Supplier QA Manual

BRAKES INDIA LIMITED

SUPPLIER QUALITY ASSURANCE

MANUAL (SQAM)

Revision 2 – November 2009

Supplier Quality Assurance Brakes India Limited Padi, Chennai – 50. http://www.brakesindia.com/brakesdivision/sqamanual.pdf

Brakes India SQA Manual

Page No: 2 BI - SQAM Rev: 2 – Nov 09

Brakes India Limited Corporate Office & Factory Brakes India Limited, Padi, Chennai – 600050 Telephone : (044) 26526000 Fax : (044) 26526960 Website : www.brakesindia.com

Other Plant Addresses: Brakes India Limited, Brakes division, Sholingur – 631102. Tamil Nadu. Telephone : (04172) 262276 Fax : (04172) 262210

Brakes India Limited, Cheyyaru - Vandavasi Road, Polambakkam – 631309. Tamil Nadu. Telephone : (044) 27544107 Fax : (044) 27544103

Brakes India Limited, Seals Division 3A, KIADB Industrial Area, Nanjangud – 571302 Karnataka. Telephone : (08221) 228222 / 228787 Fax : (08221) 228333 / 228777

Brakes India Limited 834, Udyog Vihar, Phase V, Gurgaon – 122016. Haryana. Telephone : (0124) 2347810 / 2340571 Fax : (0124) 2342584

Brakes India Limited, 110, GIDC Estate Dhunia VIII, Panchmahal Dist., Halol – 389351. Gujarat. Telephone : (02676) 226144

Brakes India Limited Plot No.3, Gar No.105, Krishna Industrial Park, Waki Budruk, Tal. Khed, Pune – 410 501 Telephone : (02135) 308031 / 308059 Fax : (04172) 262210

Brakes India Limited, B-9, ESIT,Baruabagh Udhamsingh nagar Dt..– 262405 Uttaranchal.

Brakes India Limited Plot No. AA2, 6th Avenue Auto Ancillary SEZ, Mahindra World City Natham Sub PO, Chengalpet - 603 002

Rolltec Engineering (A 100% EOU of Brakes India Limited) No.9, Avadi Main Road, Veeraraghavapuram, Poonamallee, Chennai - 600 077 Telephone : (044) 64541920, 64541921 Fax : (044) 26800522

© Copyright notice. All rights reserved. No part of the manual should be copied (or) published without prior written permission of Brakes India Limited. Initial release Nov 03 Revision 1 Sep 07 Revision 2 Nov 09



Message

As a key part of our supply chain, our suppliers play a very significant role to ensure that our

products perform consistently well in the field. Today, with the changes in regulations the entire

world has become a market place for every one. This has resulted in a highly competitive scenario,

wherein to sustain and emerge as a leader, our performance on quality has to be on par with the best

supplier in the world. Our customers expect defect free supplies on time every time. We need our

suppliers to certify their parts for Direct On Line (DOL). This translates into zero line rejections and

warranty rejections. Needless to say this should be achieved at competitive cost.

In order to achieve the above target along with you, we formulated a methodology, which has been

time tested and successful to compete globally. This was communicated to you through our supplier

quality assurance manual. Now, we are releasing this manual in line with our changed requirements.

We expect you to strengthen our hands in adopting the methodology followed by us.

S.VIJI Managing Director



Acronyms ANOVA Analysis of Variance BI, BIL Brakes India Ltd & its satellite assembly units. CAR Corrective Action Report CC Critical Characteristic CP Control Plan Cp Process performance Index (Long term) Cpk Process capability Index (Long term) CRA Cost Recovery Advice DOE Design Of Experiments DOL Direct On Line E, R&D Engineering Research & Development ESQS Evaluation of Supplier Quality System FFF Fit, Form, Function FIFO First In First Out FTC First Time Capability ISLR Initial Sample Laboratory Report LC Least Count LSL Lower Specification Limit MSA Measurement System Analysis MSE Manufacturing Systems Engineering NC Non conformance OEM Original Equipment Manufacturers PPM Parts Per Million PFMEA Process Failure Mode and Effects Analysis PPAP Production Part Approval Process Pp Process Performance index (Short term) Ppk Process Capability index (Short term) PSW Part Submission Warrant PTR Production Trial Run QC Quality Control R Range RI Receiving inspection SOP Start Of Production SC Significant Characteristic SDI Supplier Development and Integration SDS Supplier Data Sheet SIR Sample Inspection Report SQA Supplier Quality Assurance TPM Total Productive Maintenance UD Usage Decision (used in SAP) USL Upper Specification Limit VMI Vendor Managed Inventory WI Work Instruction X bar Arithmetic average of data



Foreword to Brakes India Ltd SQA Manual, Revision 2 Effective 1st October 2009 the revision 2.0 replaces earlier version of BI, Supplier Quality Assurance Manual. Production part suppliers are to adhere to the BI requirements elaborated in the SQA Manual to achieve & sustain best quality practices at all levels. List of major modifications. 1) Introduction to SQA Activities: Interaction structure modified based on the revised scope. 2) Pre-PPAP Audit: Guidelines & acceptance criteria modified. 3) PPAP: Approved supplier list reference given. PPAP categorization details & document

requirements specified. 4) APQP & Safe launch plan: Safe launch plan details were elaborated. 5) FMEA : This section revised in line with FMEA manual rev. 4 6) Quality plan & Document retention: Document retention details of various suppliers

specified. PPM expectation from suppliers specified. Quality plan format modified to include details about inspection during safe launch period & during customer complaints.

7) PSW approval: Conditional approval details must be informed to respective units & double

sampling to be done till the deviations are corrected. 8) Skip lot & DOL implementation. Skip lot procedure revised. DOL implementation

procedure specified. 9) Change management: Details about change management / Re-PPAP guidelines added. In

case of known violations by suppliers, BI’s action added. 10) Identification & traceability: DOL tag details specified & tag samples shown. 11) Quality rating & PPM calculation: Quality rating calculation procedure revised with the

modified practice of capturing rework, inspection reports receipt status, process scrap details elimination, etc. Minimum PPM requirement details & action on high PPM suppliers specified.

12) Control of non conforming products: Tips on Do’s & Don’ts added. CoPQ monitoring

requirements added. 13) Process & Product audit: Audit frequency calculation formulae & methodology specified.

Audit questionnaire modified. 14) Corrective & Preventive action: CAR flow chart modified. In line with the modifications,

revised CAR format included. 15) Cost recovery: This section added. Details regarding cost recovery details specified. Format

included. Apart from this, salient points / caution points are given in boxes for each chapter.



Index

Sl. No Section # Click on the Description to go to the respective chapters Page No.

1) Introduction: This section provides the overview of the manual and list of interacting functions of Brakes India with supplier.

1.1 Introduction to SQA activities 7

2) Supplier selection & Approval process: This section outlines the procedure for new supplier selection and development of new family of parts with existing supplier.

2.1 New supplier selection 9

2.2 Pre PPAP audit & approval process 10

3) New product Development : This section explains in detail the procedure to be followed for new part development & key elements from APQP till completion of safe launch period.

3.1 APQP & Safe launch plan 15

3.2 Production Part Approval Process - Overview 16

3.3 Design, Process, Tooling & Gauge Review 20

3.4 Process Flow Diagram 21

3.5 Process Failure Mode & Effects Analysis 22

3.6 Control Plan 25

3.7 Submission of sample parts 27

3.8 Measurement System Analysis 28

3.9 Process capability monitoring 29

3.10 Special process qualification 32

3.11 Capacity verification 33

3.12 Quality plan & document retention 34

3.13 PSW approval 36

4) Regular production & measurement of performance: This section gives details of controls required on sub suppliers, traceability, etc. It also provides procedure for measurement of supplier performance, supplier audit & DOL procedure.

4.1 Sub supplier quality assurance 37

4.2 Identification & traceability 38

4.3 Control charts 40

4.4 Receiving inspection at BIL 42

4.5 Quality rating & PPM calculation 43

4.6 Control of non conforming parts 44

4.7 Skip lot & DOL implementation 46

4.8 Change management 48

4.9 Process & product audit 50

4.10 Corrective & preventive actions 53

4.11 Tool management 55

4.12 Cost recovery process 56

5) Formats: Gives details of Brakes India specific formats as referred in the manual. ---- List of formats 57



Section 1.1 – Introduction to SQA activities

Purpose:

The purpose of this section is to

• Provide an overview of this manual

• Define the document control method followed

• Interaction structure of Brakes India with the Supplier

Scope:

This manual applies to all suppliers providing production parts to Brakes India Limited and its subsidiaries.

Explanation:

Overview of the manual

1 All direct material suppliers to B.I. production plants shall be certified for ISO 9001 or TS 16949. ISO 9001 Suppliers shall have a definite time target for TS 16949 certification.

2 Supplier selection and approval method is to ensure supplier with demonstrated abilities of sustaining required quality levels are selected.

3 Production part approval process with specific emphasis on defect prevention and also to ensure consistent delivery capability.

4 The process to be followed for re-qualification of parts that are already under supply.

5 The Change management system to be followed in the event of a change in design / process / location / material etc.,

6 System to be followed to ensure quality sustenance, quality rating and the non-conformance reporting, corrective and preventive action process.

Document control

Brakes India Quality Assurance department will provide a soft copy of the manual to the supplier and also intimate to all suppliers, in case of revision.

Supplier shall ensure that the entire operating team is conversant with this manual. Should you have any improvement suggestion about this manual, please send an e-mail to the following address. [email protected]



Interaction structure of Brakes India with the supplier

The following table describes the interacting functions of Brakes India with the suppliers

Function

Interaction for

E, R&D

- Design review (through SQA)

- Concession / Deviation approvals (through unit)

Supplier Development & Integration

(SDI)

- Supplier selection

- Business relationships

- Commercials

- Sample development (Timeline related)

- Issuing & updation of drawings/standard - upto BIR (BI Release)

Supplier Quality Assurance (SQA)

- New Supplier Approval

- Production Part Approval

- CAR adequacy closure

- Quality improvement activities

- Process & Product audits

- Sample development (Quality related)

- Supporting units in implementation of DOL activities.

Manufacturing Unit

- Delivery schedules

- Receiving Inspection

- CAR closure based on effectiveness of CAR.

- Delivery issues.

- Payments

- Implementation of skip / DOL / VMI

- Issuing latest drawings (Released through alteration notes)

Finance / Accounts

- Bill payments (through SDI / unit supply module)

Supplier shall use the documentation / format specified in this manual. However, the supplier may substitute any other forms, provided it contains all the information specified in the Brakes India format. This must be agreed with the supplier quality assurance representative prior to use.

Each & every supplier has been assigned a SQA Engineer as a single window contact. Please feel free to contact him for all your quality related issues and queries.



Section 2.1 – New supplier selection

Purpose

To outline new supplier identification and selection procedure.

Scope:

Applies to all production parts.

Procedure

Flow Chart – Supplier Selection Process

Supplier Identification

Supplier Data Sheet despatch to supplier

Data receipt `

Evaluation of data sheet

Feasibility Study Audit as per ESQS Commercials (Evaluation of Supplier Quality system) Not OK

Judgment OK

Gap analysis & closure at supplier end.

For more details on ESQS, please refer the format.

Note: A Minimum ESQS score of 70 % is required for supplier selection. Supplier should have minimum valid ISO 9001 certification to be a supplier of BI.



Section 2.2 – Pre-PPAP audit & approval process

Scope

This approval is required for an existing supplier who develops a different part family than existing.

Procedure

1. BI shall notify the supplier about the exact date of audit in advance. Audit can be planned based upon mutual consent of supplier and BI.

2. Audit will be based (focused) on audit checklist and following will be covered.

a. Part / material receiving

b. Equipments / gauges

c. Machine condition / Machine Layout

d. In-process quality control

e. Inspection

f. Parts shipping area.

g. Internal audit by the supplier

h. Line rejections & customer complaints

i. Corrective & preventive action (problem solving)

j. Continuous improvements

3. Evaluation criteria are given in the subsequent pages

4. Supplier selection is normally based on a minimum score of 3 out of 5. A minimum score of 3.0 is expected in critical areas such as inprocess, inspection & past track record of supplier.

5. If score is < 3.0, the gaps / observation shall be intimated to supplier by the concerned SQA engineer.

6. Supplier has to give proper corrective action to close the gaps/observations made during audit with time plan if selected & a re-audit will be done if required.

7. Selected supplier should follow the procedure for new product development.

8. The above audit can be waived if the supplier has been already audited / approved for that part family.



Brakes India Limited PRE PPAP AUDIT

Unit : Unit 12, Part Nos.: XXXX Product : Wheel. Cyl. assy Supplier : XX Location : Chennai Audit date : 14.07.09 Present part family supplied : Input rods Proposed part family : Alu. Plungers

Description

Rating

Comments

1. PART / MATERIAL RECEIVING a) Receiving Inspection b) Raw Material Control c) Sub-Supplier Control Average

5 4 5

4.66

Incoming parts control from sub-supplier traceability FIFO to be followed. Sub-supplier rejection monitoring required.

2. EQUIPMENT / GAUGES a) Calibration b) Availability & maintenance Average

5 4

4.5

Calibration done

3. MACHINE CONDITION / MACHINE LAYOUT a) Maintenance b) Process flow sequence & Shop layout Average

5 4

4.5

TPM activities initiated.

4. IN-PROCESS QUALITY CONTROL a) Work Instructions b) Prevention of Defect (Poke Yoke) c) Non-Conforming Parts Handling d) Monitoring process e) Tool / Fixture Maintenance f) Training for operator g) Process capability / process qualification h) Process flow / Process FMEA / Control plan Average

4 5 5 4 5 5 5 5

4.75

W1 Available To be implemented for prevention. Route cards to be initiated. Preventive maintenance to be carried out. Process capability carried out PFMEA to be prepared for all parts.

5. INSPECTION a) Availability & Adherence to Inspection Standards. (In-process & Delivery) b) Sampling Plan availability & adherence. Average

4

4 4.0

Pre-control charts available. Sampling plan available

6. PARTS SHIPPING AREA a) Handling of the Parts b) Packing of the Parts Average

3 4

3.5

Fixed quantity packed in boxes Packing instructions available

7. PAST TRACK RECORD a) PPM / Quality rating – Last 3 months b) Response to BI on complaints. Average

4 5

4.5

Rating : 5 Excellent Overall rating 0 Not satisfactory

4.34 Minimum overall rating required for approval = 3.0 Minimum 3.0 Reqd. for Sections 4, 5 & 7

Conclusion: Accepted for proposed part family.

Pre-PPAP audit sample format is given below.



Guidelines for Pre-PPAP scoring

RATING

5 Excellent

4 Good

3 Satisfactory

2 Needs

improvement

Not satisfactory 0 or 1

Receiving / incoming controls

RI Quality plan and sampling plan are clear. NC parts handling procedure is established with 100 % adherence.

RI Quality plan and sampling plan are clear. NC parts handling procedure is followed with minor lapses.

RI Quality plan and sampling plan are clear. NC parts handling procedure is not very effective.

RI Quality plan available, but not adhered. NC parts handling procedure not available.

RI Quality plan, sampling plan & NC handling procedure not satisfactory.

Raw material control

100% identification for receipts with 100 % FIFO & traceability adherence.

100% identification for receipts with 100 % FIFO & traceability adherence with minor lapses

100% identification for receipts with 100 % FIFO & traceability adherence not very effective

System is established but FIFO & traceability not followed

No identification system for FIFO & Traceability.

Sub supplier control

Sub-suppliers QC activities have been reviewed in detail and every concern have been solved. Periodical audit and development with 100% adherence

Sub-suppliers QC activities have been reviewed & concerns are solved. But no periodical review/Audit plan

Sub-supplier’s QC activities have been reviewed in detail but concerns are not solved systematically

Sub-supplier’s QC activities are not effective

No proper system for sub supplier controls

EQUIPMENT & GAUGES Calibration All necessary gauges /

equipment are available Calibration frequency and identification are clear and controlled well with full compliance

All necessary gauges / equipments available Calibration frequency and identification is clear & followed with minor lapses

All necessary gauges / equipments available Calibration frequency and identification are clear with partial compliance

All necessary gauges / equipments not available

Calibration system not effective

Maintenance availability

Preventive maintenance check list for daily, weekly, monthly and annually are clear and complied with.

Preventive maintenance check list for weekly and daily basis for all necessary gauges & equipments. Gap in disposal of rejected items & spare availability

All necessary gauges / equipments available and plan for required gauge & equipments is available

All necessary gauge & equipments are not available. Gauge plan is not available

Gauges & equipments are not available. No gauge planning system




RATING

5 Excellent

4 Good

3 Satisfactory

2 Needs

improvement

Not

satisfactory 0 or 1

MACHINE Maintenance Preventive maintenance

check list for daily, weekly, monthly and annually are clear and complied with. Dynamic plan for zero PPM.

Maintenance plan based.

Preventive maintenance check list for daily and weekly basis are available but not adhered

Periodical maintenance is

not there

Repair only when breakdown

IN PROCESS QUALITY CONTROL Process flow / PFMEA / Control plan

Process flow / PFMEA/control plan are updated based on any changes with periodical review Eg. Corrective action given to customers on failures. The above should be linked to work instructions and other relevant documents

Process flow / PFMEA/control plan are updated based on any changes but no periodical review

Process flow / PFMEA/ control plan are available and up-dated based on design change etc but it doesn’t link to other documents

Process flow/ PFMEA/ control plan are available but not updated based on design change etc

Process flow / PFMA/ control plan not available

Process capability / qualification

Cp greater than 1.67 and trend analysis for improvement

1.33≤ Cp≤ 1.67 1.00≤CP < 1.33

Cp < 1.00 Not

monitored Work instructions

In addition to requirements for rating 4, signs of updating and standardized job is incorporated

W.I are available in the worksite and critical points are highlighted with picture or diagram

Work instructions are available in the worksite but points are not highlighted

Work instructions are available but inadequate

No work instructions are available

Prevention of defects (Poka Yoke)

Poka Yoke works properly throughout the process and are checked for effectiveness periodically.

Poka Yoke works properly. But not checked periodically

Jigs and fixtures (Prevention) are having Poka Yoke but improvement is required

Detection Poke – Yoke available but improvement required

No adequate detection

Monitoring process

At specified intervals daily and action procedure is clear

Route card usage Daily check with review

Daily check but no review

Non existence

Non conforming parts handing

In addition to requirements for Rating 4, proper action for NC parts and Counter measure plan is established

NC parts container identified and segregated in each process and daily rejection review

Process by process check containers identified for defects. NC parts stop in process

Final inspection only

No adequate detection. Good and NC parts mixed




RATING

5 Excellent

4 Good

3 Satisfactory

2 Needs

improvement

Not

satisfactory 0 or 1

Training for operator

In addition to requirements for rating 4, proper action for NC parts and counter measure plan is established

NC parts container identified and segregated in each process and daily rejection review

Process by process check containers identified for defects. NC parts stop in process

Final inspection only

No adequate detection. Good and NC parts mixed

Training for operator

Skill level identified & clear instructions and monitoring progress by supervisor

Instruction available & Skill level identification is not there

Instruction available but not monitored by supervisor

On job training with instruction

On job training and no instruction

Tool / Fixture maintenance

All check point for daily, weekly, monthly and annually are clear and controlled. Worn out & rejected tools/Fixtures handling is clear

All equipments check sheet for weekly and daily basis are available. Handling of rejected items not clear

All equipments check sheet for weekly and daily basis are available

All equipment lists are available. No periodical maintenance

Repair when breakdown

INSPECTION Quality check availability and control

Standards are displayed in the work area and updated adequately / periodically & reviewed

Standards are displayed but not updated & reviewed

Standards exist but not maintained well but no review

Standards exist but not displayed & monitored

No standard available

Gauges / Fixtures are available and sufficient to meet the product quality. They are maintained very well.

Gauges and fixtures are available & maintained well

Gauges and fixtures are available but not maintained well

Gauges and fixtures are available but not identified properly

Gauges / Fixtures are not available

Sampling plan Frequency is sufficient. NC procedure is clear and countermeasure activity carried out. Zero defect policy evidenced.

Sampling plan is followed. But no NC handling procedure & No zero defect plan

Sampling plan is available but frequency is not sufficient

Sampling plan is available with partial compliance

Non existence

Handling of parts Adequate and followed as per operation instruction. Trays usage exclusively for specified parts

Handling procedure & Operation Instruction is adequate & followed

Operation instruction is available but inadequate

Handling procedure is clear followed with partial compliance

Handling procedure is not clear. (No clear instruction or caution)

Packing of parts Packing work instructions are available, clear, adequate and properly adhered

Packing procedure & Operation Instruction is adequate & followed

Packing work instructions are available but inadequate

Packing work instructions are available with partial compliance

Non existence



Section 3.1 APQP & Safe launch plan

Purpose

To explain key points and submission procedure for the PPAP schedule and initial supply controls.

Scope

This applies to domestic suppliers of production part and has to be submitted to BI on demand.

Explanation

The goal of APQP – PPAP timing chart is to provide a schedule of the manufacturing and control activities necessary to assure the quality of parts during mass production.

Suppliers are required to prepare the timing chart for each part. The schedule should span the time between the issuance of the production drawing and PPAP approval.

Supplier responsibility

• The supplier should create and maintain an APQP – PPAP timing plan before start of the part development plan.

• The timing of the various activities of the timing chart at supplier end must meet Brakes India’s requirement.

• All the related departments within the supplier must have consensus on the timing chart before submission to BI. In addition, the supplier’s top management is responsible for monitoring this plan to achieve milestones as scheduled.

• Brakes India SDI & SQA will review and confirm the supplier’s activity to master schedule. Request for any adjustments will be negotiated between the supplier and B.I.

• The supplier must review the timing plan status periodically and any revision must be intimated to BI. The supplier must re-submit the updated timing plan in consultation with Brakes India SDI & SQA.

Safe launch plan • Safe launch plan will be applied to new products & existing product with major

design change. This is to overcome teething problems during the launch & ramping up period. The supplier’s development incharge will be responsible for this.

• Safe Launch Plan shall be filed for each part and displayed at the final inspection stage at supplier end.

• By default, the exit criteria is 3 months after the part’s SOP. However, the same will be extended by BI’s discretion, based on the problems noticed in the 3 months.

• Precautionary activities & preventive activities to be carried out. Typical precautionary activities include increased inspection/ increased frequency/ increased parameters. Typical preventive actions include installing poka-yokes, deploying certified operators, frequent audits in shop floor, reduced cycle time for problem solving.

• Identify the part with the necessary pilot batch identification tag (discussed in coming pages) & ensure adequate special care is taken to eliminate mixup, damages, rust.

A sample safe launch plan is shown in the annexure.



Section 3.2 – Production Part Approval Process - Overview The Production Part Approval Process (PPAP) defines generic requirements for production

part approval. The purpose of PPAP is to determine if all customer engineering design records and specification requirements are properly understood by the supplier and the process has the potential to produce parts consistently to meet these requirements during an actual production run at the quoted production rate. Scope:

PPAP shall apply to all suppliers during the period from release of mass production drawings to start of production. PPAP is optional for lubricants, carton protection sleeves, stickers, bars, tubes, assembly fluids, sheets, packing containers, ingots & indirect materials.

Procedure Flow chart – Production Part Approval Process

Decision to buy

New supplier Existing supplier

ESQS audit Same part family New part family

Pre-PPAP audit

Not Approved Approved Capable Not capable Design / Feasibility review / Timing plan - Discussion Select another supplier Sample submission / inspection OK Not OK Process correction Production trial run by supplier / BI-SQA based on part categorization Quality plan documentation & agreement PSW Sign off Straight approval Conditional approval Review

Inform unit with details Action plan

Upload in database & inform unit



1. For a new project a routing sheet will be prepared which details out whether the parts are to be produced in house or to be sourced out.

2. Once this is done, SDI will identify the source for the same. ESQS audit approval is required for any new supplier. Details are given in new supplier selection section.

3. In case of new part family with existing source, supplier has to score 3 min in the pre-PPAP audit sheet.

4. Supplier will be called for design review, feasibility review & process review. 5. Supplier shall have a timing plan and have periodic reviews with Brakes India during

development period. 6. Samples, inspection report & process flow chart to be submitted to SDI who in turn will

forward the same to manufacturing unit for inspection. The procedure is further detailed out in sample submission section.

7. Manufacturing unit will clear the samples after obtaining comments from E,R&D and approve the initial samples inspection report.

8. PPAPs are categorized based on part criticality / supplier’s capability, etc. Documentation requirements are specified in the guidelines in the following pages.

9. List of PPAP documents to be submitted, the format to be used and methodology to be followed are explained in the subsequent sections.

10. Supplier to ensure compliance in the production line as per the documents submitted. Upon confirmation, SQA representative will visit the supplier and will witness a production run for 300 nos. or one shift quantity (whichever is minimum) as per the documents and fill in compliance audit report. Yield of OK parts should be minimum 90 % for approval.

11. If the production run is satisfactory and there are no concerns, the PSW will be approved by SQA. Otherwise, a re-run will be required or the PSW will be conditionally approved. In the event of conditional approval the supplier has to submit a firm action plan. Further details are given in PSW approval section.

12. Supplier has to inform SQA upon implementation of action plan and then it will be verified by SQA and the conditional status will be removed provided the implementations are satisfactory.

13. PPAP level is based on BI’s discretion.

• Supplier is responsible for the quality of their parts supplied to BI, irrespective of any operating conditons.

• For both sample submission & for regular mass production, supplier must buy

rawmaterial or do special processes in BI approved sources only as specified in TD 1-30-07. Violations if any will be looked into seriously by BI including cost debits.



Guidelines for categorization of parts

Commodity Group 1

Commodity Group 2

Commodity Group 3

Machining ,Casting, Forging, Sintering

Pressed parts, Special process,

Proprietary assembly

Friction, Spring, Plastic, Rubber

parts

Critical Parts – A Category

Heat treated parts

Hard chrome & trivalent plated

parts

Surface finish 0.8 Ra or less

Tolerance 50 Microns or less

Chamber brackets

Tolerance 0.1mm or less

Anti rattle clips

Pad backing plate

All coil springs

Welded reservoirs

Pin boots

Piston boots

Reaction disc

NRV, Linings

Major parts – B Category

Part from new sources

Special Fasteners

Castings


Pad wear warning indicators

Push rods

Lever pawls


Spacer for ‘S’ Cam

Non welded reservoirs

Adaptors

Filler caps

Filter mesh

Others – C Category

Rivets, Standard fasteners

Proprietary parts from TRW

Customer specified sources

TRW suppliers parts



TRW supplier parts.

Protective plugs

Spacers for calipers

Bleed screw caps

Gaskets



TRW suppliers parts



Document requirements of PPAP

A Category parts: (PTR by BI compulsory)

All 18 requirements as in AIAG manual PPAP rev. 4 which includes SIR/ISLR and Brakes India specific requirements as given below.

1) Design review minutes (or) supplier’s letter that he will meet all drawing + Cp, Cpk requirements identified in drawing as well as identified during PPAP.

2) Quality plan. 3) Capacity verification based on run at rate, shared capacity & machine utilization. 4) PPAP checklist (To be filled by SQA Engineer) 5) Packaging specification sheet 6) Compliance audit (Conducted at supplier end by SQA Engineer) 7) Conditional approval sheet (If required) 8) Fit, Form & Function check sheet

B Category parts: (PTR by BI optional)

All 18 requirements as in AIAG manual PPAP rev. 4 which includes SIR/ISLR and Brakes India specific requirement as given below.

1) Design review minutes (or) supplier’s letter that he will meet all drawing + Cp, Cpk requirements identified in drawing as well as identified during PPAP.

2) Quality plan. 3) Capacity verification by supplier. 4) PPAP checklist (To be filled by SQA Engineer) 5) Packaging specification sheet 6) Compliance audit (Conducted by supplier) 7) Conditional approval sheet (If required) 8) Fit, Form & Function check sheet

C Category parts: (PTR by BI optional)

C Category (Import)

C Category – Domestic

TRW / MAN / Hitachi / Meritor & other customer approved PSW (Level 1)

PSW – level 2 ticked (Supplier to retain all other documents at his end – Auditable by BI) PPAP Check list - C category

Accepted SIR / ISLR or Supplier’s insp. reports

Quality plan for particular part

PPAP Check list – C category Control plan (Generic) Approved SIR and ISLR by B.I Capacity verification (mail confirmation is also acceptable) Fit, Form & Function matrix (If applicable)

For all the above categories, if OEM customer asks for further documents, the same needs to be

submitted on case to case basis.



Section 3.3 – Design, Process, Tooling and Gauges review

Purpose

To explain procedure for the design, process, checking fixture, tooling and gauges review with supplier and agreement with B.I. SQA representative.

Scope

This applies to domestic suppliers of production part.

Explanation

The goal of these reviews by BI SQA representatives with supplier is to

1. Appraise the supplier of the functional requirements of the components.

2. Discuss parameter by parameter about achieving the dimensional requirements, process capability requirements & metallurgical requirements packing requirement in production.

3. Identify and agree the significant & critical characteristics based on drawing / based on functional requirements.

Design review format is given in annexure.

Design review - Once the drawing is received, supplier has to study the drawing in detail. - In case the drawing refers TS / TD / other standards, please get & understand

the related requirements. - Wherever SC/CC characteristics are mentioned, ensure that there is no issue

in meeting process capability. - In case the drawing requirements / process capability requirement meeting is

doubtful, discuss this in design review. - Understand all the Fit, Form & Function characteristics during design review. - A properly conducted design review will solve design related issues & help

deliver “First time right”



Section 3.4 –Process Flow diagram Purpose

To explain process flow diagram and submission procedure.

Scope This applies to all parts and components

Explanation The process flow chart is a schematic representation of current or proposed process flow. It

can be used to analyze the sources of variation of machines, materials, methods and manpower from the beginning to the end of a manufacturing or assembly process. It should be used to emphasize the impact of sources of variation on the process. The flow chart helps to analyze the total process rather than individual steps in the process. The flow chart assists the Product Quality Planning team to focus on the process when conducting the PFMEA and designing the control plan.

Supplier responsibility 1. Raw material, Sub supplier name and Location specific to supplier own manufacturing unit

should be clearly addressed in process flow. 2. Any changes in sub supplier activity to be informed to B.I. immediately and process flow

should be updated. All critical and significant stages to be identified. 3. All critical and significant stages to be identified.

Sample Process Flow Diagram



Section 3.5 – Process Failure Mode & Effects Analysis (PFMEA)

Purpose

To explain PFMEA creation and submission procedure

Explanation

A PFMEA is an analytical technique used to identify potential problem areas associated with all stages of manufacturing i.e. right from receipt to dispatch. Efforts shall be taken to improve the process to achieve defect prevention rather than defect detection.

Procedure

1. The starting point for a PFMEA is process flow diagram and data on things gone wrong.

2. A Cross-Functional Team should study each step of the process for process failure modes, effects of failure and potential causes. Existing conditions should then be reviewed and rates for the likelihood of severity (S), occurrence (O) and detection (D).

3. The product of these ratings is the risk priority number (RPN) for each possible cause of failure. The RPN establishes priorities for investigating counter measures for each potential cause of failure. As countermeasures are implemented, the results are recorded and RPN is recalculated.

4. Do not use words like “Operator error” as a potential failure. The failure is rooted to the process or system.

5. All critical and significant characteristics must be addressed in PFMEA.

6. The PFMEA is a living document that should be utilized / updated for the life of the part.

7. The table below gives the rating number to be given for each failure mode.

8. For further reference supplier to possess AIAG’s FMEA manual. 4th edition, release June 2008.

The outcome of a PFMEA will be the control plan; Poka Yoke and work instructions.

• PFMEA is a live document and has to be updated by the supplier during design change / process change, customer complaint elimination, reduction of internal rejection, etc.

• Wherever the severity rating of the defect exceeds 8, supplier shall plan and implement poka-yoke in process.

• RPN should not exceed 100. Wherever RPN is more than 100, suitable actions required to reduce RPN.

• When severity rank is 9 or 10 its corresponding occurrence and detection should not go beyond 2 & 4 respectively.

• In case the above is not adhered, a firm action plan is mandatory.



Severity rankings

Effect

Criteria:

Severity of Effect on Product (Customer Effect)

Rank

Effect

Criteria: Severity of Effect on Product

(Manufacturing/Assembly Effect)

Potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning.

10 May endanger operator (machine or assembly) without warning.

Failure to Meet Safety

and/or Regulatory

Requirements Potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning.

9

Failure to Meet Safety

and/or Regulatory

Requirements May endanger operator (machine or assembly) with warning.

Loss of primary function (vehicle inoperable, does not affect safe vehicle operation).

8 Major Disruption

100% of product may have to be scrapped. Line shutdown or stop ship.

Loss or Degradation of Primary Function Degradation of primary function

(vehicle operable, but at reduced level of performance)

7 Significant Disruption

A portion of the production run may have to be scrapped. Deviation from primary process including decreased line speed to added manpower.

Loss of secondary function (vehicle operable, but comfort / convenience functions inoperable)

6

Moderate

100% of production run may have to be reworked off line and accepted

Loss or

Degradation of Secondary

Function Degradation of secondary function (vehicle operable, but comfort / convenience functions at reduced level of performance)

A portion of the production run may have to be reworked off line and accepted.

Appearance or Audible Noise, vehicle operable, item does not conform and noticed by most customers (> 75%).

4 100% of production run may have to be reworked in station before it is processed.

Appearance or Audible Noise, vehicle operable, item does not conform and noticed by many customers (50%).

3

Moderate Disruption

A portion of the production run may have to be reworked in-station before it is processed.

Annoyance

Appearance or Audible Noise, vehicle operable, item does not conform and noticed by discriminating customers (<25%).

2 Minor Disruption

Slight inconvenience to process, operation, or operator.

No effect No discernible effect. 1 No effect No discernible effect.



Occurrence rankings

Detection rankings

Likelihood of Failure Criteria: Occurrence of Cause – PFMEA (Incidents per items/vehicles) Rank

Very High > 100 per thousand > 1 in 10

10

50 per thousand 1 in 20

9


8

High


7


6

.5 per thousand 1 in 2,000

5

Moderate .1 per thousand

1 in 10,000 4

.01 per thousand 1 in 100,000

3

Low <.001 per thousand 1 in 1,000,000

2

Very Low Failure is eliminated through preventive control. 1

Opportunity for Detection Criteria: Likelihood of Detection by Process Control

Rank Likelihood of Detection

No detection opportunity No current process control; Cannot detect or is not analyzed.

10 Almost Impossible

Not likely to detect at any stage

Failure Mode and/or Error (Cause) is not easily detected (e.g., random audits)

9 Very Remote

Problem Detection Post Processing

Failure Mode detection post-processing by operator through visual/tactile/audible means

8 Remote

Problem Detection at Source

Failure Mode detection in-station by operator through visual/tactile/audible means or post-processing through use of attribute gauging (go/no-go. Manual torque check/clicker wrench, etc).

7 Very Low


Failure Mode detection post-processing by operator through variable gauging or in-station by operator through use of attribute gauging (go/no-go, manual torque check/clicker wrench, etc).

6 Low


Failure Mode or Error (Cause) detection in-station by operator through use of variable gauging or by automated controls in-station that will detect discrepant part and notify operator (light, buzzer, etc.) Gauging performed on setup and first-piece check (for set-up causes only)

5 Moderate


Failure Mode detection post-processing by automated controls that will detect discrepant part and lock part to prevent further processing.

4 Moderately High


Failure Mode detection in-station by automated controls that will detect discrepant part and automatically lock part in station to prevent further processing.

3 High

Error Detection and/or Problem Prevention

Error (Cause) detection in-station by automated controls that will detect error and prevent discrepant part from being made.

2 Very High

Detection not applicable; Error Prevention

Error (Cause) prevention as a result of fixture design, machine design or part design. Discrepant parts cannot be made because item has been error-proofed by process / product design.

1 Almost Certain


Page No. 25 BI – SQAM Rev: 2 – Nov 09

Section 3.6 – Control plan

Purpose To explain Control plan creation and submission procedure.

Scope This applies to all parts and components

Explanation This is used to define all key part and process control points from raw material receipt to

shipment of finished goods. Since it applies to many areas of manufacturing, a multidiscipline team should be established to develop an effective control plan. The control plan is an integral part of an overall quality process and it is to be utilized as a living document. Therefore control plan shall be used in conjunction with other related documents like PFMEA, process flow and inspection standards. The following available information should be utilized while developing control plan

• Process flow diagrams • System / design / process failure mode and effects analysis • Special characteristics including FFF characteristics. • Lessons learnt from similar parts • Team’s knowledge of the process • Design reviews • Optimization methods (e.g., DOE, etc.) Besides Production control plan supplier may have to submit control plan for prototype and pre-launch phase, which will be intimated by SQA.

1. Part / process number: This item number is usually referenced from the process flow chart. If multiple part numbers exist (assembly), list the individual part numbers and their processes accordingly.

2. Process name / operation description: All steps in the manufacturing of a system, subsystem, or component are described in a process flow diagram. Process / operation from the flow diagram should be identified by a name that best describes the activity being addressed.

3. Machine, Device, Jig, Tools for manufacturing: For each operation that is described, identify the processing equipment, e.g., machine, device, jig, or other tools for manufacturing, as appropriate.

<

4. Characteristics: A distinguished feature, dimension or property of a process or its output (product) on which variable or attribute data can be collected. Use visual aids where applicable.

4a. Number: Enter a cross reference number from all applicable documents such as, but not limited to, process flow diagram, numbered blue print, FMEAs, and sketches (computer generated or otherwise), if required.

4b. Product characteristics: These are the features or properties of a part, component or assembly that are described on drawings or other primary engineering information.

Process controls must be established for controlling all the product characteristics. All special characteristics must be included in the control plan.

4c. Process characteristics: This column will identify the characteristics of the process that, when controlled will reduce variation in product characteristics. This must be specified. These characteristics have a cause and effect relationship with the identified product characteristics.

5. Special Characteristic classification: Use the appropriate classification as required by OEM as “critical”, “key”, safety or “significant” accordingly.



<<

6. Check method: This column identifies the measurement system required to measure product and

process characteristics. E.g., Vernier, gages etc. along with their L.C. (as applicable) Gauging issues that should be considered include: • A reasonable GRR must be attained before a characteristic can be controlled. Refer MSA

section for details. • The selection of variable versus attribute gages. • At most, special characteristics must be checked using variable gauges.

7. Sample size / Frequency: Arrive a required sample size and the frequency of checking to ensure product conformance and control.

The general guidelines for frequency of inspection are evolved based on the following assumptions. • The process is under control. • Occurrence is evolved based on internal rejections, Customer complaints and level of process

capability. • Quantum of output per hour.

> 70

Occurrence 30 – 70 X 10 – 30

Detection <10 <50 per Hr. 50-100 / Hr. > 100 / Hr

Output 8. Control method: This describes the method of controlling the operation. When selecting

the method of control, focus on. • Meeting all customer requirements • Process control rather than Product control • Prevention rather than detection • Targeting nominal rather than specification limits. • Error proofing rather than inspection This can be controlled but are not limited by the

following means, o Statistical process control o Inspection o Attribute data o Mistake-Proofing

9 Sampling plans It can reference procedures / documents for controlling. When choosing a control method sources of variation must be considered. The most important common sources of variation or dominating factors determining the quality of products are setup, machine, tooling, operator, maintenance and environment.

10. Reaction plan: This refers to the actions that are to be taken to correct any potential non-conformances.(Segregation of defectives, rework if applicable, and corrections necessitated in machine to achieve a particular part characteristic etc.)

100 % Inspection

Once in 1 Hr.

Once in ½ Hr.

Once in ¼ Hr.

Once in 2 Hr.

Once in 1 Hr.

Once in ½ Hr.

Once in 4 Hr.

Once in 2 Hr.

Once in 4 Hr.

• Wherever, process dimensions are required like before plating / before heat treatment, etc supplier to arrive process dimensions thru’ scientific methods with the help of past data & studies in present part no.

• All poka-yoke to be verified for effectiveness before start of each production shift and recorded.



Section 3.7 – Submission of sample parts

Purpose To explain the procedure for submitting sample parts and evaluation of results.

Scope Applies to all pilot and production sample parts.

Procedure Samples Development Sample submission to Unit Along with necessary reports Sample evaluation (SIR & ISLR) by Unit

Not Ok Clear Approval by E, R&D Improvements OK Initiate bulk production

Sample approval process

Wherever BI requires the part should be made in off tool – off process, that is the part should be made in production intended tooling & process. Supplier to consult SQA / manufacturing unit on details of sample size and submission of test piece, stage samples, wire rods, R/M sample etc. Along with the samples, submission of the following documents is mandatory.

• Self-inspection report – covering all dimensions / specifications in the drawing. • Material check reports including surface protection details/ wherever applicable

salt spry test. & process flow. Supplier responsibilities

1. If parts are produced from more than one cavity, mould, tool, die, pattern, or production process, the supplier shall complete a dimensional evaluation on a minimum of one part from each unique process/ variation. The specific cavities, molds, line, etc. shall then be indicated in the PSW & the dimensional results report.

2. B.I. will cross verify the Dimensional, Material and Performance characteristics. The judgement on the samples will be finally approved by BI. E, R&D.

• Suppliers to have adequate inspection facilities for measuring all requirements specified in the drawing. In case facilities are not available, arrangements to be made by the supplier to do it at third party inspection agency & to be certified OK before submission of samples / regular lots.

• Samples should confirm to drawing requirements. Any rejection of SIR at BI, will be reviewed seriously.

• Samples must accompany dimensional / material / performance test report. • Supplies should commence only after clear SIR / ISLR approval.



Section 3.8 – Measurement System Analysis (MSA)

Purpose To explain procedure to carry out Measurement System Analysis and submission procedure.

Scope Applies to all measuring instruments and gauges.

Explanation

1. The objective of MSA study is to obtain information on amount of measurement variation associated with measurement system when it interests with environment.

3. “Repeatability” is the variation in measurements obtained with one measuring instrument when used several times by one appraiser while measuring the identical characteristic on the same part.

4. Is there a common cause (Random error) variation from the successive trials under defined conditions of measurements? This is commonly referred as Equipment Variation.

5. Variation that occurs when repeated measurements are made of the same item under absolutely identical conditions – Same operator, same setup, same units, same environmental conditions & short term.

6. “Reproducibility” refers to the difference in the average of the measurements made by different persons using the same instrument, or the same person using different instruments, when measuring the identical characteristic.

7. The term “Reproducibility” refers to the variation that results when different conditions are used to make measurements ie. different operators, different setups, different units, different environmental conditions & different measurement systems.

8. Gage R&R is an estimate of combined variation of repeatability and reproducibility. GRR is the variance equal to the sum of within system and between system variance.

σ2GRR = σ2

repeatability +σ2reproducibility

Acceptability criteria:

Under 10% Error - Generally considered to be acceptable for measurement system. 10 – 30% Error - May be acceptable based upon importance of application, cost of

measurement device cost of repair, etc. Over 30% - Considered to be not acceptable – Every effort should be made to

improve the measurement system. In case the R&R is more than 10 %, prior approval from BI is mandatory.

9. Interpretation of GRR% with product tolerance: A variable gauge used to check a key product characteristic of 125 ± 3 mm has an R & R result of 22% of product tolerance. That means the gage error can be up to 1.32mm (± 0.66 mm) for any given measurement. To ensure that non-conforming product is not accepted the acceptance limits must be reduced by 22% to 125 ± 2.34 mm.

Supplier responsibility:

Supplier must provide a means to verify all quality characteristics specified on the drawing and inspection standard. The measurement method is to be mutually agreed with Brakes India Limited. In the case of checking fixture and gauge the concept must be cleared with Brakes India. Supplier responsible for performing appropriate analysis of the measurement system to ensure its performance is acceptable for its intended purpose.



Section 3.9 – Process Capability monitoring

Purpose To define the requirements for process capability studies of designated control

characteristic.

Scope Applies to all part characteristics denoted by symbol – Significant characteristics & -

Critical characteristics and for other parameters agreed as major characteristics in quality plan during PPAP.

Explanation 1. Critical and significant characteristics are part characteristics that significantly affect

performance, fit, function or workability of system or subsystem and therefore require application of statistical measures for capability assessment and control.

2. As used in this manual, “Process capability” refers to a comparison between the inherent variability of a process and the specified tolerance. It is important to note that acceptable process capability is achieved through the study and the control of key process parameters (e.g. temperature, pressure, shot weight, speed, feed etc.)

Supplier Responsibility 1. Prior to mass production the supplier must analyze the stability and capability of the processes,

which contribute to variation in the critical / significant characteristics. 2. The supplier must carry out a detailed Machine capability study as per the procedure explained

later and submit to BI – SQA for review. 3. The supplier must conduct long term process capability studies for continuous process

improvement. The results of these studies should be made available to the B.I. as agreed in quality plan.

4. Process capability studies should be performed during the high volume production trial. (See section).

5. Capability studies can be affected by dimensional, specification changes etc and therefore must be re-submitted for characteristics affected by change.

Additional Information Definition of Process measures - Process performance – The 6 σ range of a process total variation, where σ is usually estimated through sample s, the sample standard deviation. - Process capability – The 6 σ range of a process inherent variation, for statistically stable processes only, where σ is usually estimated by R/d2

σ = Σ (Xi - X )2

(n- 1)

PPpp -This is the process potential index, (short term) which is defined as the tolerance width divided by the process performance, irrespective of centering.

X

σ

6σ



Pp = USL – LSL 6σs

PPppkk -- TThhiiss is the process performance index (short term), which accounts for process centering and is

given by

Cp – Process potential index (Long term): Is defined as the tolerance width divided by the process capability, irrespective of process centering.

Cp = USL – LSL 6σ

Cpk – Process performance index (Long term) : Specifically this index is the distance from the center of the distribution of production output to the closest specification limit, measured in units of three standard deviations of production output. It relates specifically to the scaled distance between process mean and the closest specification limit to half the total process spread. Cpk - index should only be calculated after verifying that the process is in a state of statistical control.

Cpk = Min USL – X , X – LSL

3σ 3σ

X = Process Average USL – Upper Specification Limit LSL – Lower Specification Limit

σ is standard deviation and is estimated using R / d2

Cpk Cp Vs Cpk Low High

Low Reduce process variability Impossible Cp High Move process towards mean. Maintain

Process Capability Index study requirements

Item Short term Long term (Min. one month data) Samples 25 to 50 nos 25 Sub groups of 5 per sub-group

Pp > 1.67 - Ppk > 1.67 Cp - > 1.33 Cpk - > 1.33

P P pk pk = Minimum of USL - X 3 σ

X - LSL 3 σ

, s s

Where σ is estimated using R / d2

- For SC/CC & major characteristics if the process capability is not met, it is mandatory to do 100% inspection before dispatch. - In the case of one sided specification, Only Ppk / Cpk need to be computed using the formula indicated above and not Pp / Cp.



Ppk value and level of PPM

Sl. No Ppk PPM 1 < 0.55 > 100000 2 > 0.55 50000 3 > 0.78 20000 4 > 0.86 10000 5 > 0.94 5000 6 > 1.00 2000 7 > 1.10 1000 8 > 1.20 500 9 > 1.30 100 10 > 1.67 < 10

<

Process Capability Judgment and Action <

Cpk Judgment Action Greater than 1.33 The process capability is

sufficient Maintain and control process capability. (need not have to take special action)

1.00-1.33 Process needs improvement. Control the process carefully through 4Ms standardization and control chart utilization Also try to improve the process capability. i.e. 1. Enhancement of process control and machine maintenance 2. Review of jigs / tools maintenance period 3. If there is a tendency of value change, create and allowance for adjustment.

Less than 1.00 The process capability is insufficient. Need to improve immediately.

If the cause is unknown and immediate action cannot be implemented, inspection must be made more stringent through 100% screening. Clarify whether process capability in sufficiency is caused by bias or variance. Survey the cause and take proper action i.e 1. Reviewing 4M 2. Machine capability

Guidelines for conducting short term process capability study

• Identify the product characteristics to be studied and its specification. • Data must be precise, complete and clearly recorded. Incomplete and/or incorrect data will lead to wrong

conclusion in case of corrective action. • Tool change or tool resetting must not be done during study, since theses are external adjustments,

observations may not follow normal distribution. • Inspection equipment must be calibrated and the lease count of measuring instrument must be 1 / 10th of

the tolerance. This is because accuracy of observations will directly influence Pp value. • Minimum 50 consecutive samples to be taken for the study. • Measurement to be carried out by a single skilled inspector. • Other variations like material, method (tooling) should be kept at minimum. (use same operator) and same

batch of raw material) • Pre-set the machine at nominal and do the set up approval before data collection.

For multi spindle / multi head machines treat each spindle / heard as individual machine. Samples have to be retained till the completion of the report.



Section 3.10 – Special process qualification

Special processes are that process whose output cannot be verified immediately after production. The quality of the item will be known only by destructive testing. E.g. Weld Strength (Welding Process), case depth, Tensile strength (Heat Treatment).

Since the output characteristic is difficult to observe, such processes need to be validated i.e. the process parameters affecting the quality characteristic need to be identified, established through DOE and their operating ranges are to be determined. By maintaining these process parameters we get the desired output. This is known as process validation. Conducting trials in a organized manner using Design of experiments techniques does this.

Steps in validating a special process using Design of Experiments.

1. Identify the Process.

2. Identify the Quality Characteristic

3. Qualify the measurement system and standardize the measurement process.

4. Identify all the variables, which are likely to have influence on the quality characteristic.

5. Identify the controllable variables. (Variables which are controllable by us.)

6. Choose the experimental variables and constant variables.

7. Decide the ranges for the experimental variables.

8. Keeping the endpoint of the ranges as levels design an experiment. (Full factorial or orthogonal arrays).

9. During the experimental trials all the constant factors must be maintained at the same level.

10. Subject the experimental data to statistical analysis. (ANOVA)

11. If a variable is significant and the end result is satisfactory the range of the variable is to be reduced to get more consistent result.

12. If a variable is not significant and the end result is satisfactory, then the current range is validated.

13. If a variable is significant or not significant but the end result is not satisfactory then new range is to be explored.

In this manner the ranges for the process variables are established. Once the operating ranges are established, the process variables are monitored for control. Actual quality characteristic is verified on audit basis to confirm the suitability of ranges.

Design Of Experiments (DOE) DOE is a tool to help us in arriving a optimum process parameter for a given process. Contact your SQA engineer if there is a requirement to do DOE & understanding the steps in doing DOE.



Section 3.11 – Capacity Verification

Purpose

The purpose of capacity verification is to

• Determine if there are capacity constraints

• Identify process bottlenecks

• Be capable to meet full production volume at PPAP time

Scope

Capacity verification shall be performed on all the appropriate supplied components and must be completed as part of all new or major modification PPAP submissions.

Procedure

The supplier shall fill up the form for each individual part number with the following guidelines.

A. Supplier to give details about parts which follow similar production sequence occupying the same production capacity to meet the annual monthly demand of each part.

B. Cycle time (C.T.) required for one component at each stage is provided and based on which hours required at each stage is calculated. In case of multi cavity operations. Cycle time is the ratio of processing time to the no of cavities.

C. Available hours per month are to be provided for a working standard of 2 shifts of 18 hours max for 25 days.

D. Machine down time to be provided considering all setting, breakdown, planned maintenance down times etc.

E. Hours lost due to operator effectiveness like operator change, untrained operators are recorded here.

F. Out of total available hours, the hours allocated to BI is denoted in percentage. Percentage utilization for BI and other customers is also to be provided along with the spare capacity.

G. Supplier needs to submit an action plan, if there were any capacity constraints at any of the manufacturing stage.

A minimum 20 % free capacity is preferable for each process. It helps in meeting sudden increase in requirement.



Section 3.12 – Quality plan & Document retention Purpose

To explain the requirements of Quality plan sign off which includes process capability report, metallurgical inspection report & layout inspection report submission procedure.

Scope Applies to all parts and components in regular production.

Explanation Quality plan will be signed between supplier and B.I’s supplier quality representative and

B.I. Mfg. Unit before PSW approval, listing all the major characteristics that are to be incorporated in supplier’s final inspection report. It also includes the frequency of submission of metallurgical inspection report, process capability study reports and layout inspection report as given in the format enclosed.

Supplier Responsibility 1. Supplier to furnish self-certification for mutually agreed part characteristics under the

following headings. • Dimensional inspection parameters. • Visual inspection parameters. • Metallurgical parameters, performance parameters. • The revision number of B.I drawing to which the part is supplied to be mentioned in final inspection report, submitted to BI.

2. Dimensions should be listed in the order indicated in the drawing, which are to be measured on the actual part.

3. The method of checking column defines the measurement equipment to be used. The least count of the instrument is to be mentioned. The inspection criteria should include the actual dimensions and acceptance tolerance of the inspection items.

4. Visual inspection should define judgment for the acceptable limit of the inspection item. If a representative sample is used to define this inspection item, this should be noted in this section.

5. Metallurgical inspection describes the material control requirements including raw material of the part. The inspection item should give the reference standards.

6. Performance describes any functional or reliability characteristic of the part like. • Part corrosion performance • Related durability cycle testing etc.

7. For layout inspection the supplier have to include all the dimensional, visual, material and performance characteristics as per drawing and submit to B.I. every year.

9. For the characteristics identified in drawing as SC/CC, the process capability reports should be maintained as per the frequencies agreed in the quality plan.

10. For other characteristics identified as SC/CC during PPAP process, the necessary process capability reports to be retained at supplier end and should be made available during BI’s visit to supplier end.

11 Quality documents retention period at supplier end should be as per the details given below & it should be agreed in the quality plan. & adhered.



Record retention period for various customers Sl. No Customer Minimum Retention period (as per customer specific requirement)

1 Hitachi, Volkswagen 15 years

2 Nissan 12 Years 3 Maruti Suzuki,

Volvo, Mahindra renault

5 Years (as per pre contract review agreement)

4 Ford PPAP, PO, Tooling records - 1 year after length of time the part is in production Inspection and test records – 1 year after which it was created

5 Arvin Meritor Internal quality system review & management review – 3 years

6 TRW Documents and product samples for the time the part is active (a part is active as long as it is being supplied to the customer for original or service applications) in production plus a minimum period of 15 years.

7 All Other customers 2 years min.

• In case of a outsourced operation, the supplier and sub-supplier representative should agree a quality plan.

• The final inspection report submitted with every lot should contain the parameters as agreed in quality plan.

• It is mandatory to adhere to the parameters & submitting frequencies agreed in the quality plan during regular supplies. Failure in submitting inspection reports as agreed will be taken seriously by BI, and inspection costs shall be recovered from supplier.

• The revision no. of BI drawing to which the part is supplied must be mentioned in final inspection report, submitted to BI.



Section 3.13 – PSW Approval

Purpose

To define the minimum requirements for obtaining the final approval of PSW and conditions for conditional approval.

Scope

Applies to all suppliers of production parts.

Supplier Responsibility

1. Develop and implement an internal quality assurance system at their manufacturing location in accordance with this SQA manual.

2. Supply sample parts, which meet all applicable requirements that were produced under regular production processing conditions, using regular production materials. Also B.I. SQA representative will verify the process as per compliance audit checklist.

3. Meet all SQAM documentation requirements. The documents should reflect current processes.

4. B.I. SQA will review the supplier’s documents and process as per checklist and if acceptable will approve the PSW.

Situations of Conditional Approval

1. Pp and Ppk not meeting the specification in full (firm action plan like new machine or new technology introduction).

2. Inadequate sub supplier control & core process outsourcing.

3. Delay in action on gap analysis

a. Process requirement b. Availability of gauges / instruments.

c. System requirements. d. Similar part rejection reduction.

4. Delay in corrective action plan submitted for RPN improvement

1. Control improvement 2. Introduction of Poke-yoke. 5. Delay in conducting process qualification for special process. 6. Lack of infrastructure in machines, gauges, equipments. etc.

In case of conditional approval, the deviations will be informed to respective unit’s receiving inspection persons. Units will do double sampling inspection on these parameters. Suppliers are expected to take necessary corrective action & convert the PSW to straight approval within a period of 3 months from the date the conditional approval is given.



Section 4.1 Sub-Supplier Quality Assurance

Purpose

To define the supplier responsibilities on their sub-suppliers controls.

Scope

Applies to all suppliers.

Explanation

The role of supplier in co-coordinating and guiding the sub suppliers Quality assurance activities must be similar to the B.I. requirements stated in the SQA Manual. The suppler is responsible for sub supplier’s part quality and production preparedness & also for evaluation of sub supplier’s part quality and production preparedness and also for evaluation of sub suppliers parts and materials.


1. The supplier of B.I. should have a system in place for evaluating and selecting the sub suppliers.

2. The supplier shall ensure correct data (Specification, drawings, standards etc) has been communicated to the sub suppliers.

3. The supplier shall ensure and assess the production and process control capability of their suppliers including inspection and testing facilities.

4. The supplier should intimate B.I about the sub suppliers and any changes or addition of sub suppliers should be authorized by B.I. SDI / SQA.

5. Suppliers are expected to involve their suppliers in the communication, planning, and problem-solving activities, as required, to assure that quality is built in at each stage of the preparation and production process.

6. The supplier and sub-supplier representative should agree quality plan.

7. Supplier should conduct periodic sub-supplier audits.

8. Core competent process should not be carried out at sub-supplier location.

B.I. suppliers are responsible for any quality concerns arising out of their sub suppliers, including surface protection sub suppliers.

It is the responsibility of suppliers to evaluate & approve their sub supplier’s process. Sub supplier’s PPAP approval by suppliers is a must & approved PSW to be attached with main PPAP, wherever there is an out sourced operation.



Section 4.2 – Identification & Traceability Purpose

To define the identification and traceability requirements to the suppliers of production parts.

1. Identification

This refers to the method a supplier uses to identify a part so that if a problem occurs, necessary information can be discerned quickly. This typically includes Rubber parts, plastic parts, castings and forgings.

Cavity or mould number(s) Special identification marks (Material type, inspection item etc) Heat code

With the above information the supplier should be able to accurately determine the lot size, in process stock, final inventory at the supplier and in transit quantity of parts with the same dates. If the supplier is notified by BI. of non-conformance, the supplier will be able to use this information to control like material at their facility.

2. Traceability

This refers to the ability of tracking a part back through all stages of manufacturing to the raw materials. Process parameters set during production should be traceable, with applicable inspection and test results. Traceability is mandatory for all parts supplied to BI.

Supplier shall indicate the date of manufacture in the dispatch tag and limit dispatches of a lot from the same raw material batch.

The supplier must ensure that documented systems are in place at all sub-suppliers and in-house to control tractability of all components from raw material to date of manufacture.

For effective implementation, the supplier is needed to practice FIFO with material history card (Issue register) for both R/M and sub-supplier supplies, where this card reference number is to be recorded. Bar coding system of lots is encouraged.

In case of polymers, rubber, lining base products, the supplier is required to keep a master batch sample of each lot and its record of composition and process parameters. Identification of materials supplied to BI.

Suppliers are to provide proper identification tags for their supplies to Brakes India. Every package is to be tagged and the tags to clearly indicate the following details.

Part no; Part description, Rev. No. of BI drawing to which part is supplied

Supplier code; Supplier name, Date of Manufacture, Quantities.

Delivery Challan no, Raw material batch no.

Route Card No. and other part specific information. Samples and New product parts supplied to BIL are to be separately identified from the regular

supplies. Color-coded tags are recommended for clear and easy identification. In case of more than one supplier for a part, identification mark on the part is required for traceability.

TAG Color for identification Sample Parts - Pink Color tag. New Products (Pilot batches) - Orange Color tag. (i.e. for first 10 shipments)Also called

FPP tag. Regular Parts Non DOL - White Color Tags. Regular DOL parts - White color tag with “DOL” stamp affixed diagonally on the tag



Revision 1

Supplier Name: XXXXXXXXX XXXXX Ltd. Plant name :Vanagaram plant

Pink color tag - Sample inspection part

SAMPLES

Supplier Name: XXXXXXXXX XXXXX Ltd. Plant name :Vanagaram plant Part no. Part name : Quantity No. of bins / pallets DC No/ date Signature

NEW PRODUCTS


REGULAR PART


DIRECT ON LINE

Orange color tag - New products

TAG SAMPLE

Part no. Part name : Quantity No. of bins / pallets DC No/ date Signature





Section 4.3 – Control chart

Purpose

Control charts are effective tools to understand process variation and help achieve statistical control. They often lend themselves to being maintained at the job station by the operator. They give the people closest to the operation reliable information on when action should be taken and when action need not be taken.

Explanation

Properly used control charts can: 1. Help / aid operators & supervisors for ongoing control of a process 2. Help the process perform consistently, predictably, for quality and cost 3. Allow the process to achieve

• Higher quality • Lower unit cost • Better utilization / Increased productivity

4. Provide a common language for discussing the performance of the process

5. Distinguish special from common causes of variation as a guide to local action or action on the system.

X bar - R Chart

A X bar and R chart, as a pair are developed from measurements of a particular characteristic of the process output. These data are reported in small subgroups of constant size, usually 3 to 5 consecutive pieces with subgroups taken periodically. (e.g., once every 15 minutes, twice per shift, etc.). A data-gathering plan must be developed and used as the basis for collecting, recording and plotting the data on a chart.

Before control charts can be used throughout an organization following steps should be taken. 1. Process must be understood in terms of its relationship to other operations / users and in terms of

process elements (people, equipment, material, method and environment)

2. Determine the characteristic to be analyzed / managed depending upon the following a) As defined in the drawings / process control standards (significant and critical characteristics) b) The current and potential problem areas.

3. External cause of variation should be reduced before the study begins. This would mean that the ensuring process is operated as intended i.e. m/c should be operating as specified with respect to tool, speeds, feeds, setup, etc. The purpose is to avoid the obvious problem that could have been corrected even without the use of control charts.

4. The current process setting / condition should be noted down e.g. m/c setting, operator, input material, measuring system time etc. and keep noting all the relevant events such as tool change, operator change, new raw material, shift change, m/c stops etc. These information will help in subsequent control chart analysis and deciding the improvement / corrective action.

5. As data is basis for further analysis, it is absolutely essential that the reliability of data is ensured. This may be ensured through the followings: a) Using the precise measurement system (Least count 1/10 of the specified tolerance) b) Using the qualified inspectors.



Setting up of control charts

Chart Type Center Line LCL UCL __ X

= X

= _ X-A2R

= _ X+A2R

R

_ R

_ D3R

_ D4R

Values of D4, D3, A4 are given in the table below:

n 2 3 4 5 6 7 8 9 10 A2 1.88 1.02 0.73 0.58 0.48 0.42 0.37 0.34 0.31 D4 3.27 2.57 2.28 2.11 2.00 1.92 1.86 1.82 1.78 D3 0 0 0 0 0 0.08 0.14 0.18 0.22 d2 1.13 1.69 2.06 2.33 2.53 2.70 2.85 2.97 3.08s

Data taken from these control charts are to be utilized for calculating the Cp, Cpk reports and

the same to be submitted to BI agreed in quality plan, as per the below guidelines.

Guidelines

• Take 25 subgroup data from past 3 months regular control charts; ensuring

uniform spread across all control charts.

• Plot an X bar R chart by using these data’s and calculate Cp & Cpk value

• Check whether the process is in control or not

• If the Cp & Cpk values are ok, send the process capability report to BI

• If the Cp & Cpk value is not ok take appropriate action to control this variation

Suppliers are expected to maintain X bar - R chart for all critical and significant characteristics identified in drawing and short term capability data every year for other parameters identified during PPAP.



Section 4.4 – Receiving inspection at BIL Purpose

To define supplier requirements for approval of regular supplies and inspection methodology / acceptance criteria to be followed at Brakes India Ltd on receipt of material.

Scope Applies to all production parts received that are not in skip / DOL category.

Supplier responsibility • The supplier must submit along with part invoice a self-inspection report mentioning the drawing

issue no. for dimensional & metallurgical for all parts supplied to Brakes India Ltd. • The supplier must adhere to the identification requirements specified on the part drawing,

inspection standard or applicable regulation • For metallurgical inspection the supplier to submit test specimens as mutually agreed between B.I

and supplier. (Ex for text slabs, castings)

Procedure 1. Brakes India on receipt of material will check for delivery challans, inspection reports, packing

and quantity. 2. Lots delivered to B.I. will be cleared based on self-certification or sampling inspection as per the

discretion of B.I. The sampling plan followed is given below. 3. Items will be considered for skip inspection and the acceptance criteria are indicated. 4. Based on conformity to specification the component is accepted and the individual lots are rated

and the same will be reflected in Supplier quality rating

BI Sampling plan

BI Sampling Plan Accept on ' 0 ' defect Reject on `1' defect

Dimensional inspection Material Inspection Category ' A' : For all components (Other than Category ' B ' & ' C ')

Category A : Castings, Forgings, Springs & Sintered parts

Sample size Batch size Sample size Lot size Visual Dimensional

Up to 50 10 Upto 100 3 51 - 150 20 100-500 8 151 - 500 25 501-2000 10 501 - 2000 30 2001-5000 13 >2001 50 Above 5001 20

Category ' B ' : For all fasteners,castings,pressings,mouldings

Category B : Sheets, strips, coils, spring wires,etc

Sample size Lot size Visual Dimensional

Category Sample

Up to 500 30 10 Sheets, strips 2 specimen for every 5 tons 501 - 2000 50 20 Coils & Spring wires 1 test piece from each coil >2001 100 30

Category ' C ' : For bars, sheet materials and strips

Category C : Bars, tubes, etc.

Sample size Lot (Weight in Tons) Visual Dimensional

Batch size (Weight in Tons)

Specimen

Up to 5 2 Up to 5 2 5 - 10 3 5 - 10 3 >10 4 >10 4



Section 4.5 Quality rating & PPM calculation

Purpose To explain the procedure on supplier performance evaluation & monitoring

Procedure Every Goods receipt (GR) is rated for the quality of the supplied materials / components. In addition to GR rejection, line rejections & customer returns will also be taken for overall quality rating. The criteria for awarding scores for GR are listed below. Quality rating calculation

Status of lot based on Usage Decision (UD code) Usage Decision code in SAP

Score %

GR accepted based on DOL status with inspection report D1 100 GR accepted on skip lot basis with inspection report S1 98 GR inspected & straight accepted with inspection report A1 95 GR accepted on skip lot or DOL status without inspection report S2 90 GR inspected & straight accepted without inspection report A7 90 GR inspected & accepted with deviation with documented request from supplier. A3 88

GR inspected & accepted with deviation without documented request from supplier. A2 85

GR accepted based on inspection after segregation or rework. A4 , A5 50 GR rejected (Full lot rejected) R1 1 GR accepted Based on process scrap of supplier A6 --*

* Will not be considered for Q – rating calculation.

If there is any one instance of line rejection in the particular rating period, for the parts supplied by the vendor, the quality rating of the part will get reduced by 10% (Absolute). If there is an instance of OEM rejection in the rating period the rating will get further reduced by 50% (Absolute)

PPM calculation Rejection PPM is calculated every month using the formula given below.

PPM = ((Tot. qty rej. at GR) + (Tot. qty rej. at line) + (Tot. qty rej. at OEM)) x 1000000

Tot qty received from supplier

First 10 lots from supplier for a part will not be taken into account.

Note: • PPM & Quality rating details are available in vendor portal for previous 3 months. • Selected suppliers scoring PPM > 500 will be called / visited & review will be

conducted. • Suppliers appearing consistently in the high PPM list, in spite of reviews & support

from BI shall be considered for deletion.



Section 4.6 – Control of non conforming part

Purpose

To define supplier requirements for control of non-conforming parts.

Scope

Applies to all parts when non-conforming items are identified.

Explanation

Non-conforming product means non-fulfillment of the drawing / specification requirements. The procedure listed below describes the attention needed from the suppliers for dealing with non-conformities both at their own facility, at his sub supplier end those in transit and at Brakes India.


1. For non-conformance noticed after production, it should be isolated and kept in separate identified locations. Supplier should record and review the nonconformities to take decision on disposition. If decided to go for concession, supplier shall raise a concession request to B.I. Products awaiting concession acceptance shall not be dispatched without the clearance from B.I.

2. If concession is rejected by B.I., supplier has to segregate / rework or scrap the lot depending upon the condition. In case of segregation the supplier should ensure that all defective components are screened out completely.

3. Where non-conformance is anticipated prior to production, the supplier should raise deviation request to B.I. B.I. will accept or reject based on the criticality of the characteristics.

4. If the concession and deviation request raised for nonconformance is accepted by B.I, the supplier shall indicate the quantity and its reference in the inspection report and identify the quantity separately. The lot details should be provided to Vendor Quality of respective units and to Supplier Quality Assurance (SQA).

5. If decided to rework, it shall be done as per the rework instructions and should be 100% re-inspected. While reworking, supplier should ensure that other parameters of the product remains unchanged (Both dimensional & Aesthetics). If any such conditions are witnessed, separate concession request should be raised and 100% inspection should be introduced to the deviated parameter.

6. Supplier should move the scrap materials immediately to scrap yard / scrap area. Where possible they should mutilate them to prevent mix up. In case of material supplied by B.I. they should return the same to B.I. at the earliest with proper identification.

7. Records of rework and scrap are to be maintained. It is auditable by BI at any time.

8. If required by B.I. the supplier has to give corrective action for the nonconformance’s noticed to avoid further recurrence. Supplier should study their tooling, processes and inspection controls at all stages or train the personnel if required to prevent the nonconformance.

Cost of Poor Quality (CoPQ): Suppliers are expected to monitor & reduce the CoPQ. The CoPQ essentially comprises of `internal failure cost’ & `external failure cost’. This will include all rejections / rework at inhouse, Brakes India Ltd & OEM.



Hints to prevent mixup

1. Supplier should isolate the nonconforming materials to identified locations (Use separate containers where practicable) at various stages like receiving, in process and final to prevent mix-up with accepted material.

2. Supplier should reject the materials when a nonconformance is noticed during any stage of manufacture even if the material is supplied by B.I.

3. Supplier should exercise great care to isolate materials, components that are identical in appearance to one another.

4. Supplier should plan their production in such a manner that identical components, materials are not manufactured during the same period.

5. Supplier should identify the accepted material after inspection with OK tags before dispatching to B.I. This should contain part no., issue no., Quantity and inspectors signature.

6. .If supplier keeps any unidentified container with components in it, it should be treated as a “Suspect product”. All the verification and correction processes applicable to a non-conforming product is applicable to this.

7. Supplier should demonstrate the ability to identify the suspected parts to its raw material source if required. Supplier should be able to demonstrate the ability to identify & trace the source / Heat No / batch No. in case of a defect in the final part.

Hints to prevent non-conformity

1. Ensure usage of calibrated gauges, Instruments & Fixtures.

2. Deploy systems and train the personnel’s to scrap setting rejections immediately after first off approval. Make a record of the setting rejection and dispose it accordingly. Proper identification / mutilation of the setting rejection is mandatory.

3. First off reports should be recorded under these conditions.

4. a) Complete setting change over b) Tools & insert changeover.

c) Tool travel accidents

5. Always maintain a spare for critical tooling.

6. Tool life should be monitored on a day-to-day basis. Inserts, drills & other typlical tooling should not be used more than its recommended life. After regrinding, tools should be inspected and approved for tool-controlled dimensions.

7. Training should be provided to personnel’s for safe material handling of in-process and finished parts.

8. Ensure proper storage of parts preventing it from environmental threats & accidents.

9. Rework of parts should be carried in a separate location adhering the rework instruction. Rework of parts should be carried out under strict supervision.

Tips in eliminating Rust / Mixup / Damage Do’s

• Use red and yellow bins in each & every machine/ station. Ensure that the scraps are put into red bins & rework parts are put into yellow bins. Ensure operators are educated & adhering to this practice.

• Ensure threaded parts are handled carefully. Wherever possible use partitioned trays. Don’t s

• Don’t keep raw materials in open space. • Don’t keep material without applying rust preventive oil. • While doing a 100 % inspection take only one part at a time. If not OK, keep it in its

red bin before picking up next part



Section 4.7 – Skip lot & DOL Implementation

Purpose To define the minimum requirements for Skip Lot inspection of supplier parts.

Procedure

Step 1. Consideration for Skip Lot:

Supplier Parts will be considered for skip lot inspection if parts quality under any one of the following group conditions are met.

Conditions for GROUP A

A1. Supplier with valid ISO / TS 16949 Certificate for the part supplied A2. Minimum 95% Quality rating for that part for last 3 rating months. A3. Dimensional and / or material test reports for the part supplied as per agreed quality plan / control plan A4. There should not be any rejection for the minimum of last 3 months / 25 lots.

Conditions for GROUP B

B1. Supplier with valid ISO 9001 Certificate for the part supplied B2. Minimum 95% Quality rating for that part for last 6 rating months. B3. Dimensional and / or material test reports for the part supplied as per agreed quality plan / control plan B4. There should not be any rejection for the minimum of last 3 months / 25 lots. Conditions for GROUP C

C1. PSW approval and / or PPAP Documents as per SQA manual latest edition C2. Supplier with valid ISO 9001 / ISO TS 16949 Certificate for the part supplied C3. Minimum 95% quality rating for that part for last 3 rating months. C4. Dimensional and / or material test reports for the part supplied as per agreed quality plan / control plan C5. There should not be any rejection for the minimum of last 3 months / 25 lots.

Once the parts satisfy any one of the above group conditions the part recommended for skip lot. The list of such parts/suppliers and method of approval (Group A or B or C) will to be maintained by Unit QC

Step 2: Requirements for sustenance for all the groups in Skip lot.

On receipt of material the part under skip lot, the part has to be cleared at receiving inspection based on the verification of the Dimensional inspection reports and or Material test reports received from the supplier as per agreed quality plan / control plan.

The part under Skip lot will be subjected to inspection once in 3 rating months / 25 lots which ever is earlier (3 rating months / 25 lots which ever is earlier is treated as one cycle) and if found OK skip lot status will be continued. If Not OK communicate to Supplier and follow step 3

Note: If there is no supply for a part number during a month, the part is not considered for rating purpose.

Step 3: Procedure for taking corrective actions in case of line rejection / skip inspection rejection

The part will be brought under normal inspection as per BI single sampling plan. Corrective action will be raised for the part and the same has to be closed. To bring this part gain under skip lot follow above step 1 and step 2 of above procedure.



Direct On Line (DOL) Procedure:

Step 1: Consideration for DOL:

DOL: These pre-requisites are applicable for all direct materials except protective plugs, protection sleeves, etc. For DOL parts, inspection will be done once in 500 lots or once in 6 months whichever is earlier if parts qualify under the following group conditions are met:

Pre requisites:-

• PPAP / Change Management completed up to latest level. • FFF Matrix completion with respective units. • Already under skip lot and have completed minimum one cycle. • No CAR should be pending. • Process & Product audit grade should be at least B grade.

Step 2: Requirements for sustenance of DOL.

On receipt of DOL part the lot will be cleared at receiving inspection based on the verification of the Dimensional inspection reports and or material test reports received from the supplier as per agreed quality plan. A DOL tag has to be put (or) the regular OK tag to contain “DOL PART” rubber stamp.

The parts will be removed from DOL for non receipt of dimension inspection reports / metallurgical report for each lot and lay out inspection report form supplier once in a year.

The parts will be removed from DOL in case of any Line rejections / OEM customer complaint

and the same will be communicated by Unit QC to supplier / SDI / SQA and follow step 3

Step 3: Procedure for taking corrective actions for DOL.

• The part has to be brought under normal inspection.

• The Corrective action report request will be raised by unit for the part and the same has to be closed.

• The bring this part again under DOL it has to be again monitored & promoted to skip lot inspection and then to DOL status

• BI plans to stop all regular receiving inspection with effect from Jan 2011. Suppliers are expected to implement DOL before this deadline. In case of failure to do so, inspection & administrative charges will be recovered from suppliers as applicable.

• Any new part development will be taken up only with DOL supplier.

• Apart from the above DOL requirements, Brakes India Production System (BPS)

requires KANBAN requirements, usage of standard bin sizes, rationalization of despatch quantity, logistics arrangements, etc. The individual part wise requirements will be sent to supplier by respective unit supply module. Suppliers are expected to adhere to these requirements.



Section 4.8 – Change management

Purpose For re-qualification of parts that are already under supply where changes are made to

design, agreed process, tooling, measurement method, location and approved sub-suppliers.

Scope This procedure is applicable to all existing part suppliers.

Procedure

Unit/SDI to communicate the Change information design change to supplier

Supplier to submit Supplier’s change

request form duly filled to SQA

SQA registers the request Location changes No technical changes No Re PPAP NO Verification

No required required Receipt of Samples from Yes

supplier Receipt of sample, Verification Documents at supplier end Not OK

SIR / ISLR Capability Check for dimensions & Material Result evaluation

(SIR / ISLR) of samples as required OK OK Not OK Adequacy & Implementation Adequacy

OK

PSW sign off Collect action plan

Send required documents to unit / supplier Implementation check

Update the documents & close the check list

Details 1. If any of the below mentioned conditions change, the change management process is required after

mutual discussion with supplier & customer. 2. Following situations leads to change management approval process. 3. Any technical changes, PSW approval required.

Sub supplier change, Location

change, Process change, RM change

Information from supplier

Design changes , Alteration note, etc

Information to supplier



Re-PPAP is done for the changes mentioned below

a. Change in dimensions or tolerances or raw material. b. Tooling change. c. Process change

Physical verification is done for the changes mentioned below a. Sub supplier change b. Location change c. Management change. d. Acquisition / takeover

Note: On site verification is based on SQA’s discretion.

4. For design change if design authority of component is with Brakes India, unit will inform to concerned supplier for respective design changes.

5. For tooling, sub – supplier, process change & location change situations, the respective part supplier has to inform SQA/SDI/Unit before any one of above changes are initiated

6. Final decision for further process requirements will be arrived after discussion with supplier. 7. The Supplier is to submit “supplier’s change request” with indication of changes to SQA. SQA will

send back the request with requirements to approve the change.

• BIL will audit the new location / sub-supplier along with the supplier as required. The results of the findings are evaluated and the adequacy of the changes is checked. If result is found ok, decision is taken for approval.

• If the adequacy is not ok, action plan to be submitted & implemented. • If the implementation adequacy is not ok, the supplier is re audited and results are again

evaluated.

Any change in raw material source, process sequences, major tool changes, etc. must be approved by BI. BI may notify the QMS registrar of the supplier, if a supplier violates this system. Certifying body may revoke the certification if found non compliance to the ISO 9001/ TS 16949 procedures.



SECTION 4.9 – PROCESS AND PRODUCT AUDIT PURPOSE

Product and process audit is a method to evaluate the supplier performance in terms of quality systems, in-process controls, and adherence to agreed practices along with conformance of part to drawing requirements. The result of a Product and Process Audit will show the supplier’s performance and identifies potential areas for continual improvement. Product and Process audit must be done for the actual process chain at the supplier’s / Sub supplier’s manufacturing plant.

SCOPE

Applies to all production part suppliers, based on BI’s discretion.

SUPPLIER RESPONSIBILITY

The supplier is responsible to develop and maintain his product and process quality in a way that audit score of 90% or above is guaranteed.

PROCEDURE Supplier Selection Supplier to commit an action Supplier identified as “C” & audit schedule plan (AB & B) preparation Audit at supplier end Review of action plan & Monitor & close the gap Implementation within 6 months Satisfactory No Yes Satisfactory & (A Grade) improved quality

status Yes No Audit report closed Status projected to management and supplier considered for deletion

If audit rank is “C”, the supplier needs to come & present the actions planned to BI. If no improvement is seen even after 6 months of report release, in spite of support from BI, supplier shall be considered for deletion.



EXPLANATION

1. Supplier will be identified for the audit based on the following criteria. • Parts criticality. • High PPM rejections & CAR ratings • Volume of part. • Change Management • Routine schedule – Suppliers not covered in previous audit schedules.

2. BI. SQA will issue a written notification of the audit to the supplier prior to the scheduled time of the audit. The supplier must issue an acknowledgement of this request within 3 days of receiving it. It is expected from supplier, that he does a self audit before this.

3. For product audit, a part with quality issues will be selected. The audit may extend to high volume parts also.

4. On the closing day of the audit, B.I auditor will prepare a summary report and then meet with the supplier to discuss the results and countermeasure plan activities.

5. A detailed report on audit findings with actual scores will be sent to the supplier. For the audit findings, the supplier to give the counter measure plan for all the observations within five (5) working days.

Note: The countermeasures plan must be signed by the supplier’s top management 6. After the issue of counter measures plan, the supplier is required to present the plan and

actions implemented, to SQA at B.I., for the current status of the non-conformances found during the audit. This has to be initiated by supplier and completed within 30 days from the date of issue of audit report.

7. After the review, based on the status, a suitable date will be fixed for conducting the verification audit.

8. If improvements carried out are found to be satisfactory, the audit report will be closed. If no improvement is seen, supplier will be considered for deletion.

Audit frequency fixing criteria Audit frequency is fixed based on the priority rating given below

Rating % Audit priority rating Audit frequency >70 % I Once in 1 year

40- 70 % II Once in 2 year <40 % III Once in 3 year

Audit priority rating is calculated based on the formula given below. and calculated once in 3 years. (Parts criticality rankx0.35)+(PPM rankx0.15)+(Volume rankx0.2)+(CAR rankx0.3) 5 Wherein the ranking guidelines are in given in the table.

Ranking guidelines for fixing frequencies – Data period per annum Rank Part criticality PPM Volume (Qty.) p.a CAR

5 Most critical >1000 >200001 > 5 4 Critical 501-1000 100001-200000 4 3 Medium critical 251 - 500 40000-10000 3 2 Low critical 100 to 250 10000-40000 2 1 Not critical <100 <10000 1

X 100



Sections of Process and product audit 1. Process audit will be based on the following headers (As per check list) but not limited to the

following zones. Process quality planning Personnel & Qualification Receiving stage & storing Production and assembly stage Packing, storage, handling, transporting and EMS requirements Failure analysis, Corrections and Continual improvements

2. Product Audit will be based on the following headers

Dimensional Analysis Capability & Endurance In-house rejection trend Other product specific attributes

3. Dimensional, metallurgical and capability study will be carried out during product audit.



Section 4.10 – Corrective and preventive actions

Purpose

The purpose of Corrective Action Report (CAR) is to ensure that supplier follows a systematic problem solving approach to avoid the chances of recurrence.

Scope

Applies to all production parts when a non-conformance is identified.

Procedure

Flow Chart: Corrective action process Non-conformity of part

Mfg unit raise CAR request and Process capability monitoring, Standardization Sends to Supplier / SQA of documents, tryouts wherever applicable

SQA receives CAR and records it Corrected samples / Lots supply Supplier has to initiate containment Horizontal deployment of corrective action on similar action for parts within 24 hrs. Parts, if applicable Supplier should analyze the root cause Physical verification by SQA, if required Corrective action Proposal to be sent to SQA within 10 days. Adequacy CAR closure by SQA

Supplier should submit SQA forwards adequacy closed CAR to unit Alternate proposal after

Re – analysis Unit monitors the lots for effectiveness of corrective actions, for 3 lots / 1 month based on unit’s discretion If Inadequate SQA verifies adequacy of Effectiveness of CAR – Verification by unit corrective action proposal Not OK OK Return to SQA With comments

Unit to forward the closed CAR copy to SQA

Closed CAR handed over to supplier



Details

1. The manufacturing unit will raise the request for corrective action report (CAR) if they observe any non- conformance to drawing requirements including standards specified.

2. The copy of the report with details of problem statement, lot details, non-conforming quantity, old CAR ref if repeated and other information specified will be sent to Supplier / SQA by the receiving unit. (Refer CAR format)

3. CAR classified into 3 categories A.B.C. the details are given in CAR format.

4. SQA receives the CAR request from the unit and records it after verifying the completeness of all details pertaining to the non-conformity. Sufficiency of the data for analysis is also ensured.

5. BI – SQA to clear the proposed corrective action for the adequacy. In case of inadequate

corrective actions, supplier should submit alternate proposal.

6. The parts supplied before implementation of corrective action should be subjected to 100% inspection for the non-conformity raised.

7. Process capability simulation trials should be demonstrated to validate corrective action taken, where ever applicable.

8. After implementation of corrective action, samples/lots should be monitored and the implementation cut off date to be mentioned in CAR.

9. Support documents such as process flow diagram, inspection layout, control plan, PFMEA, WI etc. are to be updated if there is any change and the same to be enclosed with CAR. Supplier should get approval from BI-SQA in case of changes. Supplier should horizontally deploy the corrective actions taken on similar parts produced, wherever applicable.

10. BI-SQA will verify the corrective action implementation at the supplier end based on requirement & after approval, SQA will forward adequacy closed CAR copy to the unit.

11. Unit will monitor the effectiveness of corrective actions for 3 Lots / 1 month based on unit’s discretion.

12. If effectiveness found satisfactory, the RI unit will close and send the CAR copy duly signed to SQA for record purpose.

13. If effectiveness is not satisfactory, CAR copy will be return back to SQA for revisit.

14. Closed CAR copy will be handed over to supplier.

On receipt of CAR / information about quality issue, Supplier must initiate containment action within twenty-four hours for the parts at BI, in transit, in-house and at sub supplier end. Contained lots should be identified with details of containment. OK parts to be identified & the details to be communicated to SQA.

The supplier should analyze the non-conformance and provide the corrective action proposal within 10 working days and implement the same within proposed 30 days. Any relaxation to this will have to be authorized by BI-SQA. Unauthorized delays may lead to cost recovery.

Every effort should be taken to prevent defects in complaint resolution. Limit 100 % inspection for only containment.



Section 4.11 – Tool management Purpose

To define requirements of tool management to the suppliers of production part.

Procedure A typical tool management cycle is to be explained in the figure below. This applicable to the.

pressing, forging, die-casting and molding processes. Flow chart: Tool Management Cycle

Tool drawing Release Preparation of

- Tool Id. No. tool history cards Manufacturing of tool - Preventive maintenance check sheet

with inspection plan - Define the tool life / regrinding norms

Tool trial run

Tool Stage and layout inspection of part Correction Not OK Check Adequacy OK Send the tool for maintenance record

the tool maintenance activities Issue the tool to production, along with the (Recording activity + replacement of inspection report, limit samples. accessories in the history cards). Check

the adequacy of fixed regrinding norms. Before starting production, approval the Setup and record the same No

Monitor the tool condition by patrol inspection (as per control plan) and last off inspection. OK

Yes

Record the exact quantities produced and move the tool back to the standardized location along with the last off samples.

• Identify each jig / fixture with unique identification number. Each one should have a history card.Whenever, a modification is carried out in jig / fixture, ensure the tool’s drawing is updated.

• For consumable tools, fix the frequency of replacement / reconditioning based on scientific calculations. Please don’t wait for defect to occur to change the tool, rather once the no. of

specified parts completed, change it. • Ensure that a robust system is established to track the no. of parts produced / cycle. • Always have enough spares of tools / inserts for a trouble free run.



Section 4.12 – Cost recovery process Purpose

To recover the administrative and other costs incurred by BI, because of non conforming parts supplied by Supplier. Scope

Applies to all production parts. The Cost Recovery Advice (CRA) applies to the line rejections, GR rejections, every instance of OEM rejection and delay in CAR closure (beyond the target). etc as specified in format. Description

The recovery amount will vary depending upon the nature of complaint & no of occurrences. the amount of recovery is specified in the attached format & based on the discretion of BI. Procedure

1. Whenever the non-conformed part noticed at BI, the RI will raise the CRA and CAR to SQA in concurrence with Unit supply module.

2. CAR should be raised against the Supplier related to the complaint along with CRA.

3. SQA will register and forward the CRA to SDI after verification. Once SDI signs it will be forwarded to finance dept. for necessary recovery.

4. Finance dept. will recover the respective amount against the supplier’s account. 5. Supplier shall have to take proper corrective actions by closing the CAR and make sure the

complaint is not repeating again.

.

Amount of recovery is fixed for each category & the details are given in CRA format. Apart from administrative cost, actual costs incurred by way of rework, transportation, manpower, travel costs, etc will also be recovered.



Format - index

Sl. No

Click on the Description to go to the page

Revision No. 1 Evaluation of Supplier Quality system- ESQS 02

2 Tool Progress Report 01

3 Design Review 01

4 Quality Plan 04

5 Safe launch plan 01

6 Packaging Standard 02

7 Capacity verification 01

8 Compliance Audit Check sheet 01

9 Conditional Approval Format 02

10 PPAP Check sheet – A & B 01

11 PPAP Check sheet - C 01

12 Process capability calculation sheet 01

13 Corrective Action Report 03

14 Process and Product Audit format & report 02

15 FFF matrix 02

16 Supplier’s change request form 04

17 Process Failure Mode & Effect Analysis - 4th Rev. 01

18 Cost Recovery Advice (CRA) 02

The formats given in PDF file is for information only. Please contact your SQA window engineer to get editable excel file with embedded formulae for your day to day use.

Date:

Elements & Questions Observations 0 1 2 3 4

1 Does the Supplier has professionally managed organisation structure ?

2 Does the Supplier has OEM's/Tier 1 suppliers of OEM's as their Customerbase ?

3 Does the Supplier fulfill/ monitor the Customer satisfaction index interms ofQCD?

4 Does the Supplier has acumen to becomeGlobal Player ?

1 Does the supplier possess requiredinfra-structure for BI parts ?

2 Status of the Machine capabilities presently in operation ?

3 Does the Supplier has a good

manufacturing practices (like cellconcept, SMED, mistake proofing etc) ?

4 Does the Manufacturing process usedare adequate for BI requirements?

1 Does the Supplier's PBT is about 6%(last fin.Year) with respect to Sales?

2 Does the Supplier has Year on Yearcost reduction plan & implementationprogram ?

3 Debt equity ratio 1.5:1 max ?

1 Does the Supplier has Standard packingsystem ?

2 Does the supplier keen to establishBusiness relation with BI?

3 Does the Supplier has Adequate Controls for Traceability

4 Are they using any poke yoke setup ?

5 Is Bar Coding Practiced?Format : BI / ESQS / Rev.02 dated 1 Nov 09

FINANCE

GENERAL

Brakes India Limited

Points

EVALUATION OF SUPPLIER QUALITY SYSTEM (ESQS)

MANAGEMENT

Supplier Name :

Elements & Questions Observations0 1 2 3 4

1 MANAGEMENT RESPONSIBILITY

a) Does the supplier have anyone responsiblefor quality, reporting, directly to top management ?

b) Is manufacturing primarily responsible for product quality ?

2 MANUFACTURING CAPABILITIES

a) Does the supplier have the required manufacturingfacilities to meet the contractual requirement ?

3 CONTRACT REVIEW

a) Whether Purchase orders (includingamendments) received from the customersare reviewed considering the feasibilityalso ?

b) Suppliers preparedness for submitting APQP & PPAP ?

c) Does the suppliers have evident of PPAP documentfor similar products ?

d) Are they having adequate knowledge in preparing &using control plan & FMEA ?

e) Are they having adequate Experience in preparing and handling FMEA documents?

4 DOCUMENTS AND DATA CONTROL

a) Is there a method of controlling the documentsfor revision status, user location and updationincluding customer supplied documents likedrawings, quality/control plans ?

5 PURCHASING

a) Does the purchase document (or equivalentdocument) specify all the necessary qualityrequirements like drawing/ issue no., spec.qty/wtprice etc.., and whether the quality recordsof sub-contractors kept up to date ?

6 PRODUCT IDENTIFICATION & TRACEABILITY

a) Are the raw material and products identifiedat all production stages including delivery(I.e. from receipt to delivery)

7 PROCESS CONTROL

a) Are the products manufactured as per documented work instruction (operations/inspections) like manufacturing layout/ processsheet, drawing / specification, quality/ controlplan ?Poka Yoke works properly throughout the processand are checked for effectiveness periodically.

Format : BI / ESQS / Rev.02 dated 1 Nov 09

Points

QUALITY SYSTEM


b) Is special process qualified (design of experiments may be used) and whethertrained/ qualified presonnel employedfor special process operation ?

c) Is the preventive maintenance carried outwith checklist as per plan on machines/equipments and whether the Machinecapability indices are satisfactory (forproducts having special characteristics) ?

d) Does the supplier comply to all applicableGovernment safety & enviornmental regulations including those concerning handling, recycling, eliminaiton / disposalof hazardous & toxic substances and possessing appropriate Government certificate ?

e) Is the working environment clean & wellmaintained ?

8 INSPECTION AND TESTING

a) Are receiving inspection activities carriedout including customer supplied matierals/products ?All incoming parts are clearly identified anddemarked separately until quality is assured.

b) Is inspection carried out between stages asper quality plan / control plan / work instructions and are they displayed near workarea and updated periodically?

c) Is gauging/ measuring are avilable and done at setup and periodically for each process as per work instruction / quality / control plan and whether the special process monitored asper work instruction / process sheet ?Are Gauges / Fixtures maintained well?Sampling check is sufficient. NC procedure isclear and countermeasure carried out.

d) Does the supplier carry out final inspection &testing as per the work instruction/ quality /control plan ?Sub suppliers QC activities has been reviewedin detail and every concern have been solved

9 CONTROL OF INSPECTION, MEASURING

a) Whether the gauges, inspection, measuring& test equipments calibrated periodicallyand suitably identifed (including MSA) ?

b) Are all measuring equipments properly handled and stored ?

10 INSPECTION AND TESTING STATUSa) Is inspection and /or test status suitably

identified from receipt to delivery ?

Format : BI / ESQS / Rev 02 dated 1 Nov 09

Points


11 CONTROL OF NONCONFORMING PRODUCT

a) Are the rejected & reworked materials keptseparately identified and the analysiscarried out ?

12 CORRECTIVE AND PREVENTIVE ACTION

a) Are the customer complaints and the internal nonconformities (rejected/reworks)effectively handled for initiating correctiveand preventive actions ?

13 HANDLING, STORAGE, PACKAGINGPRESERVATION AND DELIVERY

a) Does the supplier handle, store, packpreserve & deliver items in the propermethod or in the method specified by the customer to avoid damage or deteriorationof the product?

14 CONTROL OF QUALITY RECORDS

a) Are the quality records maintained properly(I.e) identification, collection, indexingaccess, filing, storage, disposition and is it legible, readily retrievable and kept for thespecified retention period ?

15 TRAINING

a) Whether the training needs identified and provided for all presonnel performingactivities affecting quality and effectivenessto Training monitored?

16 STATISTICAL TECHNIQUES

a) Whether the supplier follow statisticaltechniques for controlling process andproduct characteristics and relevant recordsmaintained (atleast products havingspecial characteristics) ?

b) Does the supplier have any CP/CPK trendmonitoring program?

17 PPM LEVEL/SELF CERTIFICATION

a) Does the supplier maintain its quality levelin PPM ?If Yes, Present PPM Level

b) Does the supplier operate under 'Selfcertication' of parts with the existingCustomers ?

c) Supplier schedule adherence with the existing customers ?

d) Does the Supplier supplies in JIT / or keepconsigement stocks ?

e) Does the suppier has Internal system to evaluate Suppliers/sub-supplier selection ?

f) Does the Supplier has infrastructure for Raw material inspection, receiving in processand final inspection?


Points

a)

b)

c)

a)

b)

c)

a)

b)

c)

d)

e)

Acceptance Criteria : Min score 70% and not more than 3 zero scores Total marks: Supplier should have valid ISO 9000 certification as minimum requiremen Percentage:

No.of Zero scores: Recommendation :

Audited by:


If yes , specify the validity date

Does the supplier comply / plan to comply to the consent condition stipulated by the concerned SPCB

2 Water actDoes the Supplier possess the valid consent to operate under the latest prevailing Water Act.

If yes specify the validity date

Does the supplier plan to comply to the consent condition stipulated by the concerned SPCB

Does the supplier comply to the conditions stipulated in the authorization given by the concerned SPCB

3 Hazardous Waste Management & handling RulesDoes the Supplier possess the valid authorization under the latest prevailing HW management and Handling rules.

Elements & QuestionsOBSERVATIONS

Air Act1Does the Supplier possess the valid consent to operate under latest prevailing Air Act.

ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Any other legal / Regulatory requirements applicable to the nature of the process and is the supplier comply to them

Does the supplier has an adequate Trade Effluent Treatment Plant

If yes a)provide details of TETP & Disposal of TETP sludges

Does the Organisation have adequate Sewage handling facility?

If yes , specify the validity date

TOOL PROGRESS REPORTPART NUMBER: XXXXXXX PART NAME: YYYYYYY

TOOLING SOURCE: Inhouse SUPPLIER: Supangita Engineers LtdTOOLING / EQUIPMENT Press tools SUPPLIER CODE: S999 TOOL COMPLETIONN DATE:

WEEK ENDING 1/3 8/3 15/3 22/3 29/3 5/4 12/4 19/4 26/4 3/5 10/5 17/5 24/5 31/5 7/6 14/6STAGE

Receive component drawing

Design tool

Build tool

Tryout and fine tune

PLAN ACTUAL SUPPLIER SIGNATURESAPPROVED APPROVED CHECKED ORIGINATOR

TITLE

SIGN &DATE / / / / / / / /

Format : BI / TP Rev-01

12/6/2003

Date :

Note : Design review has to be done before child part sample development.

Unit Model

Supplier

# Parameter Dimension / Spec. (as given in drawing) SC/CC parameter Grid

ref

Change & Way of dimn if required

(Otherwise write OK)Reason for change E, R&D

comment Remarks

#Example:Diameter

ØXXX Yes XX

Notes

Supplier representative: E, R&D representative BI - SQA representative : SDI Rep. Unit rep (If reqd)Name: Name: Name: Name NameSign Sign : Sign : Sign. Sign.Format : BI / DR Rev- 01

DESIGN REVIEW OF CHILD PART

Note: All drawing dimension, material, finish & Notes to be covered. Consider both dimensional requirement & process capability requirement if any during discussion.

Part No. / Issue No.

Description:

Brakes India Limited

Supplier Name:Part Name:

Part number / Issue number:

Customer / Model

Unit:# Characteristics Grid Ref. Method of inspection Safe launch plan

parameter & checking freq.

Calibration freq& verification of the date

Normal Sampling / Frequency

1.1 Free from burr, rust, damage and cracks Visual Every lot

1.2

3.0 Metallurgical parameters (covering RM, HT & Finishes):

4.0 Capability report (SC/CC Characteristics identified in draiwng) * #

4.1

5.0 Capability report (Identified during PPAP) * #

5.1

5.2

6.0 Layout inspection

6.1

7.0 Rejection reports*

7.1

Unit: SQA Supplier:

Name: Name: Name:

Signature/Date : Signature/Date : Signature/ Date :Notes:* Parameters marked thus to be retained at supplier end. The same shall be subject to verification during visit of BI Personnel.

a) Supplier shall provide test certificate in accordance with the above agreement for lots as applicable.b) Capability report shall be computed from data taken across production lots over a period of time mentioned. Capability studies shall be repeated in case of change of RM, Machine, location etc.,c) Suppliers will be reviewed monthly, based on their PPM rejections and Quality issues & called for quality reviews as required.

Format No. BI / QP Rev-04 dated 3rd Nov '09

Quality Plan Agreement

2.0 Dimensional parameters

1.0 Visual parameters:

d) In case of CAR raised on any SC/CC parameter, the respective parameter to be inspected 100 % for next 1 year to avoid repeat issue.

# Parameters under 4 & 5 has to be checked 100 % if there is no prevention fail safe, during initial 3 months of buld supply (safe launch)

Documents retention : All Quality documents shall be stored for a minimum period of years & should be traceable.

Part No. Issue date

Visual

1 Date code stamping

Operation:

Visual

Feature

Comments:

Supervisor Signature: Date:

Gage

Visual

2

1 Presence of piston slot

Visual

Proper fine grain phospating of piston & any damage on piston

1

Safe Launch Plan

2 Check for mounting thread and pitch

Verification Method

3 Finish on feed port surface Visual

Ref. No.

Special Work InstructionBrakes India

Ltd.Customer/Project:

NISSAN D21TRUCK

Part/Process Description:

Safe launch checking item for Wheel cylinder Assembly viewing

The part should be marked with Yellow paint after qualification of the above points

Visual

Visual

1 Test Punch Mark Visual

1

2

Presence of caps

Proper passivation of the bleed screw

1 Check for feed thread

1 Proper seating of the boot Visual

Plunging action to check for spring

Visual

Visual

2 No cut/puncture mark on boot

1

2

3

1 2

1

1 2

1

1

2

1

Part Name: Model L Disc Pad. Supplier code: R017Part description: Model L DiscPad Supplier name: RANE BRAKE LININGS LIMITED

Revision No.: 1 Supplier address:Plot #30, Industrial estate,Ambattur, Chennai - 600 058

Packing illustration:(Attach photograph of packing arrangment)

Details of packing:

Length Breadth Height Thick340 195 200 4 0.36kg 20 7.2kg 8.39kg

Description: carton reference M635Mode of despatch:

1 Through TVS logistics (by road)2 By suppliers arrangement (by road)3 By suppliers arrangement (by train)4 By suppliers arrangement (by road and air sometimes)

Necessary details along with dispatch:1. Invoice2. Dimensional results (as per quality plan)3. Material test results / Mill TC4. Capability reports, whenever applicable (as per quality plan) APPROVED BY:UNIT : SUPPLIER : NAME : NAME :SIGNATURE : SIGNATURE :

Packaging specification sheet

Dimension (mm) Wt. / part Qty. of parts

Total part wt.

Total wt. (part wt. & packaging wt.) in Kgs

C.T (sec) Hrs. Reqd. C.T (sec) Hrs. Reqd. C.T (sec) Hrs. Reqd.

1 Input rod 0.00 0.00 0.00

2 Output rod 0.00 0.00 0.00

3 Bracket 0.00 0.00 0.00

0

% Utilization 0 0.000

% Capacity free (Spare capacity) 100 100 50

0

CAPACITY ASSESSMENT SHEET (for all BI part families with supplier)

1)avg peak demand for past 6 months

2) Plan to ach o/p for the above qty

448.81700.0

0.000

100 50

Gridning

52.8

0.00Total Hrs Required :

Number of machine

0.00

5

2000.0

100.0

200.0

Loss due to OPR EFF % Avail Hrs (5% assumed) (operator change, untrained operator etc.,)

Machine Hrs dedicated to BI %

Net available Hrs 1020.0

60.0

100

Total Qty

Sl# Part Name Part No

0 50

AMD

3 3

0.00

Available Hrs per Month (assumed for 2 shifts (18 hrs max.) & 25 days)

Machine down time [ % Avail Hrs] (10% assumed) (includes setting, breakdown, PM etc.,)

1056.0

% Utilization for other customers

120.0 105.6

1200.0

Supplier Name : M/s. XXX

Window Engineer : ---

CNC machiningTraub

COMPLIANCE AUDIT CHECK SHEET

Part No : xxxx Issue No. Start Time End Time

Control Plan W.I Produced Ok R/W Rejected FTC % yield1 Operation 1 Yes * *

2 Operation 2 Yes * *

3 Operation 3 Yes * *

FTC shall be Minimum 90 % (may vary based on customer requirement)

Supplier: SQA Representative :

Signature Signature

Date: Date :

Format : BI / Comp Audit Rev-01

QuantityOperationS.No

Controls on Cycle Time in

sec

Setting time in Min.

Date of Checking: mm/dd/yy

To : Unit Kind attention.: The following part is conditionally approved for the reasons given below. Please introduce double sampling for the related parameters till the PPAP is converted to straight approval by SQA. This will be informed to you as & when the PPAP is converted to straight.

Raw

mat

eria

l

Proc

ess

Impr

ovem

ents

Mac

hine

Con

ditio

n

Tool

ings

,Jig

s &

Fi

xtur

es

Cap

abili

ty S

tudy

Sub-

supp

lier c

ontr

ol

Mea

surin

g In

stru

men

ts

Rej

ectio

n an

alys

is

Han

dlin

g of

par

ts &

La

yout

Gen

eral

1

2

3

4

5

6

Format:BI/Cond Rev 02

Completion Status

Com

plet

ed o

n

AREAS

Inte

rim c

onta

inm

ent

actio

n

Res

pons

ibili

ty fo

r in

terim

con

tain

men

t ac

tion

REASON FOR CONDITIONAL APPROVAL

Supplier Name:

Part name: Conditionally Approved on. :

Part no: PSW No. :

Reference No. :

Supplier Representative :

Sl.N

o

BI Representative :

Supplier Representative :

Conditional Status

Reason for conditional Approval

Res

pons

ibili

ty

Targ

et D

ate

for

com

plet

ion

of

cond

ition

s

BI Representative :

# Check Point Yes No Remarks

1 Is there a design review conducted (before sample submission) or supplier has given assurance that he will meet all drawing./ Cp, Cpk requirements.

2 Does the process flow address raw material & S/C sources

3 Material specification and its availability

4 Material and its compatibility for Heat treatment / plating / painting / brake fluid

5 Are the tool sketches available

6 Is the component manufacturing location clearly defined

7 Is the SIR latest and has it been cleared without any issues

Does the control plan address the following:

- Machine name

- Process parameters

- Jigs / Fixtures

- Measuring instruments used

9 Is mode of packing and transportation addressed

10 Is between stages handling addressed

11 Does PFMEA address all requirements as per process flow

12 Co-relation of process capability and MSA

13 Is Poka – Yoke addressed for significant characteristics (force sensor in forging machines temp sorter in hot forging etc)

14 Are all characteristics of drawing addressed in control plan

15 Adequacy of the quality plan

16 Is the FTC report filled properly

17 Is the PTR samples available with supplier with necessary tag

18 Check method uniformity between BI and supplier

19 Supplier’s awareness on mating component and function

20 Is reason for conditional approval stated clearly

21 Are the special process parameters qualified and are they specified

22 Is there a list of process instruments coming under calibration

23 If capability is not achieved, Have we addressed 100 % inspection

24 Ensure SIR (layout inspection) taken after completing all processes

25 Capability studies shall be taken for dimensions which are prone to vary during the process

26 Change management agreement addressed in quality plan.

27 Study of process capability in case of RM change shall be addressed in quality plan

28 PTR and PSW capacity shall match as far as possible

SQA Engineer: Date Format : PPAP A&B / 01

PPAP Checklist – (A&B category)

Part No.Part Name :

SupplierProject :

8

PPAP Checklist ( Category : C )

Part No : Supplier : M/s Part Name : Project :

Note : Items marked * not mandatory for customer specified sources & collaborator’s sources. SQA Engineer : Date : Format: BI / PPAP C / 01

Sl No Check Point Yes No Not

applicable Remarks

1 Is the SIR latest and has it been cleared without any issues

2 * Does the control plan address the following: - Machine name - Process parameters - Jigs / Fixtures - Measuring instruments used

3 * Are all characteristics of drawing addressed in control plan

4 * Adequacy of the quality plan 5 Is reason for conditional approval stated clearly

6 * Capacity meeting the specified volume

7 * Review of Fit, Form, Function

PROCESS CAPABILITY STUDY REPORTSupplier : Ref. No.

M/S. XXXXX

Customer : PERIOD ( Month ):Brakes India Ltd Nov '07

Part No.: 29666743 Part Name : XXXXXXXCharacteristic Specification Tolerance

OUTER DIA LSL 4.74 USL 4.77 0.0310 Opn. Description : VMC

MICROMETER Least Count : 0.001CAPABLE PROCESS OBSERVED : Cp > = 1.67 CAPABLE Cp = 2.27Cpk > = 1.33 CpK = 1.63

HISTOGRAM n = 42

Observation : - No. of Class : 41 - 5 6 - 10 11 - 15 16 - 20 21 - 25 26 - 30 31 - 35 36 - 40 41 - 45 46 -50

4.760 4.763 4.755 4.759 4.761 4.761 4.758 4.760 4.757

4.756 4.760 4.757 4.758 4.756 4.757 4.758 4.758 4.758

4.760 4.758 4.758 4.761 4.765 4.756 4.759 4.760

4.761 4.760 4.760 4.762 4.761 4.762 4.758 4.757

4.761 4.758 4.757 4.760 4.763 4.760 4.762 4.758

Observed beyond Specification : Target Nominal :

Estimated beyond Specification : Average ( X ) :Std.Dev. ( O ) : (sigma)

ACTION PLAN FOR IMPROVEMENT(IF NOT CAPABLE) Prepared by :

Sign & DateApproved by :

Sign & Date

Operation No :Instrument Used

0.0022

4.7550.00%

0.00%4.759

0

5

10

15

20

25

30

2.37

4.75

4.75

4.76

4.76

4.76

4.77

4.77

4.77

4.78

4.78

0

20

40

60

80

100

120

140

160

180

200

1

Qty Received :-

Complaint Identified at

Receipt stage Assy stage Product Audit

Customer End Assy testing Others specify:

Complaint details

Fitment Functional Packing / Labelling

Dimensional Aesthetics / Visual Material

Others specify

Complaint history

New Skip Part PPAP approved

Repeated Non -skip part Yes No

Sl.No.

Defective sample retained with unit Sample given to supplier Sample / photo shown to supplier

Quantity available at Brakes India for disposition:

Format : BI / CAR Rev- 03 - May 09 Page : 1 OF 3

Specify other details wherever necessary

Defect Photo/Sketch (Attach separate sheets if necessary)

Non conforming quantity:

Supplier Plant/Location :CONCERN RANK A B C

Supplier DC / Invoice no:

BI GR no:-

Lot reference:-DC date:

Customer:

Product model :

CORRECTIVE ACTION REPORT (CAR)

BRAKES INDIA LTD

Supplier / Vendor code : Reported by:

Authorised by :

CAR raised date :

C.A.R.No. / UnitPart name:

Part number:

Drg Issue no:

Line stoppage due to quality issue/Dimensional issue in significant & critical characteristics B

GR Date:-

Customer Complaint/Repeat CAR in same part number after closure of original CAR by unit /OE fitment dimensions AGuidelines for ranking of CAR

SUPPLIER TO SEND CORRECTIVE ACTION PROPOSAL WITHIN 10 DAYS FROM RECEIPT OF CAR

PROBLEM

Unit Recommendation

CRA ref No. (if any)

CAR sent to supplier on date:

UN

IT

Others(Dimensional deviation not affecting fit & function/Aesthetics/Handling damage/Mix up/Rust,etc) C

Non conformance description

Segregate Rework Concession by BI Reject to supplier

Reject Rework

Brakes India

In Transit

Supplier Inhouse

Sub - Supplier

Guidelines :Atleast 2 tools to be used, 3 or more tools preferable.Narrate briefly the QC tool used.(Provide attachments wherever necessary)

1 1

2 2

3 3

4 4

5 5

DEFECT CLASSIFICATION

Process Tooling Gauging Packing / Labelling

System Machine Handling Operator

Maintenance Training Rework


Date OK Identification mark on OK part Remarks

SU

PP

LIER

WHY - WHY ANALYSISWhy it occurred Why it was not detected

CAUSE & EFFECT DIAGRAM

CONTAINMENT ACTION

ANALYSIS TOOLS

NGParts checked at

CHECKSHEET

STRATIFICATION

SCATTER DIAGRAMC&E DIAGRAM (4M)

CONTROL CHART

5 WHY ANALYSIS

HISTOGRAM PARETO ANALYSIS

MAN MATERIAL

MACHINE METHOD

CORRECTIVE ACTION IDENTIFIED ROOT CAUSE CORRECTIVE ACTION RESP TGT DATE

YES NO (Furnish details if YES)

STANDARDISATION OF CONTROL DOCUMENTS

PFC CONTROL PLAN DRAWINGS

PM CHECKLIST QUALITY PLAN TOOL DRAWING

GAUGE DRAWING FIXTURE DRAWING SOP

PFMEA UPDATED PACKING INSTRUCTION

Note : Attach supporting details / documents where ever necessary

CORRECTIVE ACTIONS WITH EFFECT FROM:

Cut off DC / Invoice no & Date :

Supplier Representative Name: Sign: Date:

PHYSICAL VERIFICATION OF CORRECTIVE ACTION IMPLEMENTATION (IF REQUIRED )

YES NO

SQA Engineer: Date:

OYES NO

Approved by: Date :

CORRECTIVE ACTION CLOSURE (BY ORIGINATING UNIT) :

Signature: Date:


SQA

OCCURRENCE

DETECTION

UN

IT

HORIZONTAL DEPLOYMENT ON SIMILAR PARTS / PROCESSES:

SUPPLIER

CORRECTIVE ACTION ADEQUACY

Note: Unit to monitor the effectiveness of corrective actions (for 3 lots or 1 month, based on unit's discretion), sign and forward this copy to SQA for updating the database.(SQA Repository)

Date :

Characteristics Specification Category of FFF

Machine name / type Fail Safe Process

capability 100%

inspectionOEM

complaintBI - Line

RejectionsIncoming

Rejections

Inhouse rejections@

sup end.

1

2

3

4

5

6

7

8

9

10

11

12

Sign Sign :

The below mentioned FFF activities were implemented with effect from supplies dated: _______________. Please monitor the lots after this & arrange for skip introduction as per usual skip inspection procedure (if not already implemented)

Target DOL stage inspection detailsResp.

Customer :

Past complaints (Last 1 year)

PPAP Completed: Yes / No

Present process controls available

Fit, Form & Function Matrix

Checking method used in

manufacturing line

Fit, form, function Characteristics ( including SC/CC )

Sl No.

Supplier Name :

Part No :

Remarks / action plan for improvement

No. of cavities

Dock audit & inspection Report.

Sign :

Unit Representative name:

Issue no

Sampling plan a) n=as per BI sampling plan, c=0b) n=5, c=0 If there is any rejection in sampling inspection, 100 % inspection should be done for that characteristic.

Part Name :

Format : BI / FFF Matrix Rev 2

To: Mr.

Unit no:

Fit : The ability of item item to physically interface or interconnect with or become an integral part of another item. Form : The shape, size, dimensions, mass, weight, and other visual parameters which uniquely characterize an item. For software, form denotes the language and media. Function : The action or actions which an item is designed to perform.

Note : 100% inspection required if there is no fail safe for OEM customer fitment characteristics. Recommended process capability for all FFF characteristics is Cpk > 1.67. All FFF characteristics should be covered in Final inspection report. For all OEM customer fitments 100 % insp. is required either in line or final insp. or DOL station when Poka-yoke is not there.

Supplier representative name :Window Engineer name :

Date

Part No. / Name

Process 0Product 0ProcessProduct

Machining Pressing Moulding Protective finishing Casting Springs Bar rolling

Forging Heat treatment Welding Lining / Bonding Packaging

Machining Pressing Moulding Protective finishing Casting Springs Bar rolling

Forging Heat treatment Welding Lining / Bonding Packaging

Main Elements (Product)

I Process Quality Planning 0 30 0 Dim adherence 0 10 0

II Personnel Qualification 0 20 0 Capability 0 10 0

III Receiving Stage and storing 0 20 0 In house rejection 0 10 0

IV Production Stage 0 70 0 Endurance - - -

VPackaging, Storage, Handling, Transporting, EMS & OHSAS requirements

0 30 0 Other attributes - - -

VIFailure Analysis, Corrective Actions and Continual Improvements.

0 30 0

0 200 0 Overall Score (I+II+III+IV+V) 0 30 0

Grading

A

AB

B

C

SDI Units

Complete Process Sequence

Process And Product Audit Report

High CAR / Critical

Supplier of the Month

Others ( please mention):

Score (%)

Overall Audit Priority Rating

Change Mangement ( Location /

Subsupplier)

Brakes India Ltd., Chennai

Application

Audit No.: Reason for the AuditSupplier / Sub - supplier / Satellite unit audited

Auditor:

Routine / Suppliers left our in prev.

plans

Assembly, Subassembly / Testing

Complete Process Sequence

Product AuditReference

ScoreAchieved Score

Process Audit

Result % Achieved Score

Audit

Others :

Process Owners

Assembly, Subassembly / Testing

1

Previous audit

Sub-supplier process audited (if any)

Degree of Conformity

Inhouse processes audited

Grading of the Process Remarks

Reference Score Result %

Grading

Over all Score (I+II+III+IV+V+VI)

Overall Degree of Conformity %

Main Elements(Process)

80% to 89%

90% to 100%

If any of the above elements in Process audit is less than 60%, Grading is downgraded by one step.i.e., A to AB or AB to B or B to C

Less than 60%

60% to 79%

Copies for Circulation to :

Auditor/s Signature & Date

Full Compliance

Predominant Compliance

Partial Compliance

No compliance

Auditee / Process Owner Signature & DateReviewed by Signature & Date Approved by Signature & Date

FM/SM/SA/01-Oct07

Certificate

Certifying Body

Obtained in (Year) / target dt. (if planned)

Future Plans

Major parts supplied to BIL

Business share of BIL:

PPAP Status

Business with BIL: (Since)

Business relationship with Brakes India Ltd.

No.of New parts added

Total No.of Parts supplied to BIL

Last One year CAR's raised


General Information

Manufacturing , testing and validation facilities available

Established in:

Total Employee strength : (Permanent employees)

Tie-ups (if any)

Annual Turn over

Core Manufacturing Competance:

Others ISO TS 16949

Name :

Location:

Other manufacturing sites: (if any)

At BI : At Supplier end :

Date of Cert : Date of Expiry :

Quality issues :-



Last 6 months PPM

Supplier Process Audit

Regular Working norms : (shifts x hrs)

Quality Certifications

ISO 9001:2000 ISO 14001

FM/SM/SA/01-Oct07

Rating0, 4, 6, 8,

101 0

2 0

3 0

Rating0, 4, 6, 8,

10

1 0

2 0

Rating0, 4, 6, 8,

10

1 0

2 0

Rating0, 4, 6, 8,

10

1 0

2 0

3 0

4 0

5 0

6 0

7 0

Process Audit

Audit Score Sheet

Tool management

Instruments and Gauges management

0

1 Process Quality Planning

Appropriateness of work and inspection stations to the needs.

Approval for production starts and recording of adjustment details / deviations.

2 Personal Qualification

3

4 Production Stage

Receiving Inspection & Stores

% Score

70 0

Reference score

Machine management

Adhrence and adequacy of process parameters

% Score

Receiving inspection and Subsupplier control0 20 0

Stores

Reference score

Responsibiilty and Authority0

Achieved Score

Achieved Score

Quality Monitoring.

0Qualification, training and suitability of personnel

Achieved Score

Reference score % Score

20

Achieved Score

Control plan

0300

Reference score % Score

Process Flow Chart

PFMEA

FM/SM/SA/01-Oct07

Process Audit

Audit Score Sheet

Rating

0, 4, 6, 8, 10

1 0

2 0

3 0

Rating0, 4, 6, 8,

10

1 0

2 0

3 0

Rating0, 4, 6, 8,

101 0 0 10 0

2 0 0 10 0

3 0 0 10 0

4 Endurance / Other Attributes - - - -

5 Other Attributes - - - -

Evaluation of Compliance with individual requirements:10 Points

8 Points

6 Points4 Points0 Point

Predominant compliance with the requirements with minor nonconformity

Partial compliance with the requirements with more severe nonconformity Unsatisfactory compliance with the requirements with major nonconformityNo compliance with the requirements

Full compliance with the requirements

% Score

% Score

0 30 0

Dimensional Adherence

% Score

30 00

Achieved Score

Reference score

Carrying out corrective actions on time and check for effectiveness in the process.

Product Audit

6

Availability of Target parameters for product and process & monitoring of compliance.

Continual improvements of product and process.

Failure Analysis, Corrections, Continual improvements

7 Product AuditAchieved

ScoreReference

score

5

In-house material handling. Tracebility and security against mix-up / exchanges by mistakes of parts and material flow.

Reference score

Achieved Score

Internal rejections

Tuning of transport materials & packing to the special properties of the product.

EMS & OHSAS 18001 Requirements

Capability

Packaging, Storage, Handling , Transporting EMS and OHSAS 18001 requirements

FM/SM/SA/01-Oct07

Main Element Sub Element Check

List No. Look for (Check list)Highlights of positive

compliance / Areas needing improvement

Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along with objective evidence Action Plan Responsi

bility Target

PFC No.: Issue No.:

1.1.01 Adequacy of sequences from receiving up to shipping.

1.1.02 Are the latest copies of Drawings / Specifications available with supplier?

1.1.03Any significant change in the process flow in the past 12 months due to process improvement or customer concern ? If yes, look for process validation .

1.1.04 Availability of Raw materials supplier details in PFC

1.1.05 Identification of CC & SC stages

1.1.06 Availability of sub-supplier details in PFC

PFMEA No.: Issue No.:

1.2.01 Adequacy of sequences in line with process flow.

1.2.02 Considerations & identifications on CC& SC

1.2.03 Any method exists for updating PFMEA on ongoing basis

1.2.04 Reviews based on RPN, severity, excess scrap / rework, customer concerns, etc.

1.2.05 Are actions based on PFMEA reviews completed on targets?

1.2.06 Are Poka Yoke’s included in PFMEA?

1) P

roce

ss Q

ualit

y Pl

anni

ng

#DIV/0!1) Process Flow

Supplier Process AuditBrakes India Ltd., Chennai Audit rating check sheet

0Supplier : Part No. 0

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit by observing the actual process)

#DIV/0!2) Process FMEA

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

FM/SM/SA/01-Oct07



compliance / Areas needing improvement

Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along with objective evidence Action Plan Responsi

bility Target

Supplier Process AuditBrakes India Ltd., Chennai Audit rating check sheet


CP No.: Issue No.:

1.3.01 Is CP in line with Process Flow & FMEA?

1.3.02 Are all S.C’s & C.C’s identified in CP?

1.3.03 Are PFMEA changes & concerns identified in CP?

1.3.04Is CP adequate covering all tests / checked fixtures / gauges / frequencies / responsibilities / historic concern?

1.3.05 Does CP address all dimensions as per drawings?

1.3.06 Does CP address process characteristics?

1.3.07 Does CP address corrective actions in case of non conformities (Reaction plan)?

1.3.08Does CP cover agreed standards / practices not specifically addressed in the drawing (like burr free, flash free, surface finish, acceptance limits, etc) ?

1.3.09 Does CP cover layout inspection and functional testing?

1.3.10 Does CP cover packaging and despatch standards?

1.3.11 Does CP address each stage’s process validation & frequency?

1.3.12 Are Poka-Yoke devices uniquely identified in CPand their shift wise qualification / validation?

1.3.13 Does PFC , PFMEA , CP address actions based on findings of the previous audit?



1) P

roce

ss Q

ualit

y Pl

anni

ng

3) Control Plan #DIV/0!

FM/SM/SA/01-Oct07



complaince / Areas needing improvement

Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along with objectiveevidence

Action Plan

Responsibility Target

2.1.01 Do they have a clearly defined organization structure?

2.1.02 Is there a Customer Contact Persons identified for Quality Issues

2.2.01 For management of modifications & NCs

2.2.02 For operating & work instructions ( Design / Engg / QC )

2.2.03 Adequate resource for Inspection activity covering all the shifts (QC / QA / Manufacturing)

2.2.04 For process approval and release ( QC / QA / Manufacturing )

2.2.05 For set-up approval (First-off & Last-off) ( QC / QA )

2.2.06 For interpretation of control charts ( Prod / QC / QA / Manufacturing )

2.2.07 To stop production on NCs ( QC / QA )

2.2.08 For rework approval ( QC / QA )

2.2.09 For environmental safety ( Personnel / HR )

2.3.01 Qualification / Skill matrix availability

2.3.02 Training calendar and adherence

2.3.03 Product knowledge

2.3.04 Knowledge of consequences to customer in case of N.C products / processes

2.3.05 Health and safety at work awareness.(OHSAS)

2.3.06 Availability of skilled personal ( At receiving inspection, Line inspectors, Final inspection, Production, Maintenance, Tool design/ maintenance, QA, Calibration, etc)

2.3.07 House keeping training.

2.3.08 Training on problem solving methods pertaining to their jobs.

2.3.09 Skills on process capability studies & M/c capability studies

2.3.10 Qualification records (Welding certificate, driving license for industrial trucks, eye sight test for viewers, etc.)

2.3.11 Carrying out & ordering the installation & calibration of inspection, measuring & test equipments

2.3.12 Knowledge on MSA

2.3.13 Training on handling of parts, equipments at each stage.

2.3.14 Carrying out continual improvements - Waste elimination, cost reduction, cycle time reduction, setup times

2.3.15 Knowledge on error proofing / Poka-Yoke

1) Organization structure

Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0


2) Roles , Responsibility & authority(Competency of employees, required to perform their role)

3) Qualification, training & suitability of personnel


#DIV/0!

#DIV/0!

2) P

erso

nnel

& Q

ualif

icat

ion

FM/SM/SA/01-Oct07


List No. Look for (Check list)Highlights of positive complaince / Areas

needing improvement

Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along with objective evidence

Action Plan


3.1.01 Are incoming packages appropriate (as per purchase order)

3.1.02 Availability of product drawing, Inspection plan, material history cards etc.

3.1.03 Sampling plan – Is zero defect policy evidenced?

3.1.04 Availability of suitable TD/TS

3.1.05 Is RM procured from approved source as per Specefication ( TD 1-30-07 ) & for Rubber items ( Check validation done by Supplier )

3.1.06 Are RM test parameters verified at defined interval as per CP / QP?

3.1.07 Are calibrated / adequate inspection/test facilities available?

3.1.08 Is self inspection reports received from suppliers

3.1.09 Supplier rating availability

3.1.10 Supplier audit schedule and adherence

3.1.11 Source audit approval record

3.1.12 CAR on vendor rejections & adequacy of corrective actions and how the system is effective?

3.2.01 Tidiness

3.2.02 Clear identification & separate locations for materials looking alike.

3.2.03 Roofed area / Area available to total R/M handled and any Rust preventive method adopted if any ? and Raw materiastored properly to avoid deterioration?

3.2.04 Availability of identification cards / colour codings (Status card - Accepted / Rejected / Under inspection, RM Heat code etc.)

3.2.05 Any chances of mix-up?

3.2.06 Is quarantine area clearly isolated and adequate?

3.2.07 Shelf life items storage ( Have the Shelf Life Items been identified and validation takes place periodically? )

3.2.08 FIFO controls and stack records

3.2.09 Lighting / Safety / Easy access

3.2.10 Traceability



Brakes India Ltd., Chennai Audit rating check sheet



#DIV/0!

#DIV/0!

3) P

urch

ase,

Rec

eivi

ng st

age,

sto

rage

and

sub-

supp

lier m

anag

emen

t

2) Storing

1) Receiving stage

FM/SM/SA/01-Oct07



complaince/ Areas needing improvement

Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10


Action Plan


4.1.01 Work instructions adequacy & compliance

4.1.02 Stage drawings adequacy & compliance

4.1.03 Process parameter display at relevant stages (E.g. Pr, Temp, time, speed, feed, Location of resting & butting, etc) & Are SOP's displayed near the Machine/cell

4.1.04 Inspection instructions adequacy & compliance (Does the Inspection Plan / Control Plan bears Customer designated Critical & Significant Characteristics ?)

4.1.05 Rework / Scrap instructions / procedures ( Do they have a system of handling rework / scrapped parts ? )

4.1.06 Quarantined & ear-marked WIP area

4.1.07 Availability of quarantined final inspection area

4.1.08 Tidiness , cleanliness ,ergonomics, lighting etc

4.1.09 Clear identification & separate locations for materials looking alike.

4.1.10 Availability of inspection table, work table etc

4.1.11 Availability of in & out bins

4.1.12 Marked containers for reject/ rework/ adj parts ( Eg. Red bin analysis for rejected parts)

4.1.13 Defined rework station

4.1.14 Health and safety at work (OHSAS)

1) Appropriateness of work & inspection station to the needs

#DIV/0!


4) P

rodu

ctio

n St

age




FM/SM/SA/01-Oct07



complaince/ Areas needing improvement

Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10


Action Plan




4.2.01 Set up & last off approvals (With samples)

4.2.02 1st principle method of 1st OFF approval

4.2.03 Stage inspection adherence as per schedule

4.2.04Control and regulation of important parameters, process qualification (DOE etc) & Is application of Statistical Tools evident in Shop Floor ? (Process Monitoring Chart / X bar - R Chart, Run Charts etc.)

4.2.05 Changed Production parameters

4.2.06 Availability of instruments, gauges and adequacy (Like profile projector, surf tester, height gauge,hardness tester crack detection etc)

4.2.07 Machine and process capability evidences for important characteristics and process parameters

4.2.08 Recording of rejections / rework

4.3.01 Is there a Master list of Gauges / Instruments / Jigs & Fixtures ?

4.3.02 Triggering mechanism for calibration of instruments / gauges / jigs& fixtures?

4.3.03 MSA/ R&R

4.3.04 Relaibiltity, function and corrosion resistance tests (if applicable).

4.3.05 Layout inspection schedule and adherence

4.3.06 Adherence to submission of reports as per Quality Plan

4.3.07 Availability of SQA Manual, awareness and deployment in shopfloor

Refer Annexure 1Refer Annexure 2Refer Annexure 2Refer Annexure 2

5) Machine management6) Tool Management

3) Quality monitoring

4) Adequacy and Adherence to process parameters

#DIV/0!

#DIV/0!


2) Approval for production starts and recording of adjustment details and deviations


4) P

rodu

ctio

n St

age

7) Instruments / gauges / fixture management

FM/SM/SA/01-Oct07




Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along

with objective evidenceAction Plan Responsib

ility Target

5.1.01 Suitable transporting means

5.1.02 Availabiltiy of bins (Inhouse & movement to subcontractors)

5.1.03 Protection against damage (Inhouse & movement to subcontractors)

5.1.04 Environmental influences and air conditioning

5.1.05 Expiry dates

5.1.06 Kanban / JIT

5.1.07 Defined storage area (WIP)

5.1.08 Marked containers / locations

5.1.09 Identification & marking of parts

5.1.10 Identification & marking of operation

5.1.11 Inspection & test application status

5.1.12 Route cards with Traceability

5.1.13 Batch and heat numbering

5.1.14 Protection against damage

5.1.15 No. of quantities per package / Parts Positioning in package / Work Instruction

5.1.16 FIFO controls

5.1.17 Tidiness, cleanliness & overstocking

5.1.18 Packaging- Transport worthiness (Look for drop test)

5.1.19 Work documentations (Final inspection report)



#DIV/0!

5) P

acki

ng, s

tora

ge ,

Han

dlin

g tra

nspo

rting

and

ISO

140

01 R

equi

rem

ents

2) Tuning of transport materials and Packing to the special properties of the product

1) Inhouse material handling & storage / Traceability and severity against mix up/ exchanges by mistake for parts and material flow


0

#DIV/0!


Supplier : Part No. 0

FM/SM/SA/01-Oct07




Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along

with objective evidenceAction Plan Responsib

ility Target


0


Supplier : Part No. 0

3) ISO 14001 / 5.3.01 Is your organization IS0 14001 certified?

Consumption of Power 5.3.02 Monitoring consumption and action when they are abnormal.

4) Generation of Noise 5.4.01 Any action If Noise level exceeds 90 dB(A) ?

5.5.01 Any action If Polythene cover thickness less than 20 micron ?

5.5.02 Usage of trays for keeping barrel and containers

5.5.03 Dispose of the used oil only to Hazardous waste recyclers

5.6.01 Identify High risk Fire prone areas

5.6.02 Ensure availability of adequate different type of fire extinguishers / Fire Hydrants

5.6.03 Identify key personnel and provide adequate training for fire fighting

7) Where applicable : 5.7.01 Monitor stack emission once in a year and ensure SPM

Emission Control 5.7.02 Ensure availability of pollution control certificate.

5.7.03 Safety and health policy available?

5.7.04 Do you have facilty to address safety concerns raised by Employees

5.7.05 Identification of risk potential areas and keeping it away from main area.

5.7.06 Availability of first aid boxes at prominent areas.

5.7.07 Availability of procedure to report accidents

5.7.08 Availability of inhouse / outsourced medical facility

5.7.09 Availability of control system in work place which are risk potential.

5.7.10 Availability of Risk management plan on emergency systems

5) P

acki

ng, s

tora

ge ,

Han

dlin

g tra

nspo

rting

and

ISO

140

01 R

equi

rem

ents



#DIV/0!

5) Spillage / Leakage / Movement / Storage and Disposal of oiling

6) General Maintenance activities

OHSAS 18001 requirement

FM/SM/SA/01-Oct07




Rating 0,4,6,8,10

Avg. Rating

Rating 0,4,6,8,10

Observations / Points for improvement along with objective evidence Action

PlanResponsibili

ty Target

6.1.01 Presence and absence of personnel

6.1.02 Quality indices / failure rates, audit results etc

6.1.03 Non conformities cost / Cost of poor Quality - Records / Trend charts.Non conformity costs

6.1.04 Process characterictic values (Cp, Cpk)

6.1.05 Are Customer survey & Quality Rating Reports received from customer

6.2.01 Recording of break down times, setting time, downtimes etc, OEE (Any Kaizens)

6.2.02 Availability of cycle times / thro put times (Any Kaizens)

6.2.03 Cost optimisation

6.2.04 Reducing stock level

6.2.05 No of production pieces produced per hour

6.3.01Recording of rejections / rework and Analysis - 7 QC Tools. (Is the Corrective and Preventive Actions initiated for In-house rejections / rework ?)

6.3.02 Implementation / Sustenance of improvements

6.3.03 CAR - Analysis status ( Look for all CAR's raised last one year)

6.3.04 Operator awareness of customer complaint (Both internal & external)

6.3.05 Improvement program from various B.I. Audits


6) F

ault

anal

ysis

and

con

tinua

l im

prov

emen

ts


3) Carrying out corrective actions on time and check for effectiveness in the process

2) Contiual improvement on product and process

1) Availability of Target parameters for Product, process & Monitoring compliance

#DIV/0!

#DIV/0!

#DIV/0!



FM/SM/SA/01-Oct07

Supplier : 0 Part No.

9

Spec

Reference score

Op. No. Operation Description Product CharacteristicsProcess CharacteristicsSignificant

Characteristics

Machine, Devices, Tools, Jigs & Fixtures

Adequacy and Adherence to Process Parameters in Production stage - Annexure 1

0

Rating 0,4,6,8,9


Observations / Points for improvement along with objective

evidenceActual

Audit rating check sheet Supplier Process Audit

Method of insp. Doc ref. / Process Characteristics

FM/SM/SA/01-Oct07

Main Element Sub Element Highlights of positive complaince /

Areas needing improvementRating

0,4,6,8,10 Avg. Rating Rating 0,4,6,8,10

Bed flatness

Scribing of bed

Horizontal parallelism

Ram repeatability

Spindle run-out

Chuck face-out

Slide repeatability

Safety sensors

Warning devices

Temperature

Timer

Poka-yokes

Periodic validation of Poka Yokes

Daily qualification of Poka Yoke with NG Parts

History cards

PM checklist

PM adherence

Recording of break down times, setting time, downtimes etc, OEE

Identification of accessories

Stacking of accessories

Critical spares

Action Plan

Responsibility

#DIV/0!


Mac

hine

Man

agem

ent

Target


Supplier :

Observations / Points for improvement along with

objective evidence

0

Process audit report - Annex 2

FM/SM/SA/01-Oct07

Main Element Sub Element Highlights of positive complaince /

Areas needing improvementRating

0,4,6,8,10 Avg. Rating Rating 0,4,6,8,10

Action Plan

Responsibility


Target


Supplier :

Observations / Points for improvement along with

objective evidence

0

Process audit report - Annex 2

Tool ID

Tool drawing

Tool stacking

Spare tool availability

RI of tool

Tool service life

Tool life

History cards

PM checklist

PM adherence

Poka-yokes

Tooling plan

Jig/fixture ID

Jig/fixture drawing

Jig/fixture stacking

Jig/fixture calibration

Maintenance frequency of wear parts

History card

Instrument ID with LC

Stacking

Calibration

History card

Gauge ID

Gauge drawing

Stacking

Calibration

History card

#DIV/0!

#DIV/0!

Gau

ges

Jigs

/fixt

ures

Inst

rum

ent

Too

l Man

agem

ent

FM/SM/SA/01-Oct07

Ave.

Bed flatness #DIV/0!Scribing of bed #DIV/0!Horizontal parallelism #DIV/0!Ram repeatability #DIV/0!Spindle run-out #DIV/0!Chuck face-out #DIV/0!Slide repeatability #DIV/0!Safety sensors #DIV/0!Warning devices #DIV/0!TemperatureTimerPoka-yokes #DIV/0!Periodic validation of Poka Yokes #DIV/0!Daily qualification of Poka Yoke with NG Parts #DIV/0!

History cards #DIV/0!PM checklist #DIV/0!PM adherence #DIV/0!Recording of break down times, setting time, downtimes etc, OEE #DIV/0!

Identification of accessories #DIV/0!Stacking of accessories #DIV/0!Critical spares #DIV/0!Tool ID #DIV/0!Tool drawing #DIV/0!Tool stacking #DIV/0!Spare tool availability #DIV/0!RI of tool #DIV/0!Tool service life #DIV/0!Tool life #DIV/0!History cards #DIV/0!PM checklist #DIV/0!PM adherence #DIV/0!Poka-yokes #DIV/0!Tooling plan #DIV/0!N/A - Not Applicable

Score0468

10Predominant compliance with minor NC 8Full compliance with requirement Available

Unsatisfactory with major NC 4Partial compliance with minor NC 6

Status Denoted asNo compliance with requirement Not Avail.- Not available

Tool

Man

agem

ent

#DIV/0!

Process audit report - Annex 2 (i)

Machine

Mac

hine

Man

agem

ent

#DIV/0!

FM/SM/SA/01-Oct07

Main Element Part No. / Part Name

Critical / Significant Dimension

Spec.Rating

0, 4 , 6 8, 10

Avg. Rating Rating 0,4,6, 8, 10

Highlights of positive complaince / Areas needing improvement Action Plan Responsib

ility Target

0

Product Audit Report


Endu

ranc

e /

Oth

er

attri

bute

s

Supplier :

Cap

abili

tyD

imen

sion

al

Adh

eren

ce

Overall Inhouse process rejections ( For all BI parts put together):

Inhouse process rejections Rating: PPM < 100 - 10 ; 100 > PPM < 1000 - 8; 1000 > PPM < 10000 -6; 10000 > PPM - 4; No PPM monitoring - 0.

Capability Rating:For Ppk > 2.0 - 10 ; For 2.<Ppk > 1.67 - 8 ; 1.67 < Ppk > 1.33 -6 ; 1.33 < Ppk > 1.00 - 4 ; Ppk< 1.00 - 0.

Note: For tool dominant processes like Moulding, Pressing etc. Cp will be considered instead of Cpk (Min. sample size 25 successive nos.)


Rating: Both dimensional and visual characteristics are adequate: 10; Minor deviations in the visual charcteristics but dimensionally adequate - 8;Minor dimensional deviations -6; Major and critical dimensional deviation -4; No Compliance with requirement - 0.

In house process rejections Rating (for tool dominant process like Moulding) : PPM < 5000 - 10 ; 5000 > PPM < 10000 - 8; 10000 > PPM < 50000 -6; 50000 > PPM<100000 - 4; No PPM monitoring -0.


FM/SM/SA/01-Oct07

TO

BE

FIL

LE

D IN

BY

SU

PPL

IER

B

I – S

QA

USE

ON

LY

Supplier’s Change Request (SCR)

Supplier Name : SCR Tracking No:

Part No/ Name : Issue No.: Original BI PSW No.

Nature of change (Tick applicable) Alternation Note Ref (If BI initiated) . Process Tooling Location Sub Supplier Design Material source

Change Initiated By: Supplier BIL Change Description:

Sl. No

Characteristics Affected due to change (Use additional sheet if required)

Impact of Change Remarks

For Non Technical changes PSW revision need not be required. Supplier rep. name : Sign: Date :

* Re-PPAP Required : Yes No * Verification Required: Yes No

Documents : PFD MSA Ppk reports FFF matrix

PFMEA Master sample Inspection report Quality plan

Control plan Lay out report Validation test results Compliance audit

Design FMEA SIR/ISLR Capacity Assessment Packing Spec Sheet

PSW Qualified Lab Doc PPAP Check Sheet Conditional Approval Sheet (if Any)

* Subject to the discretion of SQA.

If Physical Verification is required planned

Verified on : Action plan for non-conformance (if any)

Verified by :

Reviewed by: Signature & Date:

Approved by: Signature & Date:

SCR closure details: New PSW No.: Date:

Date of Change Implementation / Identification (If any) :

SQA Engineer to communicate customer window engineer before change implementation if required.

BI Tracking no.

Format U52 / SCR Rev. 4 dated 17 April 09

Brakes India – Corp. QA

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) – (As per FMEA Manual Rev. 4)

FMEA Number___________________________

Page_____________________of______________

Item:________________________ ___________ Process Responsibility__________________ Prepared By______________________________

Model year(s)/Program(s)__________________ Key Date ____________________________ FMEA Date (Orig)_________________________

Core Team______________________________________________________________________________________________________________________

Action Results

Process Step Function

Requirements

Potential Failure Mode

Potential Effect(s) of Failure

S

ever

ity

Cla

ssifi

catio

n

PotentialCause(s) of Failure

Occ

urre

nce

Current Process Controls Prevention

Current Process Controls Detection

Det

ectio

n

R

PN

Recommended Action

Responsibility & Target Completion Date

Actions Taken & Effective Date

Se

veri

ty

Occ

urre

nce

Det

ectio

n

RPN

Format : U52 / PFMEA Rev. 1

To: Finance Department CRA No:

Plant Date :

Unit Reason : Tick applicable & fill appropriate column

Customer if applicable Administrative costs given in brackets for each category.

Part No. 1. Rejection at receiving inspection (Debit Rs.2000/each lot rejection)

Part Name 2. Line rejection (Debit Rs.10,000 / Occurence)

Supplier code 3. Seggregation / Rework at BI - (Rs.5000 / Occurence+Actual cost)

Supplier name 4. Repeat seggregation / Rework at BI - (Rs.10,000 / Occurence+Actual cost)

Supplier D.C/ Inv. no. 5. Third party inspection charges (At actuals)

GR No. 6. OEM Customer complaint (Rs.10,000 / Occurence+Actual cost)

CAR No./ Date 7. Delayed CAR closure (Rs.5000 / Occurence)

8. Premium freight due to Quality problem / Delivery failure (At actuals)

9. Non adherance to change management commitment.(Rs.5000/+actuals if any)

Total cost to be recovered (Rs) 10. Other charges. Pl. mention………………..

Brief description of problem :

1. GR Rejection

2. Line Rejection

Administrative cost Total cost

3, Segregation / Rework costs 4. Repeat seggregation / Rework costsSegg / Rework cost for labor Consumables/Tools cost Administrative cost Total cost

5. Third Party InspectionThird Party Inspection agency / Type of work

Cost of 3rd party inspection Transportation chargesTotal cost

6. Cost to Brakes India because of OEM customer complaint

Description Quantity

Cost at brakes India including charge debited by OEM

customer's to Brakes India Total amount

7. Delayed CAR closureCAR No. CAR sent to supplier on Brief description of problem Total cost

8. Premium Freight chargesDetails Date Freight cost Total cost

9. Violation of change management commitmentNature of violation Details of violation Cost Total cost

10. Other chargesDetails Date Cost Total cost

Sign: (Unit Quality Module) Sign: (Unit Supply Module) Sign : (SQA) Sign :(SDI)

Recovery details (To be filled by Finance dept.)Details Cost recovered Signature

Note : After all the above 4 approvals are completed, CRA will be forwarded to finance dept with a copy to unit & SQA Format : BI / CRA Rev. 2

Debit note will be raised by finance dept. for all GR rejections.

Brakes India Limited - Brakes DivisionCRA - Cost Recovery Advice - For vendor parts

Cost working

Total cost to be recovered

Supplier QA Manual

Documents

Transcript of Supplier QA Manual