Supplier Process Assessment Report

Report No F13/P/003

Audit Date 27.07.12 Submission Date 06.09.12 Approval Date 06.09.12

Review Audit Date Submission Date Approval Date

Supplier Name Eltec PP SGS Pvt. Ltd. Vendor Code 10183

Plot No. 362, Pace City - 2,Sector - 37,Near Hero Honda Chowk,
Plant Address
Gurgaon,Haryana,122001

Telephone / Fax +91-124-2210016 / 2210017

Product Type PMS

Audit Brief
Eltek is in business of DC power management systems. Eltek Valere has taken over the complete business of Eltek
SGS, and company is planning to register with changed name.The company is in operations since 1997. The set up in
Gurgaon is an assembly unit with designs being developed in Norway and Module (electronic cards) manufacturing in
China factory.
The company has more depedency on the product design outside India, hence product validation, reliability testing
could not be demonstrable in the plant.
Firm is ISO, OHSAS & EMS certified alongwith BSNL certifications for the products. Quality team has very good
awareness of QMS implementation.

Audit Objective Initial Process Audit

Audited by Satyender Deswal

Disclaimer
The content in the report is based on individual assessment done for Indus Towers Ltd (herein after refered to as
"The Company") and may be used for informational purposes only.
The content does not constitute, and shall not be construed as, financial, investment, taxation or legal advice to
the supplier. The Company's objective is only to keep the suppliers better informed and help them decide for
themselves. The Company does not accept responsibility for any investment decisions made by suppliers on the
basis of content of this report. The Company shall not be liable or responsible in any manner to any party for any
consequences, including without limitation financial consequences, business allocation arising from the use of the
content. The data/ information presented in this report are derived from factual information provided by the
supplier during the audit. No part of this document may be copied or reproduced or transmitted in any form/
manner without prior permission of The Company. This document/ assessment may not be held as documentary
evidence in the court of law.

Indus Towers - Private & Confidential

Dated: June12.Rev03

Supplier Process Assessment Score

Supplier-Eltec PP SGS Pvt. Ltd.

Audit Date 27July'12 Audit Date Audit Date
Total Total Total Overall Assess Total Overall Assess Total Overall Assess
Section
No No of questions Full Points Assess Point Points Assess Point Points Assess Point Points
1 Management Control 2 10 6 60%

2 Material Management 17 85 43 51%

3 Process Quality Planning and Design & Development 9 35 19 54%

4 Measuring Instrument Control 7 35 25 71%

5 In Process Control 37 180 79 44%

6 Sub Contractor Control 5 25 12 48%
7 Control on Non Conforming Products 17 80 45 56%

8 Final Product Handling - Packing & Delivery 7 35 19 54%

9 5S 10 50 32 64%
10 EHS 9 45 31 69%
120 580 311
Assessment 53.62% Assessment Assessment
Result Result Result

Assessment

Management Control
EHS Material Management
69% 60%
51%
5S 64% Process Quality Planning and Design & Development
54%
54%
44% 71%
Final Product Handling - Packing & Delivery 56%48% Measuring Instrument Control

Control on Non Conforming Products In Process Control

Sub Contractor Control

CURRENT SCORE CHART PREVIOUS SCORE CHART

Vendor's Action Plan
Vendor Name : Eltec PP SGS Pvt. Ltd.
S. No. Area Q.No

Managemen
1 2
t Control

2 1

3 2

4 4
5 5
6 6

7 7

8 Material 8
Managemen
t
9 9

10 10

11 11

12 12

13 13

14 17

15 1

Process
Quality
Planning
and Design
&
Developmen
 Process
16 Quality 3
Planning
and Design
17 & 6
Developmen
t
18 7

19 9

20 Mesuring 1
Instruments
21 Control 6

22 1

23 3

24 4

25 5

26 8

27 9

28 10

29 11

30 12
31 13

32 14

33 15

Inprocess
Control
34 17
Inprocess
Control
35 18

36 19

37 20

38 21

39 22

40 23

41 24
42 25

43 26

44 27

45 28

46 30

47 31

48 33

49 1

50 Sub 2
Contractor
Control
51 3

52 4
53 1
54 5
55 8

56 9
57 10
58 Control of 11
Non
Conforming
59 Products 12

60 14

61 16

62 17
63 1
64 2
Final
65 Product 3
Handling

66 7

67 1
68 2
69 5-S 4
70 6
71 9

72 4

73 5
EHS
74 6
75 7
an
c PP SGS Pvt. Ltd.
Parameters

Quality Target and Focused Actions Plan to achieve the target are
established, assigned to respective departments and periodically reviewed
based on quality performance and reflection of improvement activities.

Have the responsibilities for the control of incoming material been defined
in procedures and instructions?

Does the supplier inspect or otherwise verify purchased material prior to

use?

Are adequate Receiving inspection records maintained?

Are there adequate written inspection instructions provided?
Does the supplier formally indicate inspection status of incoming material /
parts?
Are purchase orders to suppliers reviewed for completness, quality
requirements and all applicable specifications including original testing lab
certifications prior to release?

Are raw materials identified and traceable to Test or certification reports?

Does the supplier verify the contents of certification test reports against the
appropriate specification requirements?

Is Storage procedure to prevent load shift and package drop, which affect
quality damage of product, established and implemented?

Are work instructions for material handling and storage available and in use
to assure adequate protection of the product to prevent loss, damage,
deterioration, degradation and substitution?
Is Materials and products storage location clearly identified and well
organized?
Is FIFO(First In First Out) concept implemented and storage location layout
considered to help its implementation. Are old lots observed?
Is traceability maintained through all process operations, including any
subcontracted operations, to the finished components?

Are Critical and Significant characteristics identified on the control plans

and instruction sheets and appropriately monitored?
Are Control Plan, Work Standards or Work Instructions, Special Process
Control Standards, Quality Check Sheets , Equipment Check Sheets and
so on periodically updated and the latest standards and sheets are used?

Is supplier capable of prototype development?

Does the supplier have a formal procedure for controlling design changes
including review and approval responsibilities?

Are field problems considered for New product and process design?

Are gauges and test / inspection instrument maintained and adequately

stored?
Are controls in place to assure actions are taken in the event of calibration
faliure?
Are clear, concise work, controlled inspection and set-up instructions
available at the workarea?

Is identification and approval of process parameters demonstrated,

including acceptable operting ranges(max, min) for each parameter
defined? Is there a procedure for this and followed?
Are workmanship standards available in the form of controlled written
standards, visual exhibits and / or samples?
Are inspections and measurements being performed according to the
instructions?
Are manufacturing conditions monitored and recorded for special processes
like welding/heat treatment / plating/ painting/casting/forging/gluing/pressing
in / riveting?
Has process capability been established for all critical and significant
features and process parameters?
Is process capability monitored, and are all process records and charts
current and correctly completed?

Are staff and inspection personnel sufficiently trained to utilize the statistical
process control concept?

Are skill matrix for operators of “special processes” defined?

Are training needs identified as per skill matrix for operators performing
special process and records of training maintained?

Are causes of scrap/rework analysed and CAPs formulated and

implemented?
Are rework methods documented and approved?
Are Facilities, machines, equipment, jigs & fixtures and tooling checked
and recorded based on checking standards by designated responsible
person, such as operator, leader, Mfg. engineer.
Are Storing procedure for jigs & fixtures, tooling and inspection fixtures
documented and location are designated and storage condition well
maintained?
Is the status of parts / material adequately identified / controlled at all times
through out the production process?

Is Preventive measure for mixed parts and wrong parts to occur

implemented at each manufacturing process?

Do Supervisory personnel conducts periodical audit, in which he or she

confirms if operator comply work instructions, and record result of audit?

How is training need identification linked with skill matrix for persons
performing Critical operations and if that skill level been achieved.
How Regular and Preventive Maintenance activities are scheduled and
implemented.
Are breakdown records maintained and analysed? Are Corrective action
taken based on analysis?
What is competency of staff performing Preventive maintenance?
Is there Procedure for quality checking after repair and is it implemented
and records maintained.

Are History cards of Machines maintained and records available?

Are History cards of Tools / Jigs / Fixtures maintained and records
available?

When Sampling is used in final verification, are there formal sampling plans
and are they adequate to assure shipment of acceptable products?

Are controlled final verification instructions used and are they adequate to
ensure inspection and test are completed and in conformance?
Does the supplier formally indicate inspection status of parts?

Does supplier has method of subcontractor approval?

Is current list of approved suppliers maintained. Is this list reviewed

periodically and latest list avaiable?
Are requirements for subcontractor documented and distributed? Are these
updated periodically?
Is scheduled process audit implemented to confirm subcontractor's
preventive recurrence measures for quality issues?
Is there a documented system with defined responsibilities for review and
disposition of non conforming material?
Do records show that reworked parts / material are re-inspected?
Are there adequate corrective action programs implemented for the
suppliers purchased material?
Are there adequate corrective action programs implemented for suppliers
own manufactured parts?
Are containment actions implemented and effective where necessary?
Are Quality tools used for addressing problems identified such as Why -
Why analysis, 7 QC tools etc. ?
Is definition of abnormality state documented and operator provided with
visual aids for judgment of abnormality by control points illustrations
particularly for critical process?
Does the supplier identify root cause and take adequate corrective action to
prevent recurrence of reported faliures and quality problems?
Do all instances of non-conforming material reported have concern reports
issued and CAPs raised against them. Is 8D methodology adopted for
addressing Non conformity?
Are CAPs/8D monitored for effectivenss and have any repeat concerns
been reported in 12 months of implementation?
Is FIFO followed in finished goods dispatch ?
Are packaging specification/guidelines available to the workforce as agreed
with the customer
Do these specifications make use of graphics or photographs to indicate
correct and incorrect packaging methods?

Does the logistics team have system of planning and monitoring movement
of supplied material to ensure delivery on time without delay ?

Are there any unneeded materials lying nearby workplace?

Are all frequently used objects sorted, arranged, stored and labeled?
Are jigs, fixtures, tools, equipment, & inventory properly identified and in
their correct locations?
Is the lighting environment affected? Any dirty light bulbs or windows?
Are improvement ideas regularly being generated and acted upon?
Is there a system in place for personnel to report any safety concerns or
incidents including near misses?
Are Personal trained in proper selection, use and maintenance of Personal
protective equipments ?
Are proper safety labels being utilized ? (aisle ways, extinguishers, hazard
warnings, etc)
Are work area clean, organized and free from hazards ?
 Marks
Observations Score
d

Quality targets as whole are there but Respective

2
department targets yet to be set for performance review.

Yes.Responsibilities are defined in procedures.But

3
Instructions yet to be displayed

Yes.Inspection and verification is there but not for all

3
material

Receiving inspection recording yet to be improved 2

Not provided 1
Formal indication of inspection status yet to be established 2

Yes.But verification of quality parameters such as Material

3
testing to be strengthened

Tracability scope to be defined for all materials, it is there

2
only for critical parts

Verification is there but evidence by means of signing of

2
report after checking to be established

Storage procedure/Work Instructions to be improved for

2
these parameters.

Work Instructions are not there 1

Location is clearly defined and organised for small parts.For

3
big boxes it is to be implemented
FIFO is not being maintained 1
Tracability scope to be defined for all materials, it is there
2
only for critical parts

Critical characteristics are identified in drawings only.No

2
control plan is avaialable and monitoring is not there
Control plan is not there.other sheets are updated 2

yes.But no evidence/records 3

yes but system needs strict adherence 3

No such data bank is maintained for new product/process

1
design
Instruments/gauges are maintained but storage needs
3
improvement
No. As such actions are not documented/analysed 2

Instructions are there but not tidy 3

Procedure is not evident although approval of process

3
parameters is there

standards are available but Visual Exhibits /samples (Visual

3
Display) needs focus
Work Instructions for measurement are not there 1

no such montoring for special processes is there 1

No Process capability has been established 1

No 1
records are maintained for training but training needs
2
identification inline to skill matrix is not there

Scrap/rework analysis to be implemented, also for field

1
return parts
no 1
Such checking system is not there 2

Location and management of jigs/fixtures/tooling is there

2
but to be defined well

Status identification is not adequate 2

yes.but evidence required 3

Inprocess Audit is not there, only job set up verification is

2
there

Training need identification based on skill matrix yet to be

1
established

NO Preventive maintainence is there 1

no such system is there 1

Staff is competent but skill matrix yet to be defined 2

Not yet.System to be established 1

no 1

no 1

No control plan is available.Inspection is being carried out

2
and recording is there.Not adequate

No instructions for final verification 1

Formal indication of status is not there 2

yes but not adequate as quality status of

2
subcontractor/supplier is not included in approval process

List is there but periodic review not evident 3

requirements are documented but not adequate.No periodic
2
updation of requirements
no 1
no such system is there and analysis part is very weak 2
no such records at rework area 1
yes but corrective action programs are not adequate 3

yes but corrective action programs are not adequate 3

yes.but effectiveness monitoring is not there 2
no 1

Visual aids are there but not in all processes.to be improved 2

Root cause identification is there but statistical tools are not

3
used

yes.But 8-D methodology is not being used.Analysis part

3
needs improvement

Effectiveness monitoring is not there 1

No FIFO being followed 1
Specifications are there but written agreement with
2
customer is not there
No visual displays are there 1

Monitoring is there but no actions.Analysis part is missing 3

Un needed material observed at some places 3

Adequate storage is not there and labeling is not there 2
No proper storage /identification 2
Lighting enviornment is affected.But dust observed 3
not evident 2

System yet to be finalized 2

yes but no evidence 3

yes but lot of improvement required 3

yes but lot of improvement required 3
 Requirements

Respective departments KRA to be defined based on overall quality targets and

focussed action plan

WI inline to procedure for responsibility of incoming inspection to be made

available/displayed in receiving quality section
All materials to be included in inspection as per sampling plan and DOL items list to
be defined alongwith criteria for making items DOL(Direct on line)

Inspection Receiving inspection records to be maintained for all items (Except DOL
afetr defining DOL items list)
Written Inspection instructions to be provided in Receiving quality area
Formal indication of inspection status status in form of "OK"/"Rejected" tags/stickers
to be implement for 100% parts

All PO should be including Quality requirements like MTC etc. Including BOPs and
same to be verified during receiving of material

Raw materials identification to test reports need more improvement (By mentioning
Invoice No).Tracking with PO/Invoice to be implemented 100% and PO/Invoice no.
relation with physical material is to be there 100%
MTC to be verified against spec and same to be signed off and enclosed with
Inspection report

Storage procedure to be reviewed for load shift and package drop, which affect
quality damage of product

WI to be made adressing adequate protection of the product to prevent loss, damage,

deterioration, degradation and substitution

Material storage should be at defined location for all materials

FIFO implementation should be 100% in store and should be evident from storage
layout
Traceability to be defined and maintained for all materials

Critical and Significant characteristics to be identified on the control plans and

instruction sheets and to be appropriately monitored
Control plan to be made and updation frequency of all documents to be define in
system

Prototype check sheet to be developed and records for same to be maintained

Formal procedure is there but strict adherence is required for 100% cases

Data bank to be maintained based on field failures as lessons learnt/best practices

for new product/process design

Storage of gauges to be improved and gauges should be at designated locations

Calibration Procedure to be ammend for "actions taken in event of calibration failure"

Clear, concise work, controlled inspection and set-up instructions available at the
workarea but storage/display to be improve for tidiness

Procedure to be made for identification and approval of process parameters

demonstration, including acceptable operting ranges(max, min) for each parameter

Visual exhibits/samples for workmanship standard to be made available on lines

WI to be made for inspection and measurement

1) All special processes to be identified

2) Monitoring of special processes to be carried out

1) All all critical and significant features and process parameters to be defined in
Control Plan
2) Monitoring of critical/significant features/parametters to be done
3) Staff and inspection personnel to be trained to use Statistical process control
concept

Skill matrix of operators performing "special processes" to be defined

Training needs of operators performing "special processes" to be identified based on
skill matrix and record to be maintained

Scrap/rework analysis to be performed along with field return parts analysis and
continual improvement to be maintained
Rework methods to be documented after approval from concerned authority
Facilities, machines, equipment, jigs & fixtures and tooling to be checked and
recorded based on checking standards by designated responsible person, such as
operator, leader, Mfg. engineer.

Storing procedure for jigs & fixtures, tooling and inspection fixtures to be documented
and location to be designated and storage condition should be well maintained

Status of parts / material to be adequately identified / controlled at all times through

out the production process/storage by tags/stickers

Yes.But visual exhibits showing preventive measures for wrong part/mixing of part to
be displayed on line

Supervisory personnel to conduct periodical audit, in which he or she confirms if

operator comply work instructions, and record result of audit

Training need identification to be linked with skill matrix for persons performing
Critical operation

Preventive maintainence to be start for Line equipments/machines/tools

Break down records to be maintained and analyzed for taking corrective actions
Skill matrix to be formed for all staff members
Procedure to be made for quality checking of parts by quality person produced by M/c
after m/c /tools/jigs repair

History cards to be maintained for Machines and records should be available

History cards of Tools / Jigs / Fixtures to be maintained and records should be
available

Control plan to be made and based on CP , final sampling plan to be formulated to

assure shipment of acceptable products

Controlled final verification instructions to be used and they should be adequate to

ensure inspection and test are completed and in conformance
Formal indication of inspection status status in form of "OK" tags/stickers to be
implement for 100% parts

1) procedure to be made for sub contractor/supplier approval

2) Quality status/audit results should be main part of sub supplier approval

Suppliers review frequency to be defined and review to be performed as per defined

frequency
Requirements to sub contractors/suppliers should be including quality requirements
also and review frequency to be defined for these requirements
Supplier process audit to be scheduled and frequency of these audits to be defined
to ensure preventive recurrence measures for quality issues
Documented system to be formulated with defined responsibilities for review and
disposition of non conforming material
Reworked part's re-inspection records to be maintained

CAP's should be based on analysis carried out by using QC tools/Statistical tools

Containment actions effectiveness to be monitored

Quality tools to be used for addressing problems such as Why - Why analysis, 7 QC
tools etc.

Visual aids to be provided at all stations for judgement of state of abnormality by

operator

Root cause identification to be done by following systematic approach of problem

solving

8-D methodology to be used for CAP's

Effectiveness monitoring to be carried out for CAP's/8-D

FIFO to be ensure by means of dispatch layout plan in Dispatch area
Written agreements should be there with customer for packaging specifications
Graphics or photographs to be used to indicate correct and incorrect packaging
methods in dispatch area

Monitoring is there but no actions/analysis for delays.Target to be set for delivery

and action to be taken where unable to meet the target

Un needed material observed near production lines.Un needed material should not
be there near work area
Storage and labelling to be improved for frequently used objects
Jigs, fixtures, tools, equipment, & inventory should be properly identified and in their
correct locations
5-S to be maintained everywhere.Dust should not be there on windows
Improvement ideas to be generated regularly in form of kaizens etc.Same can be
linked to respective KRA's of various departments
System to be made for personnel to report any safety concerns or incidents including
near misses
Training records to be maintained

Proper safety labels to be utilized in all required areas

Un needed material removal from work place is required
Root Cause Analysis Corrective Action
Preventive Action Responsibility Target Date
Status Remarks
Back to Assessment Score
Assessment
MANAGEMENT CONTROL
5 4 3 2 1 Comments Score
Quality performance, such as customer concern, in process concern
1 and suppliers concern, are reviewed periodically and analyzed for O Yes.System is there for review of customer/supplier 4
taking corrective actions. concern monthly by means of MIS
Quality Target and Focused Actions Plan to achieve the target are
established, assigned to respective departments and periodically Quality targets as whole are there but Respective
2 reviewed based on quality performance and reflection of improvement O 2
department targets yet to be set for performance
activities. review.
6
Back to Assessment Score

Assessment
MATERIAL MANAGEMENT
5 4 3 2 1 Comments Score
Have the responsibilities for the control of incoming material been Yes.Responsibilities are defined in procedures.But
1 O 3
defined in procedures and instructions? Instructions yet to be displayed
Does the supplier inspect or otherwise verify purchased material prior Yes.Inspection and verification is there but not for all
2 O 3
to use? material
3 Is a sampling plan used and adequate? O Sampling plan is there and adequate 4
4 Are adequate Receiving inspection records maintained? O Receiving inspection recording yet to be improved 2
5 Are there adequate written inspection instructions provided? O Not provided 1
Does the supplier formally indicate inspection status of incoming Formal indication of inspection status yet to be
6 O 2
material / parts? established
Are purchase orders to suppliers reviewed for completness, quality
7 requirements and all applicable specifications including original testing O Yes.But verification of quality parameters such as 3
lab certifications prior to release? Material testing to be strengthened
Are raw materials identified and traceable to Test or certification Tracability scope to be defined for all materials, it is
8 O 2
reports? there only for critical parts
Does the supplier verify the contents of certification test reports against Verification is there but evidence by means of signing
9 O 2
the appropriate specification requirements? of report after checking to be established
Is Storage procedure to prevent load shift and package drop, which
10 affect quality damage of product, established and implemented? O Storage procedure/Work Instructions to be improved 2
for these parameters.
Are work instructions for material handling and storage available and in
11 use to assure adequate protection of the product to prevent loss, O 1
damage, deterioration, degradation and substitution? Work Instructions are not there
Is Materials and products storage location clearly identified and well Location is clearly defined and organised for small
12 O 3
organized? parts.For big boxes it is to be implemented
Is FIFO(First In First Out) concept implemented and storage location
13 layout considered to help its implementation. Are old lots observed? O 1
FIFO is not being maintained
Are shelf life, age sensitive and/or environmentally sensitive materials
14 O 4
identified and controlled? Yes
Does the quarantine area provide for the control and segregation of
15 O 4
non-conforming material ? Yes
Does the supplier’s material control system account for the number of
16 O 4
pieces manufactured, tested, scrapped and rejected? Yes

17 Is traceability maintained through all process operations, including any O Tracability scope to be defined for all materials, it is 2
subcontracted operations, to the finished components? there only for critical parts
43
Back to Assessment Score

PROCESS QUALITY PLANNING AND DESIGN & DEVELOPMENT Assessment

5 4 3 2 1 Comments Score
Are Critical and Significant characteristics identified on the control Critical characteristics are identified in drawings
1 O only.No control plan is avaialable and monitoring is 2
plans and instruction sheets and appropriately monitored?
not there

2 Are process changes incorporated in this documentation? O Process change are not incorporated as no changes 4
are there till now.But Change request system is there
Are Control Plan, Work Standards or Work Instructions, Special
Process Control Standards, Quality Check Sheets , Equipment Check
3 O 2
Sheets and so on periodically updated and the latest standards and
sheets are used? Control plan is not there.other sheets are updated
Are systems and procedures for designing and development
4 verification and control formally documented, maintained and controlled 0
including staff competencies? NA
Does the supplier has formal system for review and validation of design
5 0
input requirements? NA
6 Is supplier capable of prototype development? O yes.But no evidence/records 3
Does the supplier have a formal procedure for controlling design
7 O 3
changes including review and approval responsibilities? yes but system needs strict adherence
Are the drawings / specifications / process instructions in use by
8 Manufacturing and Inspection QC current and legible with no O 4
unauthorized changes? yes
No such data bank is maintained for new
9 Are field problems considered for New product and process design? O 1
product/process design
19
 Back to
Assessment score
Assessment
MEASURING INSTRUMENT CONTROL
5 4 3 2 1 Comments Score
Are gauges and test / inspection instrument maintained and adequately Instruments/gauges are maintained but storage
1 O 3
stored? needs improvement
Are gauges and test/ inspection equipment checked by a documented
2 O 4
system and are records maintained? Yes
2.a a. Item identity serial no. yes
2.b b. Date Calibrated / Inspected yes
2.c c. Date due for Calibration / inspection yes
2.d d. Initial or stamp of person performing calibration / inspection yes
3 Is calibration frequency for equipment and standards adequate? O yes 4
Are there Master reference standard available for calibration of
4 electrical and mechanical equipment or if standard are not available is O 4
there an acceptable calibration? yes
Are all Master reference standards certified traceable to national
5 O 4
standards? yes
Are controls in place to assure actions are taken in the event of
6 O 2
calibration faliure? No. As such actions are not documented/analysed
7 Does the supplier outsources calibration through NABL Accredited O 4
laboratories? yes
25
Back to Assessment Score

Assessment
IN PROCESS CONTROL 5 4 3 2 1 Comments Score
1 Are clear, concise work, controlled inspection and set-up instructions O 3
available at the workarea? Instructions are there but not tidy
Are these instructions in vernacular language and does the operator
2 O Instructions are in vernacular language and operator 4
understand them?
understanding is there but not maintained

3 Is identification and approval of process parameters demonstrated, O 3

including acceptable operting ranges(max, min) for each parameter Procedure is not evident although approval of
defined? Is there a procedure for this and followed? process parameters is there
4 Are workmanship standards available in the form of controlled written O standards are available but Visual Exhibits /samples 3
standards, visual exhibits and / or samples? (Visual Display) needs focus
5 Are inspections and measurements being performed according to the O 1
instructions? Work Instructions for measurement are not there
Does the supplier inspect material at key points of the production
6 O 4
process in all shifts prior to movement to next operation? yes.
Are adequate records of inspection maintained and available at work
7 O 4
area? yes.
Are manufacturing conditions monitored and recorded for special
8 processes like welding/heat treatment / plating/ O 1
painting/casting/forging/gluing/pressing in / riveting? no such montoring for special processes is there
Has process capability been established for all critical and significant
9 O 1
features and process parameters? No Process capability has been established
Is process capability monitored, and are all process records and charts
10 O 1
current and correctly completed? No Process capability has been established
Are staff and inspection personnel sufficiently trained to utilize the
11 O 1
statistical process control concept? No Process capability has been established
12 Are skill matrix for operators of “special processes” defined? O No 1

13 Are training needs identified as per skill matrix for operators performing O records are maintained for training but training needs 2
special process and records of training maintained? identification inline to skill matrix is not there
Are causes of scrap/rework analysed and CAPs formulated and Scrap/rework analysis to be implemented, also for
14 O 1
implemented? field return parts
15 Are rework methods documented and approved? O no 1
Is there evidence of effective communication across shifts; i.e.
16 0
logbooks, departmental meetings? NA
Are Facilities, machines, equipment, jigs & fixtures and tooling
checked and recorded based on checking standards by designated
17 responsible person, such as operator, leader, Mfg. engineer. O 2
Such checking system is not there
Are Storing procedure for jigs & fixtures, tooling and inspection fixtures
18 documented and location are designated and storage condition well O Location and management of jigs/fixtures/tooling is 2
maintained? there but to be defined well
Is the status of parts / material adequately identified / controlled at all
19 O 2
times through out the production process? Status identification is not adequate
Is Preventive measure for mixed parts and wrong parts to occur
20 O 3
implemented at each manufacturing process? yes.but evidence required
Do Supervisory personnel conducts periodical audit, in which he or she
21 confirms if operator comply work instructions, and record result of O Inprocess Audit is not there, only job set up 2
audit? verification is there

22 How is training need identification linked with skill matrix for persons O Training need identification based on skill matrix yet 1
performing Critical operations and if that skill level been achieved. to be established
How Regular and Preventive Maintenance activities are scheduled and
23 O 1
implemented. NO Preventive maintainence is there
Are breakdown records maintained and analysed? Are Corrective
24 O 1
action taken based on analysis? no such system is there
25 What is competency of staff performing Preventive maintenance? O Staff is competent but skill matrix yet to be defined 2
Is there Procedure for quality checking after repair and is it
26 O 1
implemented and records maintained. Not yet.System to be established
27 Are History cards of Machines maintained and records available? O no 1
Are History cards of Tools / Jigs / Fixtures maintained and records
28 O 1
available? no
Is final verification performed by / or under the surveillance of Quality
29 O 4
Assurance? yes.
When Sampling is used in final verification, are there formal sampling
30 plans and are they adequate to assure shipment of acceptable O No control plan is available.Inspection is being 2
products? carried out and recording is there.Not adequate
Are controlled final verification instructions used and are they adequate
31 to ensure inspection and test are completed and in conformance? O 1
No instructions for final verification
Are controlled customer drawings / specifications readily available and
32 O 4
used in final test? yes.
33 Does the supplier formally indicate inspection status of parts? O Formal indication of status is not there 2
34 Are adequate records maintained? O yes. 4
35 Does the supplier have sufficient inspection / test equipment? O yes. 4
Is final testing conducted on electrical, electro-mechanical and other
36 O 4
critical operating assemblies? yes.
37 Does the process output meet INDUS schedule requirements? O yes. 4
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Assessment
SUB CONTRACTOR CONTROL
5 4 3 2 1 Comments Score
yes but not adequate as quality status of
1 Does supplier has method of subcontractor approval? O subcontractor/supplier is not included in approval 2
process
Is current list of approved suppliers maintained. Is this list reviewed
2 O 3
periodically and latest list avaiable? List is there but periodic review not evident
Are requirements for subcontractor documented and distributed? Are requirements are documented but not adequate.No
3 O 2
these updated periodically? periodic updation of requirements
Is scheduled process audit implemented to confirm subcontractor's
4 O 1
preventive recurrence measures for quality issues?
no
Do the supplier's procurement procedures contain requirements that
5 assure timely and effective corrective action responses from their O 4
subcontractors? yes
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Assessment
CONTROL ON NON CONFORMING PRODUCT 5 4 3 2 1 Comments Score
Is there a documented system with defined responsibilities for review no such system is there and analysis part is very
1 O 2
and disposition of non conforming material? weak
2 Is non conforming material sufficiently identified? O yes. 4
3 Is non conforming material segregated at all stages? O yes. 4
4 Are adequate records maintained? O yes. 4
5 Do records show that reworked parts / material are re-inspected? O no such records at rework area 1
6 Is scrap material identified and segregated? O yes. 4
7 If remanufactured / reprocessed material is used or provided is there 0
adequate identification and checking to specifications? NA
8 Are there adequate corrective action programs implemented for the O 3
suppliers purchased material? yes but corrective action programs are not adequate
Are there adequate corrective action programs implemented for
9 O 3
suppliers own manufactured parts? yes but corrective action programs are not adequate
10 O 2
Are containment actions implemented and effective where necessary? yes.but effectiveness monitoring is not there
Are Quality tools used for addressing problems identified such as Why
11 O 1
- Why analysis, 7 QC tools etc. ? no
Is definition of abnormality state documented and operator provided
12 with visual aids for judgment of abnormality by control points O Visual aids are there but not in all processes.to be 2
illustrations particularly for critical process? improved

13 Are customer reported faliures investigated and information relayed to O 4

the suppliers design / production area for corrective action? yes.

14 Does the supplier identify root cause and take adequate corrective O root cause identification is there but statistical tools 3
action to prevent recurrence of reported faliures and quality problems? are not used
15 Does the supplier notify customer of the corrective action taken? O yes 4
Do all instances of non-conforming material reported have concern
16 reports issued and CAPs raised against them. Is 8D methodology O yes.But 8-D methodology is not being used.Analysis 3
adopted for addressing Non conformity? part needs improvement
17 Are CAPs/8D monitored for effectivenss and have any repeat concerns O 1
been reported in 12 months of implementation? Effectiveness monitoring is not there
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Assessment
FINAL PRODUCT HANDLING - Packing and Despatch 5 4 3 2 1 Comments Score
1 Is FIFO followed in finished goods dispatch ? O No FIFO being followed 1
2 Are packaging specification/guidelines available to the workforce as O Specifications are there but written agreement with 2
agreed with the customer customer is not there
3 Do these specifications make use of graphics or photographs to O 1
indicate correct and incorrect packaging methods? No visual displays are there
4 Are the packaging materials adequately protected against deterioration O 4
before use? yes
5 Is the method of transit documented and agreed to by the shipping O 4
contractor? yes
Are the freight optimization techniques practiced and space utilization
6 factor on lorries/ trucks monitored regularly for efficiency O 4
improvement ? yes
Does the logistics team have system of planning and monitoring
7 movement of supplied material to ensure delivery on time without delay O monitoring is there but no actions.Analysis part is 3
? missing
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Assessment
5S 5 4 3 2 1 Comments Score
1 Are there any unneeded materials lying nearby workplace? O Un needed material observed at some places 3
Are all frequently used objects sorted, arranged, stored and labeled? Adequate storage is not there and labeling is not
2 O 2
there
3 O 4
Are aisle/walk ways and workstations clearly marked and identified? yes
Are jigs, fixtures, tools, equipment, & inventory properly identified and
4 O 2
in their correct locations? no proper storage /identification
Are equipment and work station kept clean and free of oil, grease and
5 O 4
debris? yes
Is the lighting environment affected? Any dirty light bulbs or windows?
6 O 3
lighting enviornment is affected.But dust observed
7 Are display boards used, organized, current and tidy? O yes 4
Are trash bins and scrap/recycle containers emptied on a regular
8 O 4
basis? yes
Are improvement ideas regularly being generated and acted upon?
9 O 2
not evident
10 Is the 5S program discussed at Key personal Meetings? O yes 4
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Assessment
ENVIRONMENT, HEALTH AND SAFETY 5 4 3 2 1 Comments Score
How all staff are made aware of requirements of Environment, Health
1 O 4
and safety. By means of timely trainings
2 Does factory has proper mechanism of disposal of hazardous material O 4
yes.through govt. approved agencies
Is adequate importance given to safety of man and machinery in the
3 O 4
factory? yes
Is there a system in place for personnel to report any safety concerns
4 O 2
or incidents including near misses? system yet to be finalized
Are Personal trained in proper selection, use and maintenance of
5 O 3
Personal protective equipments ? yes but no evidence
Are proper safety labels being utilized ? (aisle ways, extinguishers,
6 O 3
hazard warnings, etc) yes but lot of improvement required
7 Are work area clean, organized and free from hazards ? O 3
yes but lot of improvement required
8 Does factory has emergency handling kit O yes 4
9 Are adequate fire fighting equipments installed ? O yes 4
31