what is initial process control ,and what is the procedure of IPC. HOW MAKE THE IPC PROCEDURE IN AUTOMOTIVE INDUSTRIES.

1.        INITIAL PROCESS CONTROL: iiii             Purpose: To establish a procedure for Initial Supply Control and to ensure that the           controls required for Initial supplies in the case of New Product, Change in existing            product and process are established, implemented and maintained at our end and as well      as supplier end. 2.         Scope: Applicable to all New Developments, Engineering Changes, Process Changes, Change in Machineries and Equipments, Start of Manufacturing after a long layoff (More Than Six Months), Raw material Change and Supplier Change. 3.         Responsibility: Head QA & Head Production 4.         System:
Sl. No.	Activity	Input	Output	Responsibility
1 2 3 4 5	During the Production: During the production of new products manufacturing at the production shop floor, the particular machine is identified with the identification Board of sample lot preparation and the products which are kept in the bin is also identified with “Initial Sample Part” Identification tag. During the Trial, if the trial qty is rejected and kept in the red bin and transferred to stores through “Rejection Transfer Slip” Person responsible to announce start/end of initial supply control mentioned in Project Organization Chart. The operators who are going to involve in developing the initial sample, identified and training is provided to all the concerned personnel for the different stages of operation. If any changes in the identified trained personnel’s the appropriate training is provided before putting them into the specific job. If any changes received from the customer or any changes recommended internally, during the development of components the same is handled as per the Procedure for 4M Change Control. Sharing of information with vendors. Conduct vendors audit if the change pertains to them. Same follows required at vendors end. At the time of start up, Stop or Postpone information to related departments. (Vendors, PE, Design, QA. Supply chain)	Initial Sample qty preparation Initial Sample Qty List of Operators Updated list of Operators Change Point	Initial Sample qty Transfer To stores as a rejection through Rejection transfer Slip Operators Training Record Updating  of Training Record MOM	NPD/Head Q.A & Prod. Head NPD Head/Prod. Head & QA HRD HRD 2 of 5     Engg. / QA/ Prod./ Purchase/ SQA

Sl. No.	Activity	Input	Output	Responsibility
6 7 8 9	Initial Supply Control Termination Criteria :-After completion of First Pilot Lot Production or otherwise as defined by the customer, initial production period Termination will be done after approval from Head Q.A and the product will be treated as regular products. The pending points from the PPAP will be identified and separate action plan will be initiated to complete all those pending points. Till the completion of all pending points the Initial Supply Control will not be terminated. Initial Supply Control Period for  3 months/3000 Nos which is more. (New Part) Below mention Special Control to be required at the time of Initial Supply: - *Frequency of Inspection should be double * Lot control * Process Capability Study (Cpk > 1.33) * Fast removal of problems * Inspection Method * Verification of Standards, operation standards, facility etc.(Process audit) * Special Inspection / Process control that is higher than normal controls. These could be either added inspection points or inspection at higher frequencies. IDENTIFICATION OF SPECIAL CHARACTERISTICS: The characteristics which will affect fit, function, safety, Govt. Regulations and past history of Quality Problem or otherwise specified by the customer will be identified as special characteristics and the same will be identified as per the procedure for New Product Development. The additional Controls required on those special characteristics are defined in the control plan which are derived from FMEA. Countermeasure implementation for problem reported at in house trials and customer feedback.	Changes Generated Internally/ Customer PPAP Approval from Customer In House Problems & Customer feedback	Changes in the relevant Doc’S/ Approval from Customer Termination of Initial Sample Control (Minutes of Meeting) Evidence	Head QA & Head Production Head QA & Head Production Head NPD & Head Engineering Head NPD & Head QA 3 of 5

Sl. No.	Activity			Input	Output		Responsibility
10 11 12 13	IDENTIFICATION OF COMPONENTS DURING DESPATCH: During the dispatch, the components are identified with Initial Product Tag for New Part Orange Color, for Engg Change Blue Color and Process Change Red Color TRACEABILITY: The traceability of the parts from raw material to finished products is identified through unique identification system as per the instruction for identification and Traceability. HANDLING OF REJECTED PRODUCTS DURING INITIAL SUPPLY: During the Initial Sample trial, the products which are rejected by Q.A are analyzed and necessary actions are decided by Q.A along with production After Deciding the necessary actions on process or Tool, the decision on disposing the sample quantity (Scrap, discuss with customer for fitment trial at their end etc.) will be decided and disposed of accordingly. If any changes derived on process or product are handled as per the procedure for Change Control 4M-Change Management: During the initial supply control,4M changes (Man, Machine, Material and Method) are recorded in 4M Change Control Register This becomes all the more important for operator related changes occurring in Critical stations & Processes. The added or extra controls for such type of changes could be :- *Through training of the operator about the job, its Quality & Safety aspects. * Skill assessment of the operator before putting him of the job. * Special extra checks of the operation carried out by the new operator at some defined frequency in a day by his supervisor.			Customer Inputs Like Drawing and Other Technical Information Sample Lot Rejected Component “4M’-Changes Operator Changes of Critical Processes	Identification of special Characteristics, Development of PFD, FMEA & CP Identification of Sample Lot with Identification Tag Handling of Rejected Components as per procedure “4M”- Change Control Register Training Record & Skill assessment		Head QA & Head Production Head QA & Head Production                      Head QA & Head Production Head QA & Head Production 4 of 5   Head QA & Head Production & HRD
Sl. No.	Activity			Input		Output	Responsibility
5.         Document Reference             1.         Procedure for New Product Development                              :           QSP:01             2.         Procedure for Production Part Approval Process                   :           QSP:18             3.         Procedure for Failure Mode and Effect Analysis                   :           QSP:02 6.          Records             1.         Initial Product Tag (New)-Orange                                         :           F:IPC:01             2.         Initial Product Tag (ECN) – Blue                                          :           F:IPC:02             3.          Initial Product Tag (Process Change)-Red                            :           F:IPC:03             4.          Initial Product Tag (Process Change)-Red                            :           F:IPC:04             5.          IPC Announcement                                                               :           F:IPC:05             6.         4M-Change Control Register                                                 :           F:PRD:23             7.          Initial Supply Sign off                                                           :           F:DEV:03             8.          SPC Record                                                                           :           F:QA:43             9.          MSA Record                                                                          :           F:QA:44            10.         On Job Training                                                                    :           F:HR:14
01		16.12.2017	Change done as per Requirements
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