PAGE NO.

1/4
ENACTMENT REGULATION
DATE
01.10.2010 INITIAL FLOW CLASSIFICATION No.
IFM - P- 00

MANAGEMENT ENACTING
LATEST MSD
DEPARTMENT
REVISION -
CONTROLLING
DATE PRODUCTIVITY DEPARTMENT
PROD

0.0 Definition of Initial Flow Management

0.1. Initial Flow Management is a concept of exercising special and additional controls
on the in house & supplier manufacturing, assembly operations, material flow, and
maintenance after the start of Mass production.

Objective
1.1 This procedure stipulates:-
• To define the Productivity enhancement procedures after SOP
• To ensure rapid ramp up
• To achieve target HPV

2.0 Scope of application

2.1 This procedure is applicable for the mass production stage of the following
A. New models,
B. Full Model change,
C. Big Minor change models,
C. Commissioning of new manufacturing lines
D. Manufacturing control transfer between the plants of MSIL.(With in the
plants and between the plants gurgaon and manesar plants)

3.0 Controlling department.

3.1 The controlling department of Initial Flow Management shall be the respective
individual Shift - in - charge of each production shop, Production Engineering,
concerned Maintenance, MX & MT Executives.

3.2. The overall controlling in charge of Initial Flow Management shall be the model
coordinator from production

4.0 Period of Initial Flow Management

4.1 In principal Initial Flow Management shall be observed for a minimum period of
one month from the day of start of mass production or until target HPV & production

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ENACTMENT REGULATION
DATE 01.10.2010 INITIAL FLOW CLASSIFICATION No.
IFM - P- 00

MANAGEMENT ENACTING
LATEST MSD
DEPARTMENT
REVISION -
CONTROLLING
DATE PRODUCTIVITY DEPARTMENT
PROD

are achieved whichever is earlier. However this can either be reduced or extended
depending upon the attainment of consistent HPV & Production values.

5.0 Planning of Initial Flow Management

5.1 MSD department shall inform individual production shops, Production

Engineering, concerned Maintenance, MX & MT about the Initial Flow Model in
advance of mass production and shall direct the implementation of Initial Flow
Management.

5.1.1 MSD department shall provide information of the model/ variant for which Initial
Flow Management is to be observed & basic shop wise check parameters (along with
guidelines & frequencies) that need to be checked & controlled during the Initial Flow
Management Period.

5.2 The detailed shop wise list of parameters “Daily Initial Flow management
Parameters Monitoring”. (Format No. _______) shall be prepared by each individual
shop based on the basis of basic shop wise check parameters given by MSD.

5.2.1 As a guideline, in principle Initial Flow Management parameters should contain-

a) Operator Steps & movement/cycle
b) Categorized line stoppage
c) Machine Breakdowns

5.3 The production model coordinator and MSD department coordinator shall co-
ordinate with each production shop, Production Engineering, concerned Maintenance,
MX & MT and shall obtain the detailed Initial Flow Management parameter list.

5.4 The production model coordinator and MSD department coordinator shall compile
individual Initial Flow Management parameters from various shops and prepare the
comprehensive “Initial Flow management implementation plan” & release application
form (Format No-_______/ _______/ _______ )”, and obtain the approval from MEO
Production.

PAGE NO. 3/4

ENACTMENT REGULATION
DATE 01.10.2010 INITIAL FLOW CLASSIFICATION No.
IFM - P- 00

MANAGEMENT ENACTING
LATEST MSD
DEPARTMENT
REVISION -
CONTROLLING
DATE PRODUCTIVITY DEPARTMENT
PROD

6.0 Implementation of Initial Flow Management

6.1 Initial Flow Management shall be observed by each production shop, Production
Engineering, concerned Maintenance, MX & MT on the basis of the implementation
plan.

6.2 Each production shop, Production Engineering, concerned Maintenance, MX &

MT shall carry out IFM activity and fill up the checksheets.

6.3 Issues Handling

6.3.1 The Shift-In Charge of responsible department shall prepare the report of issues
faced and action initiated during the initial flow management practice in “Initial Flow
Control Solution Reports” (Format No.______) and shall report them to the divisional
heads, model coordinator and MSD department coordinator on a biweekly basis.

6.3.2 Promotion of action

6.3.2.1 The model coordinator shall perform the follow-up of action with each
responsible department and aim at promoting the actions as quickly as possible
depending on the follow up condition.

7.0 Release of Initial Flow Management period

7.1 Production model coordinator and MSD Department coordinator shall monitor the
HPV & Production trends continuously and take decision for application of release of
initial flow management practice.

7.2. Production model Coordinator and MSD Department coordinator shall declare that
the Production figures have stabilized and shall confirm that the corrective action for
all the issues has been taken. They shall then prepare “Initial Flow Management
implementation plan form and release application form” and request approval from
MEO production.

7.3. In case MEO Production considers that Production has reached desired level then
the release of initial flow management practice shall be approved.

7.4. After getting the approval for the release of initial flow management practice,
Production model Coordinator and MSD Department coordinator shall inform the

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ENACTMENT REGULATION
DATE 01.10.2010 INITIAL FLOW CLASSIFICATION No.
IFM - P- 00

MANAGEMENT ENACTING
LATEST MSD
DEPARTMENT
REVISION -
CONTROLLING
DATE PRODUCTIVITY DEPARTMENT
PROD

concerned production shop, Production Engineering, Maintenance, MX & MT

regarding the release of initial flow management practice.

7.5. If MEO Production has any concerns regarding the completion of initial flow
management practice, then instructions shall be given to the Production model
Coordinator and MSD Department coordinator for restarting or continuing the initial
flow management practice.

8.0 Storage of records

8.1. The controlling department shall keep all Initial flow management related records
for a period of three years after IFM completion.