MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT

Vendor Attendees Date:

Supplier Name Auditors:

Part Name
Category Audit Area
(Main Clause) (Sub Clause) Concerning Regulation (Actual Audit points) Requirements (Reference Only) Judgment Remarks Follow Up

Procedure for Product development from receipt of

Regarding implementation Do you define the procedure for Product development
order to SOP at customer end including scope of
rule (procedure) of 1 including the following ? -scope of parts, responsibility
1 parts, responsibility of each department, control
production preparation of each department, control contents / items?
contents / items as per APQP guidelines.

Regarding management / - Development Time plan (Master and Micro level)

implementation by production
2 preparation plan / report
(master plan)
1. Production
preparation / New
Product
Development
Defect prevention on the
3 stage of process design by
using FMEA/Matrix diagram
Do you implement follow-up to control the schedule and
- Review frequency and evidence
1 progress of production preparation items? Incl top
- Reason of delay and action
management
- Evidence of review by Top management.
Do you consider following items and implement
corrective and preventive action to the processes and
standards before regular production? - FMEA Procedure
1 -Troubles in the past; - FMEA / QA matrix.
-Defect items expected; - Past defect history and Potential defects.
-Defect items unable to capture at customer;
-Defect items difficult to repair;

Product/process evaluation at - List of Quality issues / defect faced In-house and

Do you prevent defects by quality improving activities of
the quality evaluation meeting 1 Customer end during trials.
4 cross-function team to evaluate quality performance?
in each trial - Their complete analysis in the form of PDCA.

Do you define following items related to initial production

Initial Production Control Procedure including
control by standards ?
- Initial Production Control period (3months for new
-controlled parts;
parts)
-controlled items;
- person responsible to announce start/end of Initial
1 -inspection method;
Production Control
-initial production control period;
- Control items & inspection method (check method)
-a person who announce start/end of initial production
- Criteria for termination of Initial Production Control
control;
period
-finish condition;
Regulation (procedure) for
1 Initial Production Control
Stricter Control during Initial Production Control
２． period:
Regulation for - Increased sample size or frequency
Initial Production - Frequent Process Capability Study (Cpk > 1.33)
How do you define items requiring special control during
Control - Fast removal of problems / analysis
2 Initial Production Control? Do you set stricter inspection
- Change in Inspection Method
methods than the ordinary inspection?
- Verification of Standards, operation standards,
facility etc.(Process audit)
- Stricter visual inspection (100% inspection/ 200%
inspection)

Evidence of process capability study / defect rate

(rejection % or ppm) monitoring and action if not
Do you control process capability and defect rate during
Implementation of Initial 1 meeting the target as decided for product and critical
2 Initial Production Control?
Production Control parameters as mentioned in Spec. Meeting or Critical
parameters decided by supplier

Procedure / WI for expected changes (4M : Operator,

1
Do you define unexpected change (unusual/unplanned) machine & jig/die, material and method change) and
and expected change (usual/planned) clearly? unexpected changes (Tool breakage, power failure,
machine breakdown, inspection equipment failure etc).

Definition and implementation

1 of Change Management Do you define procedure(rules applied from sharing Rules to be defined from sharing information (to the
2 information to result confirmation) at change concerned person / Deptt) to result confirmation of
occurrence? product produced before and after the change.
３．
Change Recording of product quality check with product
Do you record product quality check results to ensure
Management 3 details like Lot no, quantity and marking on products
traceability? Incl retroactive checks
etc.

- Definition of Initial Part (First Part/Lot).

Do you define and control Initial Part (First Part/Lot)
1 - Control method/ system in procedure.
clearly?
- Identification tag
Definition and Control
2 method for Initial Part (First
 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Vendor Attendees Date:
Supplier Name Auditors:
３．
Change
Management

Part Name
Category Audit Area
(Main Clause) (Sub Clause) Concerning Regulation (Actual Audit points) Requirements (Reference Only) Judgment Remarks Follow Up
Definition and Control
method for Initial Part (First
2 - Inspection & test record of initial parts / lots (All
Part/Lot) Do you control Initial Parts separately and make quality
development lots including pilot lot).
2 records about them?(both internal and outsourced
- Inspection / test reports of sub vendor is required in
process are included)
case part produced by sub vendor.

- Procedure for preparation and review of Process

Procedure to make Process
Control Standards (QA
1 Instructions/Standards for all products which are
process charts)
４．
Standards
Management Procedure to control
standards
2 ・Process Control Standards
・Inspection Standards
・Operation instructions
Do you make and review Process Control Standards
(Control Plans), Inspection Standards, Operation
1 operation Instruction/Standard of all parts.
shipped to SMC / MSIL / Tier 1 ?
Do you have consistency to keep Process Control
1 Standard, Inspection Standard, operation Instruction
and parameter chart?
Control Std (control Plan), Inspection standard and
- Review system and record of updated std against a
change.
Coherence between all documents like PCS / Control
plan, inspection Standard, Operation Standard and
MIS -P.

Training procedure / WI including person responsible

for training related to Quality (QS, Process Audit,
Inspection, Using inspection & testing instruments /
equipments etc), Training need identification and
Do you clarify the department in charge of promoting
effectiveness check system.
quality education (training), implement education
1 - Training Calendar for all Operators, Supervisor and
(training) based on annual plan?
Managers
Are records of education (training) kept?
Education/ Training - Training systems and record for New Joinee (Staff /
1 procedure operator)
- Training Plan v/s Actual records
５． - Effectiveness check records
Education and
Training
Do you define and implement the skill evaluation of
2
operator to determine whether operator can work without WI for Skill evaluation criteria level wise, evaluation
surveillance?(e.g. acceptable level/evaluation frequency and method.
frequency/evaluation method)

Education for Cross checking of operator's skill periodically against

Do you periodically monitor the skill of certificated
managers/Inspectors/ 1 a decided parameter and by simulating defect.
2 operators and follow up to improve their skill?
Special operators Evidence of retraining plan and effectiveness check.

Plan and evidence of conducting Internal Quality

Do you conduct quality audit to identify issues and system audit/process audit/product audit.
Activity to keep/improve 1
1 properly improve them? Action taken for improvement against the Quality
production quality
Issues observed during audit.
６．
Quality audit and
process 1
Do you confirm consistency between actual operation Evidence of process audit based on work
verification and standard? instructions / PCS and actual working.
2 Content of process review

2
Do you confirm if countermeasures are taken properly to Evidence of Countermeasure effectiveness check at
prevent reoccurring of quality fail? shop floor during process audit.

New Supplier selection procedure indicating supplier

７． 1
Evaluation method for new 1
Do you define criteria to certify new suppliers and audit check sheet & min qualifying criteria especially
Supplier control suppliers implement them? for quality.
Evidence of audit done and supplier list

1
Do you define clearly what is abnormal situation and Definition of abnormal situation and Operator's
make operators know the definition? awareness about the abnormal situations.

Do you clarify and standardize the handling rules/routes Procedure for customer complaint handling, in-
2 for customer claims, in process failure and supplier process failures (defect/rejection/rework) and supplier
Handling when abnormal
failure? failures
1 situation occurs
Do you have criteria to estimate the scope of suspected Procedure for handling suspected parts at the time of
3
lot for abnormal situation?　When abnormal situation abnormal situation including criteria for estimating
occurs, do you trace suspected lot based upon the suspected parts (quantity produced before abnormal
criteria? situation)
８．
 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Vendor Attendees Date:
Supplier Name Auditors:

Part Name
Category Audit Area
(Main Clause) (Sub Clause) Concerning Regulation (Actual Audit points) Requirements (Reference Only) Judgment Remarks Follow Up
８．
Handling
5 Why Analysis/Root Cause Analysis to be done for
abnormality in Do you prevent recurrence of issues by analyzing cause
the defects
quality 1 of occurring defect based on process investigation result
Criteria for raising A-3 sheet/DAR for internal and
such as 5-why analysis?
supplier issue
Prevention of recurrence

・Customer claims
2 process and review the standards?
・In process failure
・Suppliers failure
2
Do you take corrective actions for improvement of Standardization (Review of standards) of
countermeasures as decided in Defect Analysis Sheet
Onsite check up of countermeasure at regular interval
After corrective action are taken, do you conduct on-site
3 check up and evaluate the effectiveness? And horizontal
Evidences of horizontal Deployment of
deployment.
countermeasures

Do you keep store material, work-in-process, finished

Storage of RM, BOP, WIP, FG and bins/trolleys to
products, inventory and container at appropriate storage
1 prevent from dust, rust, scratch, deformation and
prevented from dust, rust, scratch, deformation and
rainwater (Shop floor audit)
rainwater?

Do you control material, work-in-process and finished

Storage of RM, BOP, WIP & FG parts at designated
2 product by designated location, volume and standard
location with identification tag for visual control
using visual control?
1 Location of production site

Inspection or critical operation under properly

controlled environment:
Do you implement inspection or critical operation under - temperature
the properly controlled environment - humidity
９． 3
5S management (luminance/temperature/humidity/vibration/noise/ work - noise
table, etc.)? - Proper layout/ arrangements on work and inspection
table
- lux level etc

Physical condition of production equipments, jigs and

1
Do you keep condition of production equipments, jigs tools
and tools properly? Evidence of daily/ regular check
Storage arrangements with identification
Production equipments
2 management
Physical condition of inspection equipments
Do you keep condition of inspection equipments
2 Evidence of daily/ regular check (Validation report)
properly to ensure accuracy?
Proper storage arrangements

Do you conduct daily/regular check of production Daily and preventive maintenance of production
1 equipments, dies and jigs? Are records of maintenance equipments, dies and jigs
kept? Machine/ tool history card and PM check sheet
Do you confirm regularly the function of Pokayoke,
Maintenance of equipments , Regular check of Pokayoke and their record
1 jigs and tools
2 automated stop and alarm? Are records of maintenance
List of Poka Yoke
kept?
１０． Do you standardize frequency of polishing and
Equipment/Inspe Frequency of polishing and replacement for
3 replacement for consumable tools(blade/electrode/rub
ction equipment's consumable tools and change records
stone, etc.)?
management
Calibration record of inspection equipments
Do you calibrate regularly inspection equipments and put
1 Calibration status on inspection equipments
the expiry date on them?
(Calibration date & due date)
Maintenance of inspection
2 equipments Do you control deterioration (expiry date) of boundary
Expiry date on limit samples (for objective judgments
2 samples for objective judgments such as appearance
such as appearance inspection)
inspection?

Do you use easy expression (visualizer, onomatopoeia Visual confirmation of work done (glowing of
1 (alarm) ,etc.) for operation instructions? So that operator green/yellow/red light or alarm indicating completion
can easily understand process and critical points. or incompletion of work)
 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Vendor Attendees Date:
Supplier Name Auditors:

Part Name
Category Audit Area
(Main Clause) (Sub Clause) Concerning Regulation (Actual Audit points) Requirements (Reference Only) Judgment Remarks Follow Up

Work Instructions to be made in Local Language

Do you keep operation instructions on the accessible
2
place and post important quality points and critical Display of WI's, Quality Check points & instructions
operation points on the place where operators can see it related to critical operations at easily accessible
１１． easily? location (so that operator can read and take out them
Implementation 1 Implementation of standards easily for reference)
of standards

Periodic records of operator observance audit to

Do you regularly monitored that each operator operates
3 check operator working as per various standard such
according to the operation instructions？
as WI, PCS, Daily check etc.

Is it possible to judge OK/NG specifically by each check Judgment criteria should be mentioned on each check
4 sheet (of daily equipment check, quality control report, sheet (e.g..- Upper/ Lower tolerance, check method
etc.) you use? and criteria )

Do you keep first-in first-out of finished products and Incoming Material / WIP / Finish Goods to be
1 work-in-process (material, reserve parts） by using maintained with Identification Tags and storage
identification tag or lot indication? location at each stage.

Management of parts flow Do you control following production history by product

1 Production Date/ Lot/ Qty/ dispatch date to be
2 lot numbers?
recorded for traceability purpose.
-production date; -production volume; -shipping date

１２． Similar parts control by different colour bin /

Products
3 Do you control identification of similar parts separately?
tags/packing material
management

1
Do you control identification of non-confirming parts and Separate area/ red bin for storing NC part with reason
parts on hold. Do you store them separately? tag/ marking on NC part

Non-confirming parts
2 management - Rework procedure/WI
Regarding repaired non-confirming parts and parts on
- Responsibility for Rework and area/table for rework
2 hold for re-use, do you define responsibility to
- Inspection record of rework material
implement? Are repair record kept?　
- Traceability (Lot detail) of Reworked Material

Do you make arrangements with customers about the

packing style & transportation system to prevent damage
1 Packing standard and transporation mode
during handling of finished products & perform
13. accordingly.
Handling 1 Bins/ Trolley Management
Management WI to maintain Bins/Trolleys ( WIP & FG) in good
2
Do you have system to maintain Bins /Trolleys in Good condition
Condition. Bin/trolley cleaning and repairing area and check
points of bin/trolleys

Special check points for Maru A/Critical parts in

Do you have Special checks/Inspection of Maru A/Critical
1 Inspection standards (in-process & final) as per
parameters of Maru A/Critical parts
inspection standard/drawing
14.
Maru A/Critical Parts Identification of Maru A processes/operators by
Critical parts 1
Do you have Identification of Maru A Process/Operator
Management 2 displaying Maru A symbol on work stations, operators
Management on Shop Floor.
and machines/lines

Do you keep the repair history when repairing & using

3 Record of Rework/Repair history of Maru A parts
Maru A items

Does the supplier has all inspection instruments required

1 Inspection instruments list.
as per drawing requirements

15. Adequate 1 Testing Facility Does the supplier has all Testing Equipments/Rigs
testing facility 2 Testing equipments list and arrangements.
required as per drawing requirements

3
Does the Supplier has trained manpower to operate Lab person and inspector's training records and
these inspection and testing instruments experience.
 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Vendor Attendees Date:
Supplier Name Auditors:

Part Name
Category Audit Area
(Main Clause) (Sub Clause) Concerning Regulation (Actual Audit points) Requirements (Reference Only) Judgment Remarks Follow Up

1 Conduct process audit as per process control standard Plan and actual evidence of Process audit. NC list.
16. Process 1 As per PCS
Audit
2 Closure of all the observations Verification of closure evidence of observations.

Achieved Score 0

Maximum Score 112

Audit Rating 0