DEPTT:

QAPI DIV/QAPIS, QAPI-G1, QAPI-

CONTROL REGISTER FOR DEPARTMENTAL PROCEDURES G2,QAPI-G3,QAPI-M1,QAPI-M2,QAPI-
M3,QAPI-E1,QAPI-E2,QA-MA
CONTROL. MERGED/
S.NO. WORK AREA TITLE ENACTED ON REVISION STATUS
NO. ABOLISHED ON
1
PROCEDURE FOR NEW/ MINOR MODEL PARTS
1 QAPI-001 All QAPI DEPARTMENTS 1/6/2013
APPROVAL

2 QAPI-002 All QAPI DEPARTMENTS PROCEDURE FOR SAMPLE EVALUATION 1/6/2013

3 QAPI-003 All QAPI DEPARTMENTS PROCEDURE FOR PROCESS CONTROL STANDARD 1/6/2013

4 QAPI-004 All QAPI DEPARTMENTS PROCEDURE FOR APPROVAL OF MIS-P 1/6/2013

5 QAPI-005 All QAPI DEPARTMENTS PROCEDURE FOR LIMIT SAMPLES 1/6/2013

6 QAPI-006 All QAPI DEPARTMENTS PROCEDURE FOR PROCESS AUDIT 1/6/2013 4/8/2014

7 QAPI-007 All QAPI DEPARTMENTS PROCEDURE FOR ENGINEERING CHANGE NOTICE 1/6/2013

8 QAPI-008 All QAPI DEPARTMENTS PROCEDURE FOR QIR/DIR REPLY 1/6/2013

9 QAPI-09 All QAPI DEPARTMENTS PROCEDURE FOR INTERNAL COMMUNICATION 1/6/2013

10 QAPI-010 All QAPI DEPARTMENTS PROCEDURE FOR TRAINING OF NEW MEMBERS 1/6/2013

11 QAPI-011 All QAPI DEPARTMENTS PROCEDURE FOR SKILL MATRIX 1/6/2013

1
PROCEDURE FOR PPVT (PEAK PRODUCTION
12 QAPI-012 All QAPI DEPARTMENTS 1/6/2013
VERIFICATION TRIAL)

13 QAPI-013 All QAPI DEPARTMENTS PROCEDURE FOR DEFECT PUNCHING 1/6/2013

14 QAPI-014 All QAPI DEPARTMENTS PROCEDURE FOR SMIR VERIFICATION 1/6/2013

15 QAPI-015 All QAPI DEPARTMENTS PROCEDURE FOR REVALIDATION ACITIVITY 4/8/2014

 ANNEXURE - 3

GUIDELINES FOR INSPECTION OF MINIMUM NO.OF PARTS

S.NO ITEM NO.TO BE INSPECTED

1 Dimensional Inspection 3 (1 no./ cavity)

2 Plating Thickness, Welding Penetration, 1

Heat Treatment

3 Rubber / Plastics / Glass/ 1

Metals (Specimens)

4 Mechanical Properties 1

5 Salt Spray / Ozone Resistance / 1

Weatherometer

NOTE: Where vendor inspection report for 3 parts is available, inspection of one part
may be considered sufficient, by QAPI.

If facilities for inspection are not available, vendor inspection report can be
considered for disposition.
 ANNEXURE - 1

GUIDELINES FOR INSPECTION OF MINIMUM NO.OF PARTS

S.NO ITEM NO.TO BE INSPECTED

1 Dimensional Inspection 3 (1 no./ cavity)

2 Plating Thickness, Welding Penetration, 1

Heat Treatment

3 Rubber / Plastics / Glass/ 1

Metals (Specimens)

4 Mechanical Properties 1

5 Salt Spray / Ozone Resistance / 1

Weatherometer

NOTE: Where vendor inspection report for 3 parts is available, inspection of one part
may be considered sufficient, by QAPI.

If facilities for inspection are not available, vendor inspection report can be
considered for disposition.
 Process Audit Report
Part No. Part Name A /F/G Supplier Name Vendor person (s) Date:

A. AUDIT PREPARATION
Identify Critical to Quality parameters ( Drawing study and discussion Understand vendors inspection plan (Study MIS - P, PCS ) 0
with Engineering) . Besides dimension also consider items like chamfer,
burr scratches etc.

List past problems & their C/M (study defect history)

B. PROCESS SPECIFIC CHECK POINTS (Mark O , X or - )

Stamping Forging Machining Surface Treatment

Sheet thinning - Forging & Quenching crack - Coolant flow - Shelf life of chemicals /paint -
wrinkles - Temp control - Mixture of coolant - Check for ELV' compliance -
tool marks - Flaws & Scales - Improper surface finish - Mix-up of Cr+6 & Cr+3 -
burrs - Incomplete forging optn - Tool/chattering - Welding/Brazing
Casting MPI - Cp/Cpk study(critical) - Current shunting -
Blow holes, shrinkage - Minimum wall thickness - Assy Parts Correct robotic programme -
Crack - Plastic & Rubber Sequence of Assy(child parts) O Wheel/electrode alignment -
Incomplete filling, cold shuts - Storage & Shelf life of R/M - Part miss O Nugget dia -
X- Ray - Colour - Mix up of child parts O Spot pitch / no of spot -
min wall thickness - Mixing operation - wrong Assy O Spot indentation -
Heat Treatment Preheating - Incomplete operation O Under cut/bead offset -
Temp, time & pressure control - Torque check - Incomplete welding -
Sample selection (corner/centre) -
Gate cutting & weld line - Contamination O Puncture/Burr -
Daily check - Short moulding /appearance points - Adhesive application Weld penetration (5 items) -
Check method - Baking / post moulding treatment. - Storage and shelf life -
Check location - Proper mixing -
Weighing of chemicals & process Oils -
Heat Treatment parameters - Uniform application - _
Test Piece storage - Is pressing consistent? -
Is curing time ensured? -
Process Specific NG points Actionable points / NG observations Target Date Second Audit

C. Process audit report as per PCS. (Actual observations to be recorded for all process and product parameters on the PCS sheet). Please note NG below. Add annexure if required.

Sno PCS- Specific NG points Actionable points / NG observations Target Date Second Audit

_ _ _ _

D. RAW MATERIAL & SUB VENDOR CONTROLS

Sub. Contents O X Observation. Also action in case of NG. Target Date Second Audit

Check if R/M, BOP & Consumable sources are as per vendor

a _ _ _
declaration?

Check for completion of sample approval of BOPs.(For critical parts,

b _ _ _
also check if Tier 1 has verified the Tier 2 PCS.).

Is incoming inspection adequate.

R/M & Sub Vendor Control

c _ _ _
(Availability of C/F, inspection standard & adequacy of frequency)

d Check for rejection level in incoming supplies and containment. _ _ _

Identify critical Tier 2 vendor and New Tier 2 vendor along with
e _ _ _
Tier 1 and audit them along with Tier 1.

Check the condition of the parts being sent & received from tier-2
f (covering the job work sources too) : _ _ _
1. Packing condition
2. Rust / contamination presence
3. Lot traceability
E. PROCESS CHECK (Ask vendor to demonstrate operation & judge the following).

For first time vendor/ first time process- confirm difference point wrt
a _ _
mother plant and identify concerns.

Check for availability of experts from mother plant at SOP upto 3

b _ _
months from SOP.

Check for availability of rule to deal with parts produced at time of

c abnormal production stoppage- like power supply disruption, welding _ _
wire finishing, machine breakdown.

Check for availability of rule to deal with parts produced at time of

d _ _
planned stoppage - shift change, lunch.

Check clarity of operation standard & correctness of display location.

e _ _
( Simple and pictorial)

Are all CTQ parameters identified. Are there special checks for all
f _ _
these parameters.
Process Controls

Check Tool ,Fixture,& work flow for possibility of

1. child part miss , operation miss
g 2. wrong part _ _
3. wrong placement
4 part mix up.
If Part or Weld miss is possible, add inspection stage (Confirm that
h _ _
inspector is marking on top of check item )

i Check for ease of operation at each station . _ _

j Check possibility of unauthorised tampering of process parameters _ _

Where Poka yokes are installed, confirm working condition as well

k _ _
as effectiveness (logic).Also check who has authority to bypass

Is method of monitoring, regrind & change of tool / inserts /

l _ _
electrode, adequate

In case of batch production, check for bin stage identification & bin
m _ _
location control & WIP storage condition.

n Check for storage condition of finished parts _ _

Are inspection methods available, clearly defined and being

o _ _
followed.
Inspection

Are inspection instruments & gauges available ( Limit sample for

p _ _
appearance defects). Are they calibrated.

Have the checkpoints of EOL (End of Line) tester been selected on

q _ _
the basis of potential problems.

Confirm (by questioning) the capability of the person responsible for

Operators

daily setup.
skills

a _ _
For available operators check knowledge of operation, tool change
& inspection

a How are NG parts separated and disposed to avoid mix-up _ _

Disposal of NG parts

b How are initial setup part confirmed & disposed. _ _

c How are pre-ECN parts disposal done and confirmed. _ _

Check records for control of rework & rejection.

d _ _
Are rework and rejected parts clearly identified and separated.
Special check for Maru A / critical parts

a Are Maru A stations identified, Operators fixed and trained. _ _

b Are inspectors identified, fixed and trained. _ _

Confirm awareness of operator and inspectors about implications of

c _ _
defect.

d Confirm availability of traceability .and FIFO _ _

Cut open
analysis

Cut open one Assembly and confirm condition of all child parts. Also
a _ _
check condition of inside bores where seals slide.

Inspect one part yourself for critical parameters. _ _

Critical items during 1st. process audit DPM Comments

Signature

Person I/C
Sect. Mgr.
DPM
Confirmation of countermeasure during 2nd visit Person I/C Section Mgr. DPM

PIGA-316/01
COPY TO DIVISIONAL PROCEDURE PAGE NO. 1/2

ISSUE Title: ALL QAPI

QAPIS 1/6/2013 DEPARTMENT
DATE DEPARTMENTS
PROCEDURE FOR DEFECT
ISSUE
QAPI-G NO 1 CONTROL CONTROL NO. QAPI - 008

1.0 OBJECTIVE :
QAPI-M

1.1 The objective of this procedure is to lay down the guidelines for the actions related to control of
QAPI-E
defects in newly developed parts reported at MSIL .

2.0 SCOPE OF APPLICATION :

2.1 This procedure is applicable to all newly developed components (approved by QAPI) supplied by
vendor directly to MSIL (upto one month after SOP).

2.2 This procedure shall not be applicable for Consumables, Semi Finished Parts, Raw Materials
& Spares.

3.0 CONTROLLING SECTION :

3.1 All sections of QAPI Departments.

4.0 OPERATION PROCEDURE :

4.1 Information regarding the defects is captured in central database including the relevant fields of:

a) Model
b) Details of Defect
c) Vendor Name
d) Part Name
e) Reported from (Origin of Defect)

4.2 Information regarding defect occurrence at MSIL , shall be collected / reported from following : -
a) Production Shops ( Weld, Paint , Assy, Engg. Assy ) & Vehicle Inspection Dept.
b) From special quality check on new models by QA (if any).

4.3 The defects shall be attributed to Vendor only after analysis, in principle. It needs to be confirmed
that the defect has not occurred due any of the reasons as given below :

a) Improper handling / storage in MSIL

b) Improper usage / fitment at MSIL
c) Pre modified parts used after implementation of ECN
APPROVED BY

4.4 The investigation & analysis for defects shall be completed within five working days and necessary
corrective action shall be taken.

S.NO. REVISION RECORD DATE SIGN.

VERIFIED BY
PREPARED BY

M101-3 QS/QS 1
 PAGE NO 2/2

4.5 QPCR is raised for vendor defect which meets the guidelines for QPCR.
COPY TO DIVISIONAL PROCEDURE PAGE NO. 1/2

ISSUE Title:
QAPIS DATE
16/2/2015 DEPARTMENT QAPIS

PROCEDURE FOR CLOSE MONITORING OF

ISSUE
QAPI-G NO 0 NEW VENDOR/POST SOP LOCALISATION CONTROL NO. QAPI - 018

1.0 OBJECTIVE :
QAPI-M

1.1 To have close monitoring of new introduced vendors or Post SOP Localisation in quality system
QAPI-ME

2.0 SCOPE OF APPLICATION :

2.1 Applicable to all vendors/parts developed in recent past(3 months or less)

3.0 CONTROLLING SECTIONS :

3.1 QAPIS

4.0 OPERATION PROCEDURE :

4.1 Old Vendor and New Part

4.11 The reciept status of all newly developed parts to be made NDC by default and all SRV's to be confirmed by QAPI for first 3 months.

4.12 Defect monitoring system to include a drop down for newly developed vendor (Y/N) in order to monitor for first three months after implementation
Implementation date to be fed in the system while punching the defect

4.2 New Vendor and New Parts

4.21 The reciept status of all newly developed parts to be made NDC by default and all SRV's to be confirmed by QAPI for first 3 months.

4.22 Regular process audits for first six months (part specific) and closing audits after six months.

APPROVED BY

VERIFIED BY

PREPARED BY
COPY TO DIVISIONAL PROCEDURE PAGE NO. 1/2
ISSUE Title:
QAPIS 12/2/2015 DEPARTMENT QAPIS
DATE
PROCEDURE FOR ACTIVITIES
ISSUE
QAPI-G 0 CONTROLLING PART DEVELOPMENT CONTROL NO.
NO

QAPI-M

QAPI-ME 0 OBJECTIVE :
0.1 This stipulates a procedure for controlling the activities related to the development of parts, it includes design and
of product and process. It's objective is to ensure the smooth flow of activities related to introduction of part at the desired
Quality levels and as per the desired time schedules

1 SCOPE OF APPLICATION :

1.1 This procedure shall be applicable to all new models

2 Below mentioned activities to be initiated at various stages of development

2.1 After DP Trial and before PP Trial

2.11 Tech Review: Concerned member of selected vendor, MSIL supply chain, MSIL Engineering

and MSIL QAPI(if required) participate in Tech Review. Controling department is MSIL Engineering

2.12 Spec Meeting: QAPI to participate in spec meeting alongwith MSIL Engineering and Supply Chain

Following points ensured in spec meeting

1. Implementation of counter measure for problems reported in similar parts in past.

2. Checking fixture and testing requirement.

3. Details of raw Material and child part source

2.2 After PP Trial and before MPT Trial

2.21 Tool/Mold Trials: QAPI to identify parts for which QAPI to participate in tool trial.

Selection Critieria: Parts decieded as per to DPM descrition of concerned QAPI Department.

2.22 Tool Buy Off: QAPI to identify parts for which QAPI to participate in tool buy off.

Selection Critieria: Parts decieded as per to DPM descrition of concerned QAPI Department.

APPROVED BY 2.23 PCS Verification: QAPI to conduct the process verification as per to PCS of uncommon parts.

Selection Critieria: All Maru A, Functional and General Parts.

2.24 Process Audit: QAPI to conduct the Process Audit alongwith concerned members of engineering to identify critical parameters

Selection Critieria: All Maru A parts; All Functional and General part with new technology, new vendor and past problems.

2.3 After MPT Trial and before Pilot Trial

2.31 Tier 2 Part Check and Process Audit: QAPI to conduct the child part checking and process audit of parts.
Selection Criteria:
1. First Time T2 Vendor
2. New Type of Parts
3. New T1 Parts

VERIFIED BY
PREPARED BY
COPY TO DIVISIONAL PROCEDURE PAGE NO. 2/2

ISSUE Title:
QAPIS 12/2/2015 DEPARTMENT QAPIS
DATE
PROCEDURE FOR DIVISIONAL
ISSUE REPORTING
QAPI-G 0 CONTROL NO.
NO

QAPI-M

2.32 Common Part Revalidation: Parts Common with running models to be revalidated
QAPI-ME
Parts Selection Criteria:

1. All Maru A Parts

2. All Functional Parts with past problems

3. All General Parts with past problems

2.33 Process Audit: QAPI to conduct special audit at vendor end alongwith concerned member of MSIL Engineering in

order to identify critical to quality parameters and check the process accordingly

2.4 After Pilot Trial and before SOP

2.41 Peak Production Volume Trial: QAPI to conduct PPVT as per procedure format no. QAPI - 012 at vendor end along

with concerned member of MSIL Supply chain

2.42 Uncommon Part Revalidation:Uncommon Parts as per following selection criteria to be revalidated

Criteria for part selection:

1. All Maru A parts

2. All Functional and general parts with new vendors, new technology or old vendor with new parts.

2.5 After SOP

2.51 Initial Flow Control: QAPI to ensure IFC implementation at vendor end for period as per following criteria:

1. Intial 1500 Parts or 3 months whichever is later

Audit Verification to be done as per following criteria

1. 2 Times for A/F/Problematic parts and 1 Time for rest all parts
2.52 SND Vehicle Check for delayed failure: QAPI to check SND vehicles for delayed failure as per defect checklist based on

APPROVED BY
past experience for first 6 months after SOP. (Checklist may very as per season and type of parts)

Note: Problem root cause identification and countermeasure confirmation audits will be conducted
where ever applicable

VERIFIED BY

PREPARED BY
 PAGE NO.
1/6

ENACTMENT REGULATION
DATE PROCEDURE FOR CLASSIFICATION NO.
DEVELOPMENT ENACTMENT
LATEST OF NEW PART DEPARTMENT
REVISION CONTROLLING
DATE DEPARTMENT

0.0 OBJECTIVE :

0.1 This stipulates a procedure for controlling the activities related to the
development of parts it includes design and development of
of parts and prototypes, production preparation, trial production and
actions related to the stablisation of product and process. It's objective is to
ensure the smooth flow of activities related to introduction of part
at the desired Quality levels and as per the desired time schedules

1.0 SCOPE OF APPLICATION :

1.1 This procedure shall be applicable to the new and parts under development

2 Below mentioned activities to be done at various stages

2.1 After DP Trial and before PP Trial

2.11 Tech Review: Concerned member of selected vendor, MSIL supply chain, MSIL Engineering
and MSIL QAPI(if needed) participate in Tech Review. Controling department is MSIL Engineering

2.12 Spec Meeting: Spec drawing released ,time lines and quality requirements are studied and
actions decided amongst concerned member of selected vendor, MSIL supply chain,
MSIL Engineering and MSIL QAPI .Controling department is MSIL Engineering

2.2 After PP Trial and before MPT Trial

2.21 Tool/Mold Trials: Mold Trials are conducted at vendor/tool makers end along with concerned
member of MSIL QAPI and Engineeing
2.22 Tool Buy Off: MSIL Engineering, Supply chain and QAPI participate in tool buy off activity after
final OK trial sample reciept
2.23 Common Part Revalidation: Parts Common with any other developed model to be revalidated.
Criteria for Part Selection in revalidation: All Maru A, Functional Parts and General Parts with past
problems.

2.3 After MPT Trial and before Pilot Trial

2.31 Uncommon Parts Revalidation:Uncommon Parts as per following selection criteria to be revalidated.
Criteria for part selection in uncommon part revalidation activity: All Maru A Components ;
All functional and general parts with new vendor, new technology, old vendor with new part,
critical past problem and frequent past problem parts.
 PAGE NO.

2/6

2.4 After Pilot Trial and before SOP Trial

2.41 Peak Production Volume Trial: PPVT to be conducted at vendor end along with concerned
member of MSIL supply chain and QAPI

2.42 Uncommon Part Revalidation:Uncommon Parts pending for revalidation actiivity must be
revalidated in this stage
2.43 Special Audit: Special process audit along with concerned member of MSIL engineering
and QAPI to be done at vendor end to identify the ciritical to quality parameter and check
the process accordingly

2.5 After SOP Trial

2.51 Initial Flow Control implementation at vendor end

2.52 SND Vehicle Check for delayed failure

2.53 Uncommon Parts revalidation

2.54 Process Audit for critical parts problem

Note: Problem root cause identification and countermeasure confirmation audits will be conducted
where ever applicable