|
Record Reference
Sample to be presented from the month of July’2019 to January’2020
Name & Designation of the following personnel:
Designation
|
Name
|
Joining
Date
|
Last
Training Date
|
Training
Subject
|
General Manager
|
Engr. Jilani Ahamed
|
15th
Sep 2017
|
12/08/2019
|
Product QMS
|
Manager Production
|
Engr. M. A. Masud Khan
|
23th March 19
|
12/08/2019
|
Product QMS
|
Production Officer
|
Engr. Mahadi Hasan
|
20th Nov 19
|
02/01/2020
|
AutoCAD Basic
|
Production Supervisor
|
Engr. Gyano Joti
Chakma
|
10th
Nov 11
|
02/01/2020
|
AutoCAD Basic
|
Shift In-Charge
|
Md. Himal Khan
|
22th Nov 19
|
12/01/2020
|
Winding QMS
|
Production Executive
|
Md. Rakibul Hasan
|
22th Nov 19
|
12/01/2020
|
Winding QMS
|
Quality Objectives
(Provide 03 major targets of the year for production department):
Objective
|
Target
|
Responsible Person
|
What Action Plan Initiated
|
Current Status of the target till January’20
|
Record Reference (Name & Doc. Code)
|
Production
|
50 %
|
Engr. M. A. Masud Khan
|
Increase Machine and Manpower
|
Just Machine Collected
|
LC Document
|
Production Loss reduction
|
15%
|
Engr. Jilani Ahamed
|
Setup Automated machine
|
Collect Specification
|
|
Wastage Management
|
25%
|
Engr. Jilani Ahamed
and Engr. M. A. Masud Khan
|
Try to for by products
|
Research and development
|
Contact with consultant
|
Risk Assessment &
Opportunity (Provide 3 Major Risk &3 major opportunities for production):
Risk
|
Action Proposed to mitigate risk
|
Responsible Person to review risk
|
Record Reference (Name & Doc. Code)
|
Any Risk Reported till January’20
|
How the risk has been removed or mitigated
|
Skilled Manpower
|
Working for employment of skilled man power
|
Engr. M. A. Masud Khan
|
|
Collect CV
|
Working for employment of skilled man power
|
Accident
|
|
|
|
|
|
Wrong Raw Materials
|
|
|
|
|
|
Opportunities
|
Action Proposed to improve
|
Responsible Person
|
Record Reference (Name & Doc. Code)
|
Is the risk and opportunities discussed during MRM
|
Any decision taken by top management
|
Increase Skilled
Manpower
|
Training Ensure
|
Engr. M. A. Masud Khan
|
Listed
|
Yes
|
Yes
|
Production Maintain
through Software
|
Buy Software
|
Engr. Jilani Ahamed
|
Listed
|
Yes
|
Yes
|
By Product
Manufacturing
|
Buy Software
|
Engr. Jilani Ahamed
|
Listed
|
Yes
|
Yes
|
1.
Manufacturing
Standard Reference:
Name of the Product
|
Manufacturing Standard (BDS)
|
Manufacturing Standard
(International)
|
Standard Version
|
Transformer
|
|
1
– Phase IEEE – C57.12.00 -15, C57.12.20 -17, C57.12.90 -15.
3
– Phase IEC – 6007 / BS - 171
|
2015
& 2017
|
2.
What
Identification Tag you used in the final product before delivery
Name
of the Product
|
Identification
Tag used
in
Final Product
|
Name
of the major Raw/Incoming Materials
|
Transformer
|
1.
Company Name
2.
Logo
3.
SL. No
4.
Rating of Product
5.
Customer Short Name
6. Name Plate
7. Terminal Marking
|
1.
CRGO Silicon Steel Sheet
2.
Paper Covered Copper Strip
3.
Super Enameled Wire
4.
Transformer Oil
5.
Insulation Paper
6. Mild Steel Sheet
|
3.
Production
Capacity Ref.
Monthly
Production Capacity
|
Current
Production/Monthly
|
Current
Product Storage Capacity
|
4500
Pcs for Single Phase Transformer 5/10/15 KVA
|
1500
Nos
|
2000
Pcs
|
4.
Packing
& Material Ref.
Name
of Packing Material
|
Packing
Material Type
|
Packing
Material Size/Weight
|
05 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
55.00
|
10 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
42.00
|
15 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
43.00
|
25 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
49.00
|
37.5 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
52.00
|
50 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
53.00
|
75 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
59.00
|
100 KVA Single Phase Distribution Transformer
|
Wood and Polyphone Package
|
64.00
|
200 KVA Three Phase Distribution Transformer
|
Polyphone Package
|
85.00
|
250 KVA Three Phase Distribution Transformer
|
Polyphone Package
|
85.00
|
5.
Raw
Material / Material used in the manufacturing process
Product
Name
|
Name
of the Material
|
Raw
Material/Material Usage % in the manufacturing process
|
Transformer
|
1.
CRGO Silicon Steel Sheet
2.
Paper Covered Copper Strip
3.
Super Enameled Wire
4.
Transformer Oil
5.
Insulation Paper
6.
Mild Steel Sheet
7.
Others
|
1.
30.33 %
2.
10.66 %
3.
10.33 %
4.
20.66 %
5.
7.2 %
6.
15 %
7.
5.82%
|
6.
Provide
10 sample of Production record/data as per below (must submit in word file):
Provide Sample of Production Data
(Randomly from July’19 to Jan’20)
Production Record:
1
|
Name of the Customer
|
Seinea Industries Ltd
|
2
|
Name of the Customer
|
Mim Enterprise
|
|
Customer Address
|
Ajimpur, Uttara.
|
|
Customer Address
|
Gopalpur, Gopalgonj.
|
Work Order Ref. No.
|
01122019001
|
|
Work Order Ref. No.
|
01122019002
|
Work Order Dated
|
02/12/2019
|
|
Work Order Dated
|
08/12/2019
|
Product Name
|
250 KVA transformer
|
|
Product Name
|
1250 KVA transformer
|
Product Size/Capacity
|
250 KVA
|
|
Product Size/Capacity
|
1250 KVA
|
Product Design Input
|
|
|
Product Design Input
|
|
Product Design
Validation
|
|
|
Product Design
Validation
|
|
Design Validation Done
by
|
M. A Masud Khan
|
|
Design Validation Done
by
|
M. A Masud Khan
|
Design Output date
|
03/11/2019
|
|
Design Output date
|
10/11/2019
|
Design Approved Date
|
07/11/2019
|
|
Design Approved Date
|
14/11/2019
|
Order Quantity
|
01
|
|
Order Quantity
|
01
|
Production Planned
Date
|
03/12/2019
|
|
Production Planned
Date
|
10/12/2019
|
Production Started
|
04/12/2019
|
|
Production Started
|
11/12/2019
|
Batch Size:
|
|
|
Batch Size:
|
|
Production Start Date:
|
04/12/2019
|
|
Production Start Date:
|
12/12/2019
|
Production Finished
Date:
|
10/12/2019
|
|
Production Finished
Date:
|
13/12/2019
|
Fabrication Work Done
|
05/12/2019
|
|
Fabrication Work Done
|
14/12/2019
|
Painting Work Done
|
06/12/2019
|
|
Painting Work Done
|
15/12/2019
|
Core Cutting Date
|
07/12/2019
|
|
Core Cutting Date
|
16/12/2019
|
Core Assembling Date
|
08/12/2019
|
|
Core Assembling Date
|
17/12/2019
|
Core Coil Assembling
|
09/12/2019
|
|
Core Coil Assembling
|
18/12/2019
|
Transformer Heating
|
10/12/2019
|
|
Transformer Heating
|
19/12/2019
|
Tank up Process
|
11/12/2019
|
|
Tank up Process
|
20/12/2019
|
Testing
|
12/12/2019
|
|
Testing
|
21/12/2019
|
Painting
|
13/12/2019
|
|
Painting
|
22/12/2019
|
Product Model No.
|
250 TXBPD
|
|
Product Model No.
|
1250 TXBPD
|
Product Serial Number
|
1219002
|
|
Product Serial Number
|
1219002
|
3
|
Name of the Customer
|
Alif Group
|
4
|
Name of the Customer
|
NDE Ltd.
|
|
Customer Address
|
Mirpur -1
|
|
Customer Address
|
Gazipur
|
Work Order Ref. No.
|
|
|
Work Order Ref. No.
|
|
Work Order Dated
|
15/12/19
|
|
Work Order Dated
|
01/01/20
|
Product Name
|
Transformer
|
|
Product Name
|
Transformer
|
Product Size/Capacity
|
100 KVA
|
|
Product Size/Capacity
|
75 KVA
|
Product Design Input
|
12/12/19
|
|
Product Design Input
|
25/12/19
|
Product Design
Validation
|
|
|
Product Design
Validation
|
|
Design Validation Done
by
|
M. A Masud Khan
|
|
Design Validation Done
by
|
M. A Masud Khan
|
Design Output date
|
15/01/20
|
|
Design Output date
|
13/01/20
|
Design Approved Date
|
M. A Masud Khan
|
|
Design Approved Date
|
M. A Masud Khan
|
Order Quantity
|
50
|
|
Order Quantity
|
25
|
Production Planned
Date
|
11/12/19
|
|
Production Planned
Date
|
25/12/19
|
Production Started
|
|
|
Production Started
|
|
Batch Size:
|
|
|
Batch Size:
|
|
Production Start Date:
|
13/12/19
|
|
Production Start Date:
|
26/12/19
|
Production Finished
Date:
|
01/01/20
|
|
Production Finished
Date:
|
05/01/20
|
Fabrication Work Done
|
25/12/19
|
|
Fabrication Work Done
|
27/12/19
|
Painting Work Done
|
26/12/19
|
|
Painting Work Done
|
28/12/19
|
Core Cutting Date
|
13/12/19
|
|
Core Cutting Date
|
29/12/19
|
Core Assembling Date
|
14/12/19
|
|
Core Assembling Date
|
30/12/19
|
LT & HT Coil
Winding
|
14/12/19
|
|
LT & HT Coil
Winding
|
30/12/19
|
Core Coil Assembling
|
15/12/19
|
|
Core Coil Assembling
|
31/12/19
|
Transformer Heating
|
16/12/19
|
|
Transformer Heating
|
01/01/20
|
Tank up Process
|
17/12/19
|
|
Tank up Process
|
02/01/20
|
Testing
|
18/12/19
|
|
Testing
|
03/01/20
|
Painting
|
19/12/19
|
|
Painting
|
04/01/20
|
Product Model No.
|
|
|
Product Model No.
|
|
Product Serial Number
|
1219005
|
|
Product Serial Number
|
1219006
|
5
|
Name of the Customer
|
Khan Enterprise
|
6
|
Name of the Customer
|
Akotha Enterprise
|
|
Customer Address
|
Banani
|
|
Customer Address
|
Uttara
|
Work Order Ref. No.
|
|
|
Work Order Ref. No.
|
|
Work Order Dated
|
01/01/20
|
|
Work Order Dated
|
12/01/20
|
Product Name
|
Transformer
|
|
Product Name
|
Transformer
|
Product Size/Capacity
|
10 KVA
|
|
Product Size/Capacity
|
25 KVA
|
Product Design Input
|
01/01/20
|
|
Product Design Input
|
08/01/20
|
Product Design
Validation
|
|
|
Product Design
Validation
|
|
Design Validation Done
by
|
Engr. Azad Akond
|
|
Design Validation Done
by
|
Engr. Azad Akond
|
Design Output date
|
01/01/20
|
|
Design Output date
|
08/01/20
|
Design Approved Date
|
02/01/20
|
|
Design Approved Date
|
13/01/20
|
Order Quantity
|
50
|
|
Order Quantity
|
20
|
Production Planned
Date
|
03/01/20
|
|
Production Planned
Date
|
4/01/20
|
Production Started
|
|
|
Production Started
|
|
Batch Size:
|
|
|
Batch Size:
|
|
Production Start Date:
|
03/01/20
|
|
Production Start Date:
|
14/01/20
|
Production Finished
Date:
|
15/01/20
|
|
Production Finished
Date:
|
26/01/20
|
Fabrication Work Done
|
04/01/20
|
|
Fabrication Work Done
|
15/01/20
|
Painting Work Done
|
05/01/20
|
|
Painting Work Done
|
16/01/20
|
Wiring Done
|
06/01/20
|
|
Wiring Done
|
17/01/20
|
Core Cutting Date
|
07/01/20
|
|
Core Cutting Date
|
18/01/20
|
Core Assembling Date
|
08/01/20
|
|
Core Assembling Date
|
19/01/20
|
LT & HT Coil
Winding
|
09/01/20
|
|
LT & HT Coil
Winding
|
20/01/20
|
Core Coil Assembling
|
10/01/20
|
|
Core Coil Assembling
|
21/01/20
|
Transformer Heating
|
11/01/20
|
|
Transformer Heating
|
22/01/20
|
Tank up Process
|
12/01/20
|
|
Tank up Process
|
23/01/20
|
Testing
|
13/0120
|
|
Testing
|
24/01/20
|
Painting
|
14/01/20
|
|
Painting
|
25/01/20
|
Product Model No.
|
|
|
Product Model No.
|
|
Product Serial Number
|
1219007
|
|
Product Serial Number
|
1219008
|
7.
Any
Non-Conforming Product or faulty product found during production (give us 06
samples):
1
|
Product Name
|
Transformer
|
2
|
Product Name
|
Transformer
|
|
Product Code Or Serial
|
10 KVA
|
|
Production Batch No
|
250 KVA
|
Product Model No.
|
10
|
|
Product Type
|
Three Phase
|
Work Order Ref.
|
N/A
|
|
Batch Quantity
|
01
|
Production Started
|
|
|
Production Started
|
|
Non-Conformity Details
|
Dies
|
|
Non-Conformity Details
|
Man Power Limitation
|
How you rectified
|
Collect New
|
|
How you rectified
|
Time consideration
|
Final Test Ref.
|
03/01/20
|
|
Final Test Ref.
|
07/01/20
|
Final Test Date
|
05/01/20
|
|
Final Test Date
|
10/01/20
|
Final Test Done by
|
Zahid
|
|
Final Test Done by
|
Zahid
|
3
|
Product Name
|
Transformer
|
4
|
Product Name
|
Transformer
|
|
Production Batch No
|
1250 KVA
|
|
Production Batch No
|
1500 KVA
|
Product Type
|
Three Phase
|
|
Product Type
|
Three Phase
|
Batch Quantity
|
01
|
|
Batch Quantity
|
01
|
Production Started
|
01/12/19
|
|
Production Started
|
04/12/19
|
Non-Conformity Details
|
Tap Changer Connection
|
|
Non-Conformity Details
|
Tap Changer Connection
|
How you rectified
|
Reconnect
|
|
How you rectified
|
Reconnect
|
Final Test Ref.
|
12/12/19
|
|
Final Test Ref.
|
16/12/19
|
Final Test Date
|
26/12/19
|
|
Final Test Date
|
28/12/19
|
Final Test Done by
|
Zahid
|
|
Final Test Done by
|
Zahid
|
5
|
Product Name
|
Transformer
|
|
Production Batch No
|
1500 KVA
|
Product Type
|
Three Phase
|
Batch Quantity
|
01
|
Production Started
|
10/12/19
|
Non-Conformity Details
|
Tap Changer Connection
|
How you rectified
|
Reconnect
|
Final Test Ref.
|
16/12/19
|
Final Test Date
|
28/12/19
|
Final Test Done by
|
Zahid
|
Monthly
Basis Process Loss Analysis Report
Name of the Month
|
Process Loss Parameters
|
Process
loss %
|
Product
Return qty.
|
Product Return %
|
October’ 19
|
Raw
Materials
|
15%
|
|
|
November’ 19
|
Product
Return
|
|
5
|
0.5%
|
December’ 19
|
High
Voltage fail
|
|
3
|
0.3%
|
January’20
|
No
Load & Full Load Loss
|
5%
|
4
|
0.4%
|
Total Average
|
|
Total Average
|
|
Production
Efficiency Report
Name of the Month
|
Production Target in Qty
|
Production Achievement in Qty
|
Production Efficiency in %
|
Efficiency % increased or decreased
due to
|
October’ 19
|
4500
|
15
|
0.33
|
Lower
Sales
|
November’ 19
|
4500
|
15
|
0.33
|
Lower
Sales
|
December’ 19
|
4500
|
15
|
0.33
|
Lower
Sales
|
January’20
|
4500
|
15
|
0.33
|
Raw
Materials shortage
|
Total Average
|
|
|
Wastage Percent Analysis
Name of the
Month
|
Wastage in %
|
Wastage Type
|
Reason of
Wastage
|
October’ 19
|
15
|
MS
Sheet
|
Market
Raw is not as design
|
November’ 19
|
13
|
CRGO
Silicon Sheet
|
At
time of slitting there is some of side used part
|
December’ 19
|
2
|
Transformer
Oil
|
Last
drop of oil inside dram is not possible to used
|
January’20
|
10
|
Copper
Wire
|
Last
lengthen and insulation problem
|
Total
|
10
|
|
|
Product Complain Analysis
Name of the
Month
|
Product Complain
Qty.
|
Product
Complain %
|
Reason of
Product Complain
|
October’ 19
|
5
|
5
|
High
Voltage
|
November’ 19
|
6
|
6
|
No
Load Loss Higher
|
December’ 19
|
10
|
10
|
%
of Impedance Higher
|
January’20
|
4
|
4
|
Insulation
level is lower
|
Total
|
6.25
|
6.25
|
|
| 
