor information unsatisfied customer ratings Customer delight
Ensuring fulifilment of Customer Specifc req. Management Decisions
Query handling Customer feedback mail
Ensuring quick response Changes in action report
Resolution of customer complaints
Customer feedback
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
Risk Assessment chart
Customer Satisfaction Survey Customer Satisfaction survey report
Customer complaints
Customer Supplier rating

DESIGNATION Prepared by MARKETING Approved by COO

SIGNATURE
 Ref. No
PROCESS TURTLES Rev. No
Rev. Date

Quality Process
Material Resources Process Risks for Company, System, Product, Human Resources/ Competency
Computer network, communication channel Interfaces
LAB & Quality Assurance Inspection skills,
Measuring, inspection & testing equipments, RISK Computer skills,
required Reference material/ literature Not as per schedule Analysis/scrutinizing skills
Variation in specification Decision making skills
Not as per requirement
Not as per quality plan
Electrification failure
Unskilled inspector
Inputs Variation in instrument Outputs
Quantity variation
Incoming products / samples Tool breakdown Inspection reports
Customer Specific requirements m/c Breakdown Cost reduction
Quality plan, Specification Storage of tools Rejection reduction
Results of quality test Lack of space Customer delight
Not as per control plan
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
Cost of Poor Quality Incoming, Inprocess & Final quality plan
Customer End Rejection PPM Control of NC product procedure
Customer complaints CA procedure
Vendor Overall rating Risk Analysis
Calibration Plan Adherance Incoming, Inprocess & Final Test reports
Inhouse rejection records
Customer feedback
DESIGNATION Prepared by QUALITY I/C Approved by COO
SIGNATURE
 RGF.QMS.F.01
00
01.06.2019

sources/ Competency

ng skills
kills

Outputs

ntation, Records, Tools

ss & Final quality plan
uct procedure

ss & Final Test reports

ecords
k
roved by COO
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
CALIBRATION PROCESS
Material Resources Process Risks for Human Resources/ Competency
Testing machines, Instrument & Gauges, computer, Process knowledge,
Communication channel Calibration process Knowledge about equipments
Not as per schedule
Not as per requirement
Not as per quality plan
Inputs Variation in specification Outputs
Expected reults criteria Quantity variation Calibrated instruments,
Calibration plan, Not as per PO Inspection & Test results recods,
Awareness about new equipments/testing / Calibration history card,
measuring process Euipment breakdown
Process / Product details, TC not issue Calibration certificates,
Instrument & Gauge details
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
Adherence to calibration schedules Quality Manual
Calibration history card,
Calibration plan,
Procedure for calibration
Calibration status on intruments

DESIGNATION Prepared by QA I/C Approved by COO

SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019

MR/QMS Process
Material Resources Process Risks for Human Resources / Competency
Company, System, Product, Interfaces
International Standards Quality System Knowledge
MR/Quality Management System
Communication tools Internal Auditing Skills
Computers / Printer Wrong management decisions Management Skills
Objective analysis failure Communication skills
Collective data and feed back failure Presentation skills
Noncompliance to standard requirement Analytical skills
Noncompliance to customer requirement
System failure
Failure in Documents information
Inputs Gap Analysis Outputs
Not in line with system
Standards Update Incomplete audits Process changes, Management
Process change suggestions, decisonsfunctioning of organization
Smooth
Result of audits/MRM System driven company
Customer information, All processes in line with company
quality objectieves
Internal Data analysis results
Organization changes

Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools

Internal Audit & MRM As per Plan Quality Manual
Product Audit as per plan Procedure for document information
Process Audit as per plan Objective monitoring chart & analysis
Mandatory Procedure

DESIGNATION Prepared by MR Approved by COO

SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019

Internal Audit Process

Material Resources Process Risks for Human Resources / Competency
Company, System, Product, Interfaces
International Standards Quality System Knowledge
Internal Audit
Procedures Internal Auditing Skills
Management Skills
Gap Analysis Communication skills
Not in line with system Presentation skills
Noncompliance to standard requirement Analytical skills
Noncompliance to customer requirement
Dissatisfied customer
Inputs Wrong management decisions Outputs
Incomplete audits
Audit schedule, Management Decisions,
Methodology Corrective Actions,
Process & Performance Improvements,
Audit Nonconformity, Audit Result analysis,
Customer information, Overall organiztion performance
improvement
Standards Update,
Internal Audit / MRM results,
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
IQA Planning Quality Manual
Internal Audit & MRM As per Plan Internal Audit plan and Schedule
Observation Sheet
Quality System Procedure for internal Audit
IQA NC closing report
MRM
DESIGNATION Prepared by MR Approved by COO
SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
Production Planning
Material Resources Process Risks for Human Resources/ Competency
Company, System, Product, Interfaces
Communication tools, telephone, Internet, fax, Analysis skills
Planning tools Production Planning
Reasoning skills
Wrong scheduling Production process awareness
Machine breakdown Resource allocation skill
Material stock out Experience
Poor delivery performance
Customer dissatisfaction
Market share variations / decrease
Product / Process limitations
Inputs Poor business performance Outputs
WIP
Customer Forecast / schedules Monthly production plan
Customer requirement changes Daily Production Plan- Display
Resource availablity updates Daily Production report
Inventory level Contigency plan on non achieving
Controls / check points for the success of
Process, Effectiveness, Efficiency Indicators planning
Documentation, Records, Tools
Manufacturing Planned Vs Actual Objective monitoring & analysis records
Production planning reports
Production reports
Process WI
DESIGNATION Prepared by PRODUCTION I/C Approved by COO
SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
Production Process
Material Resources Process Risks for Human Resources/ Competency
Company, System, Product, Interfaces
Production equipments/machines Knowledge of product & process
Inspection /Monitoring / measurement tools / Production process Optimum utilization of allocated resources
equipments
Plant layout/Drawing /Specification Variation on marking Leadership & Management skills
Material handling equipments Not as per drawing Machine operation skills
Skilled operators Shortage of raw material Inspection skills
Raw material Un even edges/Surface
Inputs uneven level and surface Outputs
Variation in dimension
Customer schedules/Drawing/Specification Power failure Right products at right time
Production Plan (Monthly / Weekly/ Daily) Machine breakdown Plan Achievement
Techniques / Methodology CO₂ Shortage Customer delight
Raw Materials , Man power required Variation as per drawing Rejection control
WI/Control plan Low Allowance As per Dimension
Low Allowance during machine
Process, Effectiveness, Efficiency Indicators Variation in dimension Documentation, Records, Tools
Inhouse Rework Variation in dimension/ component variation
Variation in design Schedule
Assembly not as per PO Control plans
Hydrostatic testing failed Work Instructions
Uneven painting surface
Packing improper

DESIGNATION Prepared by PRODUCTION I/C Approved by COO

SIGNATURE
 PROCESS TURTLES

Tooling Management
Material Resources Process Risks for
Company, System, Product, Interfaces
Production equipments/machines
Inspection /Monitoring / measurement tools / Production process
equipments
Plant layout/Drawing /Specification
Material handling equipments Not as per drawing
Skilled operators Shortage of raw material
Raw material Un even edges/Surface
Inputs uneven level and surface
Variation in dimension
Customer schedules/Drawing/Specification Variation as per drawing
Validation Plan (Monthly / Yearly) Low Allowance
Techniques / Methodology Variation in design
Raw Materials , Man power required
WI/Control plan

Process, Effectiveness, Efficiency Indicators

Validation As per Plan

DESIGNATION Prepared by PRODUCTION I/C

SIGNATURE
 Ref. No RGF.QMS.F.01
Rev. No 00
Rev. Date 01.06.2019
ent
Human Resources/ Competency

Knowledge of product & process

Optimum utilization of allocated resources

Leadership & Management skills

Machine operation skills
Inspection skills

Outputs

As per Drawing
As per Fitment
Customer delight
Rejection control
As per Dimension

Documentation, Records, Tools

List of Templates and Validation Plan

Template Validation Report
Mould Life Monitoring
Mould History Card
Mould Validation

Approved by COO
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
Maintenance Process
Material Resources Process Risks for Human Resources/ Competency
Company, System, Product, Interfaces
Tools, Instruments, Analytical skills
Spares Inventory,
Maintenance Knowledge about available machinery
communication channel Improper Maintenance Knowledge about basic electrical maintennance
Man Power Absentism Attending breakdown
Non Availability of Spares parts
Inputs Machine continously breakdown Outputs
Non availability of Critical Spares
PM Plan Shortage of tools Breakdown analysis leading to few decisions
Machine manufacturers guidelines and On time Preventive maintenance
Shortage of manpower
checklist
Spares Parts list, Continous break down of machinary Machines ready to use on required time.
On time & Right reporting of Machine Uninterupted production due to less breakdown
variation in contract and agreement
Breakdown
Power failure frequency
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
Variation in requirement and communication

Breakdown Hrs, Machine Operation Manual

Maintenance cost, Preventive maintenance plan
Mean Time Between Failure (MTBF) Preventive maintenance checklist
Mean Time to repair (MTTR) Process procedure for Maitenance.
B/D history records

DESIGNATION Prepared by MAINTENANCE I/C Approved by COO

SIGNATURE
 Ref. No
PROCESS TURTLES Rev. No
Rev. Date
Training/Human Resources Management
Material Resources Process Risks for Human Resources / Competency
Company, System, Product, Interfaces
Computer, Communication Channel. Financial Presentation skills
resources Human Resource Management
Reference Material Persuation skills
Excess man power Motivation skills
wrong competency Communication Skills
Productivity decrease Training skills,
Increased Absenteeism Anlysis Skills
Efectiveness not achieved,
Non Adherence of Training Plan,
Inputs Loss of Man days, Outputs
Training is not understandable
Resource requirements, Inadequate resources, Positive Environment
Training Need Identification Decrease motivation level Efect on Quality / production / behavior /culture
Information on training programmes Build up incompetence Motivated work force
Management review decisions Penalty, Initiation
Motivation schemes Improvement in quality of work
Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools
Training Topic Motivation scheme
Training efectiveness Training plan
competency mapping
skill matrix
Training record and efectiveness evaluation records

DESIGNATION Prepared by HR/Training Approved by COO

SIGNATURE
 RGF.QMS.F.01
00
01.06.2019

urces / Competency

Outputs

ction / behavior /culture

of work
tion, Records, Tools

tiveness evaluation records

ved by COO
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
Purchase Process
Material Resources Process Risks for Human Resources/ Competency
Company, System, Product, Interfaces
Computer network, Communication channel with Negotiating skills, Sources & current rates in
suppliers, e-mail, telephone etc. Purchase market.
Shortage of RAW Material, Purchase management
Rejected Material, Product knowledge
Wrong External provider selection Computer litracy
Lack of communication with external service Raw material knowledge
Inputs Delay in delivery Outputs
Material requirement plan, Lack of cash inhand due to demonotization Purchase Order
Purchase requisition Market value higher side External Provider performance rating
OA Cost of raw material too high External Provider Evaluation
ML Labour cost increased External Provider invoice
List of External Provider, Stock list Wrong scheduling leading to line stoppage or
External Provider TC , Inspection report
excess inventory,
Process, Effectiveness, Efficiency Indicators efect on On-time delivery if lead time Documentation, Records, Tools
requirements are not met,
Supplier performance rating inaccurate information to the supplier on part Activity Chart
changes,
Stopage to Production Scheduling after the PO quantity is exhausted, Evaluation & re-evaluation of supplier
increase in premium freight because of wrong list of approved supplier with need and expectation
scheduling
Delay in Production & Delivery External Provider Performance rating
Wrong specification

DESIGNATION Prepared by PURCHASE I/C Approved by COO

SIGNATURE
 Ref. No RGF.QMS.F.01
PROCESS TURTLES Rev. No 00
Rev. Date 01.06.2019
Stores Process
Material Resources Process Risks for Human Resources/ Competency
Computer network Company, System, Product, Interfaces Computer skills
Racks / Bins Stores Exposure to production process
strorage facility material shortage Inventory/stock monitoring skills
Communication Channel Variation in specification Raw Material knowledge
Less max and min
Shortage in stock
Inputs wrong identification Outputs
Material List Less max and min Inventory data
Raw Material stock list Failure in FIFO Material requirements to purchase
Telephonic requirements, Availability of materials
Min & Max Issue records
Material Receipt /inward
Issue Request
List of shelf life times
Awareness about storage condition

Process, Effectiveness, Efficiency Indicators Documentation, Records, Tools

Maintain the stock level Min Max level Store Procedure
Inward cum stock record,
Stock list
Min & Max chart

DESIGNATION Prepared by Store I/C Approved by COO

SIGNATURE