<> MARUTI SUZUKI VENDOR QUALITY ASSURANCE MANUAL Third Edition COPYRIGHT MARUTI SUZUK! INDIA LIMITED. All ighis roserved, “Aline proves tain sents nalecel Popes sed py MARUTI SUZUKI INDIA LIMITED (Quality Assurance Business Vertical$ manuTi suzuKt PREFACE Incian automat industry pasting though » cra pata of tranelormation, Wah wer ineraecing Ssonstviy cf customers towarés prerict Quay. ireclustien cf reser sataly and omission reguletions and erlootien ot newer teshrolegies, the noes! he hours to nospert and uparace eur aay Systm 50 that we are always alle ta lie upto custeener expectations. Al then sal oF AS Quay requcenents need tae fate noun Ven Oval Rsneee Manual Wilh thie objoctiv, tia revised edt of Vendo: Quully Assurance Manus” bing brought out ‘emphasizes MSIL noreasod oxnnctationsragering Quay Assurance Sjsteme fom ks sono partners infine wth the curent and future bushess ness. Imajerly coets important aspects toate to prncoss Donte. ewer canto, change management, traceabiliy, and complarce to regulations ‘The actos discussed inthis manual form a part of he requiernts thal haus oe fille bythe vendors lo provide ths assuranes hal Qualy of Producisisbeing consislerlly deleted SIL requasteallverdov Ib ulive the marual awa guida and move lagether on tha path of coin inprovemont. tus fuliling ur quest of ping high Quality prasuctsto cssomors. Also. all onvovs ar Fegiuested ta extond tho roquromonts proscribed in this manul te their supers fo ensure that Quay iscconsistert thmughout the supply chain ‘The journey to Zero Defect il equirs high level o eam work, coramiment and engagement ard ve recquesl ha supper! of cur vendor prinarin this endaevor by ersaing 100 percent adherence the reqquremenis cf his marualin lla and spi \ Z Suniro oe 7.SUMINO D.K. SETH! Senor Adhisor Bact Advisor (uty Assurance) (Guay Assurance) MARUTI SUZUKI INDIA LIMITED CGuality Assurance Business Yerical ‘VENOSROUALV ASSIEANCE NANA iINTRODUCTION CHAPTER 1INTRODUCTION marnun suzuKi INTRODUCTION 40 “The purpose ofthis mnarual i 10 explain ths expectations and requcsnsits of Maruti Suzuki Ine Lititad {HSI} fromm ila vendors in delivering Gunliy products and alsning higher val of Quality by dong coutinsal mprowmeant 12 13 1.34 492 13a “The bani raquitenants of MBIL are define Gf key weds abe pao boi um mcrisod inthis chaptot. Th2e9 woul halp andor in ooneictng Cast Aesurarca action aczording tothe oolanation given in each chapkor ofthis maria The besio Quality opaotietion of tho pate purstaood by NIL from verde challbe dine through ene ar note athe flloving documents 18) Standards, Drawings, Specitcaions. Mutually agreed standards, in assordanse with ths ‘manual snd or any elles decursenl ada by MSIL ned provided tothe wenden by Drawings, spouifictions and decunarts mada i accunlaies with this manual and ast focumante mad by tha wandore and eppraved by MSL, 19) National or International standards auch a9 I, JIS, JAGO, EAE ete, which ove mainly secertntla to tha verve ane MSIL (in sich casa where tems manfianed ins & bl ar ‘et ailable but National! Interiatonalslandards are ville, “The lataetversien cf the manual can bo obtain tm MSIL'e Vendo Exerst of Cnovis, Definitions of words and phrases used by MSIL, ® Symbok: is reoncunesl as’ Maru. Ihe word MARU Japanese language moans circle, [hus Man (or Iterally Circe A) means the letior A, wkich iste rst alphabet ercled to omahasiae itpenanes, This NAPLI A eybolves samahirg wich fell irl nihe orderal impotence GIL ves this synbel lo designate oaely fis easton, whic indeed must be out fat land feremodt cence. In othor words, MARU. pats are euch, wlichif ductive ean pos a gree dangsr andsafsly hazard toocapants and padastians causng accdensand fa Jeopardizng hunan ives. Part “2 pat isdeined as , frase pats andl components which are eszential forthe safe operation of etieles under rormal use, and ¥ dafoctive, could rseut in ineients of personal nny of fatality by casing bss of vliels central of, & tom: 1 hums aottese Qually charactors off pa. which detect, coukl sul in nc ksanes ‘of persanal injury er taay by causing loos ef vohisioscortrolor fre ‘VENDOR SUALITY ASSURANCE VANUAL a$ manun suze INTRODUCTION Functional Part: Furtional pars are defn as those parts and components ol ths engine abd transmission ‘yhich, i detective, could resuh ina redusten or atatal ess of vehicle metive poser and per forrrance, Funotional Item: {A functional lam is dafinal ne 2 Qunity characte functional pats which, faction, ‘oul resul ina todution ot tual lass of vahici motive powal and perfomance Goneral Parte: ‘All the other pavte ofa vohicte, wich are nether, nor Tanational, au celled gonad paws ot Parts: Petts which are having backend traceability re denoted by +r symtl. 1B) Precass: Promos haying Poker arednoted by synbol ‘Quality Assurance of Parts: NSIU's Qualty Assurance systom fer bought out pats hae bron oxplainod with the help of allow shart which f alvon m pages 7-11. Yenders aro requied to pla & premacte Quality Assuranoe acivivasior MSL parts wba thelr onpenies ater theroughly understanding We ven ow of weve stall nga of aps ifs oye 1s Documents to be submitted to MSIL: Various decumerts need io ba submitid by the vendors to MSIL a diferent stages, as ‘erdanea of Cally Aecutanes acvlles. Theve dociments ata quan in Teblet.1 Vanots fre rise to foto this char. For details of each ofthe dacuments rexpoctve chapters of ‘hia menial uo Ye be tofored 18 Nate: 47 Model Codes: Nodal coda used by MSIL for ts products shall be provided to is venders by vespacive Engnovrng deperunents c€m31L ‘Salus of part .@, 0), Funelonal or Genital or ne developments shall be intr duis hes speiicaion wag by MSIL, For pats away under supply, clarifications (Wary) may bo ssught rom RISILs Parte Quaity apartment (novoinafter called ae NISIL's APO) for A 4 Funetonal pate tems. Vendor Acknowledgement ‘Ventor Top Management (SEO) shall submit he below signed acknowlestgement document to NIL (efer Fomat-t1),INTRODUCTION MARUTI SUZUKI ‘Vendor Acknowledgment: Wo huroby unertake. declare and corm 4+ That wohaworoceland urderstecl tha Vondar Cuslty Assurance Manual (YOM) andagioa ‘omect horeeuitementsmersionet therein andto deliver aly rede o Barn Suzuki India ire CSI", + Thalthe contents of VOM are sutiee! to chenns viol orice nates ed hus 96 shal alin, agres tc relat only fo ths lala! version of the YOU ohil is available a MSIL Vaneor Potal iExtanel/Enovie Pata: + That shall ensure compliance withthe VOM in aloar cealinas with MSL and shell ao ‘ensure complies of VOM by aur sut-vendor's and sub-contractors els ‘+ That VOM the conffential ane proprietary document of MSIL andveshallrot make ery Unauthorized discosura, reproduction in hols or part of VOM. + ThatMSILmalesno rtosuntation or warranties wth raspoct VOM ard shalres beak fer ary damage losses, costo expenses. ditoa,droct, consequential o spac, aisng tt of or related to the use of YOM and any information caniained therein,INTRODUCTION (ei-ea) eatl semicon = = fs iva pn ISN O1 SINSINN500 40 NOISSIMENSTHSIL'S QUALITY ASSURANCE SYSTEM CHART FOR BOUGHTOUT PARTS (PART 1 OF 5 0B \vexon Pans anne jprcouc. — rezoencx -O- mememmron woven cere, § camcrorommsors (Flow Chart - 1.1)TSC GURL ASSURANCE STEW CART FO BOUGHTOUT PARTS AT TOF sraaes. | St vowen aroun | aman | coneme | oo PERIL o>. Cae O ° eS aa LEGENDS acrwies «= —— FeEDROX —O> PARTICIPATION @ COMING FROM PARTI OF 5 = wreamnce Swear, g cawecrvrommeers QP cowetoronmaersTHSIC'S GUALITY ASSURANCE SYSTEN CHART FOR BOUGHT.OUT PAATS (PART SOF a) vevoon once surmvoun | ramtsouiry | mraneene | orc preRueTo $ aa) LEGENDS res —— FeeDanck -O- ‘MRTEIORTON @ coOMNGFrOMMAEZOFE 3 _Freaireo 1 wrowsivsrr: f° cowmecreprommsors _cowecreprommr4ors connenre0 To rare OF 5TMSIL'S GUALITY ASSURANGE SYSTEM CHART FOR BOUGHT-OUT PARTS (PART 4 OF) 70 ue aes ycknon 0 aaron | oaraauun | wwanccna | ove PEDETO oe @ | =e Canean ot ee 2 TEGENDS eg mack 0 ARTOPION @ COMING FROM PKATS.OFS som IPREQUED CI THROUGH DEFTT. $b (CONNECTED TO PARTS OF 8 2 COMING FROM PART OF & CONNECTED TO PRETO 5TMSIL'S QUALITY ASSURANGE SYSTEM GHAAT FOR BOUGHTOUT PARTS (PART § OF 6) vention nino orevenae an | wen | oe PRET = ee es mas) (ca) LEGENDS: Femwones — -O- pemicmien © comne tow mars ors — reac 3 vmosiomr 4 comecreoToRmsorsVendor Acknowledgement oy Jaarum suzvia wou uMreD, lea asa. Devt ete oftubmisson Day __Morth Year ‘Wiesel [ender Cate sarees Laon ype of kanes Guchas eet ett ase uber Foes, ered aie or wich pars ee sled [fendarGaifeaton tasacon Fat (Giegar tan I > chasis Pats iF Maru) be. ls bea Fans f= tunesona ln erghe Pars te Geert fe lo erica Pars 5 {orves the Farner, ss] yard dace are cone “That wehave rear urdertod the Vardor Guay Assurarce Marval VOM) anéapeets mest the requrewents mantoned therenandte fciverquoty products ot Manat Sulina Limited MSI"; “That the cotens af YON are stb charge witht ror nie ard his we cal /OM ubicris alae MSL Verde oral ExtareVEnova Pesta, “That weshal ensure compare wi the VaMInal cur decirgs lt MsiLatdshal aso eau complarc of VOM by cur sub- vero’ and sit- Jontactors ase; “That ORM ste cenfieril nd propietary documenta WSL and weshal na make anyunasthorie dselasur, reproduction mn wholear impart Lrvan. “That MIL makos na epreseraton a waranlas wth respect aM ard shallot be Ine fer any damage, esses, cass or mpenses, det, irc sensraveiol seca arising out of oreate oeuse of YOM ag any information ating ern. times, see to releronly to he lestveien ofthe Serre Ip maragerent (20) (Format- 1.) NOLLONGOULNIMANAGEMENT RESPONSIBILITIES CHAPTER 2MANAGEMENT RESPONSIBILITIES nent to build a Quality organization : through 3 key element. ominate Principal QA incharge — having erall responsibility for Quality & Deput form the names of Incharge to MSIL's case af change of QA Incharge / De| arge, information to be provided to MSIL age the requirements related tc ally in the Management Revi ment a system to communicate M: requirement within the company and at sub vendor’s endMANAGEMENT RESPONSIBILITIES marum suzua TOUS Seas See SS 20 ie vangor ‘op manager's aspen Io implement Cully Manager Syst th ‘igatizaton, ep menagomont hea to communica, ta their ceganizatcn, the imporianse of mooting customer roquitonante ae well ae regulatory and logal reciomonte. Thay should ‘nel egulay managomont views ard escussion meetings af the Quay Systom Key Fle of Management [he by role of management f to build a Clty erganizaion stuntue. his can be achieved by 9 bey ert Quality Planning + Quality Cental > Quality improvemert& standardization Quality Panning: = Dosilop and dine Quality enganizaion butane + othe vison and Guat policy. + Detre Gualty targets in ine wth customer expectations + Develop Cuslly Standards, procedures, processes and work instructions inline withthe Faquiraments mentioned inthis manual (Hefer Arnesure lV Guidslinos for Documentation requirments and its cunt + Focus on hurian resource dovolopmont, develop and maintain ining prozac. + Give feeus 01 tisining of manpower and develen system for upgradation of manpower ski Conduct managamsnt review facushyg on Qualy System Quality Controt: “+ Dasalop customer frac moritoding and handling process, + Develog ad msintsin Quliy pln ond conte pla + mpiemars mstako-proonng technique + npioment a systom of Quality gato Le. no defect should pass on to next process alin urn, to end customer, + Implement a system for Qually and precsss contol by individual employees. + Monitor cost of Poot Quai, + Detelop and maintain change netifeation procedure + Aahore ta pecblem conisirment and tracoabilty prosodic + Roel cates aval ce ton iar2a $ manun guzun MANAGEMENT RESPONSIBILITIES Quality Improvement + Dotelop asysten for continual improvement + Detolop astendand sysiom fortzcking Quality atnomaaltes. + Doument and adhere he WI posed.res ‘stonderds + Followa standardized epproach of FGA to solve Gualiy issues + Take fosdbacks fom customer proactively andintoduce improvement in product + Develop akaizen team and motivate them by giving recognition tine 1 tme “+ nplemant Quality les and fomis on imrmamant of Gualty care Management Review ‘The vendors Management with executive respensibiites (CEOML:DireciorsPreserts ee.) shallrenene Guality Planning: + Quaityeystem roquromerts of NSIL (8 spocitid in thi manual) + Customersatetaction + ASL telat performance monsures + Provuss pasformance & output product + ternal External aus rosuts e fags LDatatoing gonerated at the compary lve shal be rvioweeland used improwe the perermanon Ccominually. Froqueney of such roviwss should be doined in a documented proce, Nomination of Quality Assurance Incharge Inonlorte anoure amooth working of Quality Asourance Sym snl te continuing suiatity fn eflectveres, venders ate advised Ieee the alle Nomis "Prinsipal Gully Assurance Incharge’ anda "Deputy Quliy Assurance Inchaige! ard inform thet nates o MSIL. The bllaving explains regatdig tha quaficalien ef Principal A Inchaige and Deputy GA inchaigeand the mathod of nfermFig abut thst nomination and changa te MSIL ‘Qualifications and gelection of the QA Inchsrge: Principal GA Incharge: The Prircipal QA Incharge is a petson, who has been delegated the overall esponsbilly ané autherity regarding Gualy Assurarce ty the hie! Fxeculive Office (Le Pasian! orMenaging Director ofthe vido. pipe, the Principal QA inchaige should bea oa of lve ‘qual to oF above Ganoral Manager analleompanis, one of he wters ora vankorparzcn Stel ake this respensibity In paincklo. the Pineal QA Inchstge sroukl be indopondt Production in takrg soeisions ragarding Quality,MANAGEMENT RESPONSIBILITIES MARUTI SUZUKI 23.2.2 Deputy QA Incharge: 292 2aa4 234 235. The Deputy QA Incharge it person, hn hes the tineional espansitiltyregaicing Quality Assurance in the company, Inprincile. he should be an officer of Menanerlevel or above. Metred ot informing NSIL regarding OA Incherg Thefonnal Guay Assuiance Ince Nominationtharge Noticaion Far (fet Forma-2.1) {or frat nominalin i to be used and aubrritle to MSI's APG. Rate Purchase Aryeement nea of erganizaonal cvanges in tha compary alc, ha fou ie tobe fila once rors th tho upeated information and sufmited to MSIL QAPO in duplicate wah ove marth of te change How to fill up the “Quality Assurance Incharge Nomination/Change Notification Form”: (1) Purpose of Submission {tha fron bing suber tir, ‘Norninatin fata bo anced and Change? io bu ruck out. View-vorea noede to be dona in enue of change (2) Vendor Name, Errerthename of e company and also the Verlor Gove assign by MSIL alse mention the canpany's Email B, Telephone No! Fax Na along with the 8.7. Code @) Acsress: The company slulladdtess, whutethe vendo's QA nchage ie rotmaly vailable tobe wonton. (Type of business: White the main business ofthe company. 2.9 sheet metal pats, rubber parts ete (6) Dato of nominationichange of new @.8. incharaois): tothe dees of nomination orchengs ofthe GLA inchargoe} (©) Principal Quality Assurance Incharge: ‘The namns and designation ol th person rominaledas the’ Pincpal Qa inchargs"istobe ‘artes, Hi should put his specimen signura in ths column aboea the word "Signature (7) Deputy Quality Assurarce ineharge: ‘The name and designation cf the person nominated asthe Deputy GA Incharge"is tobe lartten, He should put his specimen signature inthe column steve the werd "Signature Dutios of QA Inchargos: The Principal QA Incheane ard Deuly QA lncharae have lo bs axclained thal hey besides acharging thir ola dulias, are spaced lo ensuite te falling (@) Hoseivng. safekecning, proper conttl and imely updation of Guaity elatoé decuents recoked om NSIL. (©). Pattcpatenin Guay Sreciicaton mestiva and understanding MSI's Cualty requirements (ei, Tinely eubmiscion, saiakeoping proper conta nd pier intimaten regarding modeatione 1o MSIL for rosa ocumants which ara prepared by ta vendor ang arbre by RIL, (@) Tinoly and proper comactive tion cabo of Gusity abnernaltoe and intimation of a same to MSI (LTV ASSURANCE VANNAL 7$ manun suzuia MANAGEMENT RESPONSIBILITIES (©) Adherence tothe provisions of these mania and other isttucons fom MSIL regarding Ouaity Assurance (1) Cotablsh systomof conducting VOM waning crits affectiwonoss chovk: (g) Hoguisly monttor the '&: & funcional tems of the parts & the processes, & ensure that ane are in proper ord (ty Prepate SUB (a soected in‘Submission of documant Tabla? 1) & maintain record In plain & also send a copy to MSIL; (refer 12.1 of Chuplst 12). (Present Qualty date to Managsmant for reviaw 24 Organisation Chart An organianion chart shall ta mace & maintained! which defines clear the rmsponsibitins & ‘autherties ofliferent personnel who ae imoved in assuring the Guslty Ths cra includesrot rly the personnelrom Guaity but also ftom preductin, hspection, purchasing. desparching, fginaeringete The cart must shaw tha hat raation el tha parson, ek aval anc reporting val (tien parsen is reporting to tiom) clear. 25 Communication of Requirement \endor shoul! implementa systom to communicats MSIL renuitermenis and change in ASI roquitemants with their omarisaton and atsub vundor's and. ( efor Chaptor 23), 2.6 Quality Management System Expectations YYoruurs shall haw ufoctve Gually manayemon systems ard musi orsurD aderowew as or th Namie provided by MSIL fren Fagurenart Quality Manegement Systems TATE 160402018 18090072015 ‘Gustomer Specife iarwal and Standards communicaled by Requirements NSIL tineta time 2.7 Emorgeney Contact Information ‘A oontact Ist shal be piovkted by vendor 9 MSIL, This Ist stall cantan name of person, Hesignaion of person at! his conic nimter that Grn be comicted f required during nom praduation hous orin onze of extraordinary siution VENDGE OIA ASSIA AMIR@ manu suzura MANAGEMENT RESPONSIBILITIES: (ve ewe.) ‘mele cBinyou eouencey| ‘Auer Aucoa| anes Biapu sources ‘eng redoing oan voreubise ay, won -ssuryo | ‘Hounyosdy jooreg reowe o adensieu yack uous pawn sie fssy Oona ae e10u3 suecfpoa odoo poids a ne {BHA 1) SHB ‘onews oyrey nordoa., ‘ON 8p#9 pum, suey 220U09] wa, qa fe, womens 10-490 WHOA NOUWOULION ENV /NOUWNIWON ZOUVED NI ZONVEREEY JTW yo onvuny aD ‘oaunmwanininzne unewn “amarum suzuKi This Page Is Left Blank ‘VENDOR QUALITY ASSURANCE MANUALSTARTING DEVELOPMENT OF PARTS CHAPTER 3STARTING DEVELOPMENT OF PARTS ify separate storage area for trial parts and st ‘parts with proper identification —STARTING DEVELOPMENT OF PARTS ESE aM Sea GS 3.0 A Latter of comfert (LOG) / Lottr of Intant (LON will be iasued to the vendor Ly Supply Chain department of MSIL, Part development aetniiee may be started altar the reoaipt of the LOC / Lol MARUTI SUZUKI 3.4 Part Development Stages Normally, a neve part shall undergo following stages of new moel development in MSIL. Ossn La Premaion Lm Let Ly Stat rote roto. Produeton >) Production Praduetion Tral(oP) “| TaalPey | Taal ae) 7] Thal (Sor) The stage mise status and rentirement of MSIL are explained in Table 8.1 “The following documents ites shall he ieaued by MSI ta vendor: (2) MSIL Drawing oF Sposifications (in case af now consopt design or proprictary parts) () 8 DCAD Data (required) (©) Applicable standards (in the form of SES / Intemational standards) (2) Applcabla inspection and tasting standard (f available for referancs) 3.2 Technical Review Meeting In principla, a Tochnical Review masting shall ba held by Engg SC dapartmant of MSIL with vendors (bofote o after Issuing LOC LOH}, The agenda and requiramants of Tach. roviaw meeting wil be informed to vendor, normally, 7 days in advance. Tech, review meeting, in principle, shall be hel forall proprietary parts / parts which have {functional / performance requirements, However Engg. may request for Tech, review meeting {or other pars alse in casa of ned. Vendor shall submit all elavark details and presentation io tenginasring 3 days prior to technical raview mosting 3.3 Specification Meeting 8.8.1 AllertheOG/I Olistaceived, tis vary important io understand ckorly the funtion, spsiicaions and ethor requirements of the partto be devolapesd, 3.8.2 —A-speofcation mooting will bo held with vender’s now product development toam and MISIL’s Supply Chain (SC), Enginooring and Parts Quality departments soon after the issuance of LOG! LOI. In principle. this meeting shall be held within 15 days of receipt ef specication / eancopt! final ering from MSIL “The items to be discussed in thie mating ata given below ‘©. Function oftha component (purpose ofthe component, use conditions, ts ralation with mating parts} © Citicalty of the component: | Functional or General pert! characteristies ‘YEUDOR SUALITY ASSURANCE WANUAL Ba MaRUTI SUZUIC STARTING DEVELOPMENT OF PARTS Requirement af vendor drawing / prototype approval Design FMEA requirements Rig testing anc! other pertormaneo testing roqutoments to be conducted by vendor MSIL lesting requirements Regulatory requirements # any (ie, CMVR, ECE, ADR etc.) Indication method and location of vendot identification marking and batch code on parts Provious part development history Process FMEA quirements Process capabilly requirements Measurement system analysis (MSA) requirsmsnts (© Apparance approval requirements © Details of Sub Vendor for child parts including special outsaurced Processes like Heat Treatment, Plating sto, + Dia! Mould information & their source section = List of approved raw materiaoulsourced vandars & Sub-Vendors Yendor's control plan on Sub Vendors Diseussion on Tracesbilty Information sheet (TIS-P) for Tracestility Level for tems i.e, un {a Tier? or up to Tier=t © Manufacturing requiramonts ja. accuracy dosined, produetion techniques ate] © Mos of manufacturing procoss and important process control parameters © Inspection & test methods and equipment to be used For inspection of impertant Quality characteristics Development schedule to be followed (Le.for diss, tooling, igs, fitures, aquipment, training ‘of manponst etc. for production of naw part) (©. Submission of Process Control Stancarc (PFD (Flow Diagram} & PCS (Control Plan} © No. of samples to he manufactured and inspected by the vendor and inspection and! test eports tohe prepared No. of samples: and Last specimens to be submitted to RISIL far ev tical inner parts & A? rast material ison by Senco Evaluation ef child pars in ease of proprietary parts © Peak Production Verification Trial (PVT) requirements End oflite vehicle (ELV) requirements (Refer Annexure-VI, Guidelines for Environment Regulations) Classification of /A\, functional & ganaral parts tame Roguiromomt of init samplos as material vender finalisation Inputs for making proper jigs & fixtures required for manufacturing VENDOR QUALITY ASSURANGE MANUALSTARTING DEVELOPMENT OF PARTS 3.3.3 MARUTI SUZUKI © Identification # Marking (pecil tage ! bar code colour coding ete) of tial part shall he dacicled in spac. maating © Past failures in sirilar parts and thoir countomuasunas © Packaging ar! handling requirements (to be discussed with OPC department of MSIL, for details refer Chapler 15) © Mew DesignNew System/New VerdarNew Procass parts lo be elserly identified during Spec Mecaing. © Identifying foolprooting (Poka- Yoke) areas and their schaduls fr implamantation MSIL shall decide @ mutually convenient date and time for these meetings. Note: On the basis of discussion done regarding laws and requlalions, weno shell ensure thal the products filly comply wilh allthe applicable laws and regulations. The vendor shell ensure ‘that all tho parts suppliod to MSIL, conform to roquiramments that dofine tho stiucturs, funetian and performance of parts with spect to regulation, environment and safely Incase, itsome child parts of regulatory parts are precured trom Tet 2vender, then regulatory compliance of parts and child parts supped hy Tier -2 vendors shall he ensured Documents required during Process Specification meating: + Drawing of das, jgs and manufacturing facilities + Schedulus of various activiiss (ag. dasign of dios, jigs, fictures, their manufacturing schedules, trial production schedule eto,) Tho ftoms discussed! shall bo recorded in the “Specification Mooting Record” and the paut development schedule shall be record inthe "Part Development Activity Chart” by concemed Fnag department Acony file Specification Merling Rape and Pail Developmen! Acily Chal shal be provided tu tho vendor by MSIL, ‘VENDOR QUALITY ASSURANCE Development Monitoring ‘Yondors shall constitute a project team comprising of personnel from Engineering, QA, Process Engineering andl Produetion in their organisation for carrying out development activtios of MSIL. This shall be informed to PASIL at the time of Specification Mecting. In due course of development slage, if here is any change in The structive of key vendor's person, then same should be communicated fo MIST Vendors shall plan & align thair developrnant schadulss lo mest MSIL development milastones (such as pioduction piolo Wial, mass production tial, Pilol and SOP ale.) as decided in the specification meeting, _An intemal monitaring system shall be devised by the vendor's project team to monitor & review {the progress of acivties against [MSIL development milestones at Fixed intervals, These internal reviews shall be conducted by the project! development head of the vendor, Vendors shall have a joint development review with MSIL before MSIL landmark milestones. Vendors shalladhere tothe inital developrnen! schedule, as agreed wilh MSIL and shallinfoorn MSIL in case of any eelay along with the reason and sabmage plans. waNUAL aMARUTI SUZUICI STARTING DEVELOPMENT OF PARTS CAD data chal be submitted to MSIL and approved before th statt of tooling pracess al the vendor's ond Venders shall carry out process design simulations to the extent possible to minimise process related detecte at Iter stages of development Development activity must be reviewed by the vendor's Top management after completion of each staqeiphase, 35 354 Part Development Problem History Vendors shall keep a chronological track of all major problems / defects encountered during various stages! phases ofthe part development (fil SOP al Ml alang wih the countermeasures taken. tho implemantatian date of countermeasure & a status of the offactivenass of the ountermeasures, Un example of format to be utilised fer this purpose is presented in Format 3.1) Is chronological summary shell be utilised to check tt canto (refer chaplet 11) and as a knowledgebase lor pearl developmen in the fulure. ia for termination of initial flow ising lial lage defects for sinliar 36 3.6.1 Proper Storage of Hal Parts & Handling of Pre -ECN Parts Vandor shall idsnlily the separala storage arsa for lial parts. Thay should Biave identification systam for Trial Parts & Production Parls ke Tag / Colour marking / Bar code. Identlicalion method for tial parts should be discussed in specication mexting, Incase of any ECN received during development trial, Vendor shall properly scrap the Pre-ECN Part (as ner ECN). Also, vendor has ta add this checkpoint in his internal monitoring, Vendor shall establish internal guidelines for handling of Pre ECN pan and their serapping {based on ECN) Colour and Grain Approval All calor and grain aprravals must las achis the schedule agiaed with MSIL's QAPQ. Any change from the approved schadule and plars must be com mun MSIL's QAP. fed prior a. mass production ancl in accordance 10 sated and approved by the GENOOR GUALITY ASSURANCE WANUALmanum suzuKi ‘STARTING DEVELOPMENT OF PARTS sare fa pa 5 jomunsniis| soma |B ‘mpm sm mapas BAR woudersaapsnowen w Bus qs Jo 5S “‘ARUIUINS SIUsLUSAINbawg seBms 1usMdojaNeG Wed TSW YENDOR QUALITY ABGURANGE MAMALSTARTING DEVELOPMENT OF PARTS $ marum suzuxi (ve-sewog) en ” a i on z ® 2 z ' crane | nea | emme | ave | ous er, wep wa | wigan woutiowea | on weneyion | vopecunen-ew | emery | onescuanneg | hoy meu | JosemD, er ? ‘ZSOISIN WSTGOHd INSWAOTSASo LavPREPARATION AND CONTROL OF DRAWINGS CHAPTER 4$ Maruti suzuki Zaga0 summon 0) ns td 9 90 wrt en ssidtp on puoyaonta mors Aasioy mas Avo emo ALLO bry uunua mor SONIMVHC 30 “TOULNOD 8 NOLLWYVdSud ‘VENDOR QUALITY ASSURANCE MANUALPREPARATION & CONTROL OF DRAWINGS $ manun suzuci Fate GF MONE AO Mal ea aE INTC) 40 Drawings are required to be submitted to MSIL in the following cases: (1) Wher the part to ba suppliod by vendor is of propriatary design as par SOF (Statement of Flequiromant) (i) Wher any change requested from the MSIL in Drawing, spoctfications is requited ii) Wher specifically requested by NISIL to submit drawings of as discussed in specification meting (iv) Wher design countermeasure / design change ie done by a propriatary design vendor. 44 “Design Failure Mode & Effect Analysis’, shall bs carriad out as per "AIAG Manual for FMEA" {or proprietary parts / concept design parts or as discussed in sporitiration mecting Note: FMEA shall be carried out by a cross functional team{Crass functional team (CFT) means ateam which have members from diferent areas like Engg, QA, Production, Production Enginesiing and Purchase atc) 42 Ihraquived, detalad danings for parte shall be preparad. The dramings taquirad by MSIL for checking include: (1) Vendor Past Drawing Drawings showing the hasic details of @ parts assembly e.g. drawing should have, in ackition to theull desl dimension of the outside surface are fiment cimensians, Fegulalary Compliance Notes. a cut saction shosing the eniangament ofintarnal pats, abillof material tiving name and materiel of each part ancl performance specs which the part ks raquinad to meet. (2) Incase of concep! design, any outside shape /form developed joinlly shall be the properly of MSI, This shall nol he passed on to any olher party without prior approval of MSIL (3) Assembly Parts Drawings: Part Diawings: Drawing of internal parts as mutually agioed between vendor and MSIL 4.3 Vendors shall prepare their drawings based upen the spec. drawing / 31D GAL data. concent sheets andl other teme mentioned in 3.1, issued by MSIL and their cwn technical know-how anv experience, Vandor shall piapare the drawing as pat MSIL *SES 02335" and gat il checked by MSIL, 4.9.1 denttying % pants drawing Allthe drauirgs of parts shall be cloaily indicated by" "in the tl column, Apart from indicating ® symbol for ‘X part casing, :X parameters lke. A welding / spats, {8 toque etc. should also le clezvy identified in coneuttation with MSIL Engg. department ‘VENDOR OU8_I7V ASSURANCE WANUAL aiaa 45 4s ar 48 2 MARUTI SUZUKI PREPARATION & CONTROL OF DRAWINGS Diaisings shall be submited hough MSIL approved platform alrsacly informed to vendors. |n principle, vendor shal submit the copy of DEMIEA (vsherever required) to MSIL’s Engineering department \ersdor shall submit child part drawings based on MSIL Engineering's requirement, These child faut drawings shall be received by concetned engineering department. After registration, a copy ofthe registered drawing shall be shared wih vendor ty MSIL. This dlrenving isto be controlled as the original and any modification init shall he done only with the ‘consent of ISL, MSIL Engineasing is aulhoriad lo make necessal y changes in the drawing submilled by vendor iv accordanca to MSIL requiremant and mutual agraament wilh ths vendor. All such changes shall be specifically marked by MSIL and the ravised accepted dianing shall be sharad ‘with the vendor fer necessary action ‘Samples ean then be made based on the drawings ancl sukmited to MSIL fr evaluation, Modification in MSIL approved drawings: Modifications initiated by MSIL: If 2 design macification is proposed by MSIL which resuites a change in the MSIL approved ‘trewving. then the concerned Engineering department of MSIL will prepare an “Engineeting Change Request (ECR) and it wil he discussed sth the vendor, After coming to an under standing regarding feasibility andtima tame fr implamertation of the medication, Enginaating dopartment wllissus the Enginaring Changs Nota {ECN). In some casas ECN can baissued lise, The ECN will contain: Content of Modif oason i briet © Current and naw part numbers (0 Likely date of implementation 9 interchangeably of new andl current parts ‘© Whether sample approval ot First production parts evaluation is taguted or not required © Adview regarding old patte usage ‘VENDOR GUALITY ASSURANCE MARUALPREPARATION & CONTROL OF DRAWINGS $ manum suzuxi 4.9.1.2 In casa the medication is minor, Le. for which sampls approval is nol requirad or which can ba implemented in a short time. modifications is proposed by MSIL hased on the agreement with vendor. Modified drawing (dencted by 'S" mark} shall be registered in the MISIL system andl officilly shared wih vero. 4.9.2 Modifications initiated by Vendor: 4.9.2.1 In case the vendor wishes to make @ change in the approved drawing, the format “Change Approval Request from Vendors" should Ee used to intimate the: proposed changes to MSIL (wafer chapter 26).This form is to be subm tad to the concemed Supply Chain department of MSIL. IF MSIL agroas to the proposal, concatned Engineering department will issue ari EON, 4.10 For Proptistary pats, drawing updation is mandatory in case of dusign countermeasure takan by varder. ‘VENOOR OUR ITY ASSURANCE WANLIAL #marum suzuxi ‘This Page Is Left Blank ‘VENDOR QUALI ABEURANCE MANUALPRODUCTION PREPARATION CHAPTER 5PRODUCTION PREPARATIONS CFT formulation (Engg, QA, Production, Production Engg and Purchase etc.) ( Define Accuracy requirements of Parts r Carry out PFMEA, review the past Quality q problems and establish Poka-Yoke | Design & plan the process layout so as to minimise material movement, inventory levels & wherever possible achieve single piece flow _ (for Packaging requirement refer chapter 15) _ ——— Plan and control the procurement of jigs, dies & machineries, equipments etc. to produce & deliver parts as per development activity chart) _ Establish a detailed documented system to communicate serious Quality issues within the company ( [ Ensure process capabilityPRODUCTION PREPARATIONS $ marum suzuia PRODUCTION PREPARATIONS. 5.0 Before the sa af masse praduction, Ihe folloning actives ned lo be cauried oul for ensuring. ssmaalli running of praduction fig and manufacturing of dafcl free components a1 Process design: While designing manufacturing process, *Procss Failura Mods and Etec! Analysis (PEMEA}” (rafor AIAG Manual for FRIEA) shall ba conducted, as decided in ths specification mssting. In case of procase changes alse, PEMEA shall ba carried out, Following points should also ber taken care in order to avoid problems during mass production Note: PFMEA shall he carried out by cross functional team at vendor (GFT-EnggiGA'Prod Production Engineeiing and Purchase), (a) Vendors shall carry out process design simulations using standard simulation software, ‘0 extomt possible to minimise prucass tolatod defacts at eter stages of dewalopment (b}Theaccuracy roquirements.of the pant should be-learly understood andi is tobe ensured ‘hal adequate process capably is achievable for meting them, fe} Quality problam hisloty of similar pals shall bs vaviezed andfool proofing melheds (Poka Yoke's} shall be considarad in he process design slage ial. (¢l) Proper consideration should he given to the pracess flow: As far as possible. the lengthy of process flow should be less and in-provess inventory should foe minimum possiole. Yernfors should. in principle, have a Single Piece Flow process, Ihe flow should be so arranged lo avoid mix up of paris and lo minimise the malsiial movement and transportation, (2) Proparlocation should be definad forinspaction points, placing visual aids, repair station, rejected & OK pasts, 52 5.2.1 52.2 Schedule monitoring In ordar to produce and deliver parts atthe roquirad time without doley in mass production and to stabilize Qualty al the earliest tis very important fo carry out thorough planning snd control of the schedules of procurement and installation of machinery , dies, jigs, fixture, inspection equipment etc. In order fo adhere lo the "Parl Desvslopimenl Activity Charl” (fer 3.8.4), i advisable to use sschedula monitoring tachniquos ike gant charts, notworkanalysis ote. This wll hopin checking, tha progress during maotings and on ather occasions, 5.3 Communication of information within the company: A fall sate system (totet 2.5) should be established by the vondar for commu related information lke: control items, inspection ilems ete. which have been MSIL during Speciication Meeting ancl aka modificalions alc. to the concemed deparimentst personnel within their arqan sation, For his purpose: (QUALITY ASSURANE WARUUAL aPRODUGTION PREPARATIONS (@} Information flow routes shall te clarified using flow charts etc. (b}) A decumerted system should be astablishad whereby itis possible te confirm whether particular information has boon property communicated to the necessary departments! agencies without fal 5.4 Yonlor shall submit the Design & Piocoss Poka Yoki/s i Maru (AP & Functional Parts beset fon Past learnings! Process FMEAs (refer 3.3.2), 5.5 Yondor shall earry out the validation for tools, Js & Murs etc, usod Tor production, during development stage 5.8 Contingency Plan to handile risk Vendor shall havea contingency plan forhandling any unexpected ahnarmaliy # extraordinary sition circumstance ke mannawer shoriage, key equipment failure, proces insufficiency te, This plan should be cemmuniosted t all the concerned peuple ao ae to handle any abner Featracrdinary situation within ime anc fo contiel the eatent ef impactESTABLISHMENT OF PROCESS CONTROL STANDARD CHAPTER 6$ marun suzuxi ESTABLISHMENT OF PROCESS CONTROL STANDARD in! ps Flow Chart-6.1 ‘as go ah he complet cher dea recuremente MSR @ ‘VENDOR QUALITY ASSURANCE MANUALESTABLISHMENT OF PROCESS CONTROL STANDARD marun suzuxi SESS er SIE) 60 6.0.1 6.0.4 Why is Process Control Standard necessary? ‘Quality can never be achiaved only through inspection of finished parts. It has to be built into the process. For builting Quality in the process, t must be carefully planned and controlled. This can be done by establishing standards for controlling the process in all stages from receipt ‘of raw materials to shipment of pars. A properly planned and effectively implemented process ‘control standard will help in: (2) Achieving stable Qualty by conttolling variations. (0) Knowing if stable Quality is being maintained or not (6) Knowing if defects are being detected quickly or not (@) Knowing f futher processing/despatch of defective product is to be stopped or not after detection. Verbal instructions to workers, making judgement by intuition and working with only common ‘sense are some of the basic reasons for generation of defects. The method to avoid defects is {to make a Process Control Standard or operation standard and implement thoroughly. Process control standard shall be prepared before sample production. As itis dificult to meet all conditions during sample production, the process capabilty shall be studied and carefully ‘examined, The process control standard must be modified suitably on the basis of sample production results. Check sheets should be carefully designed to record data of various checks on the basis of the Process Conttol Standard, The check sheets should contain check items, specification, ‘measuring insirumentiequipment used ete. so that they provide handy data which can be used for investigation in case of defects and also for up gradation of process Procedure for formulation and approval of Process Control Standard Enactment & Revision The route and persons responsible within the company for formulation, approval, enactment, control and revision of Process Control Standard should be clearly spectiod by the vendor. In principle, Process Control Standard should be approved by the Principal QA Incharge or in his absence by the Deputy QA Incharge ofthe company. It shall be ensured that whenever a standards vised / newly made based on Qualiy problem, feadbacks etc all the requirements of drawing should be captured. Also, latest drawing shall be referred while revising or proparing new standard. Process Control Standard shall consist of two parts, PFD (Flow Diagram) & PCS (Control Plan). Bath the parts of Process Gontral Standards ie, PFD (Flow Diagram) & PCS (Control Pan) should be prepared by the vendor fr all parts ordered by MSIL, including the inner parts, ‘sub-assemblies. Process contol standard shall specily a) functional and critical parameters (identified in specication meeting and FMEA) fr each part. In case of raw material for‘) parts affecting ‘A) tem and ertical inner parts, bought-out by the vendor, sub-vendors should be ‘guided by the vendors to make Process Control Standards and include their important contro Parameters in the main Process Control Standards made by the vendor. ‘VENDOR GUALITY ASSURANCE MANUAL a$ MarnUTI SUZUKI ESTABLISHMENT OF PROCESS CONTROL STANDARD 613 61a 6Add 61.4.2 615 616 6164 50, the important items to te checked during receipt inspection by the vendor should be included, For canying out the Inspaction wf both raw matetial and chil pat, at incoming stage and in process stage, the inspection frequency and equipment to be used, shall be discussed with MSILs QAPQ., Submission to MSIL: Vendor is arlviserto submit Proves Contvol Stanslam (How Chart & Control plan} to MSIL for approval in case of A. paxts, functional parts and thase general parts, for which MISILS QAPQ. requests during specification messing, Ths following documents must be submited to MSILs QAP {rsfar fo the flow cat) (a) Forney pats, draft Process Gontrol Stancerd copy along with sarnplas shall be submitted. (b) After finalisation of the Prscoss Control Standard (atthe time of sample pracuction) the original Process Control Standard should be submitted with one copy for approval of MSIL beforenith supply of nes part or changed part sample, (c} In ease: of design changes inlialed by MSIL through *Enginseting Change Notice” or changes ir prooass or sub-verdor approved by MSIL through the “Changs Appreval Request fram Yondots”(rofor Chapter 28) submitted ty the vondor, the Procoss Contra Standard should bo updated and submited te MSIL up toone wookbefore the supply of ew parts or change part (8) For vexisionss othr thatthe above mentioned, submail one copy giving clear explanation of the reaizon for revision, along with the °Changes Approval Requssl from Wenn” {0} Incase cf compote rovisian ofthe Process Control Standard, vondor to submit the original vith one cory to MISIL tor approval (8) Revision history of Process Control Standard should he maintained. E.g. Change in PCS. because of ECN, CARV, process: change ete, along with rexision date, All these tyne of changes should be traceable, Approval by MSIL: Tor new parts or completo revisions, tho original Process Gonttol Standard submited by the ‘vendor shall ae retuined tothe wencor with approval signature ator the details are chook! by MSIl's Parts Quali depertment How to prepare Process Control Standard? Format Ths Piocass Contiol Standard should be preparad as pat the format 6.1 and 62. Ifthe vendor ‘wants to use theit own format (Foimal shall meal minimum requirement), MSILS format should be attached tn the Process Control Standard of the vendlor as the cover age. First sheet of Process control standard is 6 Flow chart, (Format 6:2), which explains the entire manufacturing sequence along with the flow of bough!-out parts! subcontracted processes. is to be noted thal this fist shoe! is a mandatory requirement of MSIL in the Process cont ol stand. Serial nutnber 1.2, ete. should be given to each patoub part (ehlld part) ofthe PFD (low Diagram), PCS (Control Plan} of wach part ‘sub past (chikd part) shall be made on individual ‘VENDOR QUAL TY ASSUEANGE WANUALESTABLISHMENT OF PROCESS CONTROL STANDARD $ maryri suzuKi sheets giving the same serial numberto the comespeanding sheet 6.1.62 Process Control Standard - Flow Chart (refer Format - 6.2) tome ta tie rocurdodt ) 2 3) 4) 8) Vendor Name: Ihe name ofthe company to be writen Model: The name(s) of the MSIL modelis) tin which the part isto be used} to be writen. lsue Date: Issuance date to be written. Part Number: MSIL par numbat as indicated on MSIL diawing/MSIL approved drawing should ba tocordad. Por assombles, itis not necessary to write part numbor of cach inner part, ifthe sorial numbor has boon written as por the flow chart. Tor A: parts, to be written and for Functional parts, °F” is to be written at the-end of part number, Part Name: Pail name ax indicaled in MSIL draning’MS I approved caving should be vite Process Flow Description: fa) All the activiies 7 steps should be captured against Sr. no. 1, 2 eto. The same serial numbers should be used on the corresponding sheets of the main Prosess Control Slandand (Control Plan} fo the parlisub part (b) For each stop indicated, in case the process is carried out by a sub vendor, provide sub vondors name, The. 2 /Sub- Vendor check points should be added in begining ff pracess control standard af Maru and functional parts. (0) White we or "F" atthe end of process name. for pracesses which are related to ‘i and Functional lems respectively, id) While “Sub-contracted” within brackets below the Process name, if proces is subcontiacted / outecurced (fe) For and functional parts write ( Wtke tor processes having backend traceabiliy. (@)_Crical to Quality parameters to be clsarly highlighted in PCS, for processes having oka Yoke. 6.1.6.3 Process Control Standard - Control Plan (refer Format - 6.1) » a 3) 4 Items to be recorded: hhoms vendor name, Model & part number. should be ted in the same ways as described in respective sub clauses 1), 2}, 3) & 4} of clause 6.1.6.2 Process Description: Wits the name of each manufacturing proces in saquanice ancl also indicale IF is carried out in-house or by a sub-vendor. Please wil ot F al the tend of process name, for such procassas wich are related to @) and Functional tems respectively. If a process is cubcontrarted £ Cutsourned, write “Sub-contracted” wrthin brackets below the Praress name, Process Machine: Write the name, type and canacity etc, of machinelenuipment used! for the process Control Parameter: Ertor prucoss patameter(s} and also Quality char acterstc(s) of the part, which need fe be contullad in that process, Standard and Control Specifications: Write the specification values and loo tolerances: without fal for each of the contal lems, Control specificalions shall be tighter than the ENDS NQUALIYY ASSUF AVE URUUAL =MARUTI SUZUKI ESTABLISHMENT OF PROCESS CONTROL STANDARD standard ar engineering specifiations 8] Inepection Method: Writ briefly thi muthodl of chucking the contol parameter 6g visual, gauging ote. Alsa write the name of measuring instlumenttost equipment uscel for checking «9. mictomotor plug gauge, thermemator ete. 7) Transportation Method: Write mode of ransportation of pat from & ta ather slations. 8} Control Incharge: Write level of the person iwho is incharge of checking 4.9. operator supervisor, inepaclor alc; use tha codes explained in the for mal, 9} Sampling Scheme/Frequency: Vivite check frequency in tha manners explained in the fellossing examples: 8) eS. =0)if start up if nane is defective) b) Fed, e-Gihour (La checks piocos avury hour and continuo if none is defective) ©} F100, n-a, 6-0 (1.0. check ploces For ovary 100 pcos produced and continue ‘only none Is defective) 0, and so on, check 6 pieces at the time of process setting and start only ) fol fis clieck 10 pisces in each lol and accespt only frione is decline) 10) Recording: Wiits the name of formal used far recording check data 4.9. ragister, shift repnrt, contol chart. automatic recording etc. It datais not recomen, write Nat recarded 11) Remarks Write remarks 2.9. for what to do in ease of abnormality etc 12} Poka Yoke: Identify the critical onerstions while eslablishing the process low andindicale the operations where paka-yoks will he used for foal practing. Indicalion af Poka-Yokes epetation shall be done with 6.2 While preparing operation standards, it should be ensured that all the operations and thair sequence are dafined as per the process flaw chart a WENDGR GUL TY ASSUFANGE WANUAL‘STABLISHMENT OF PROGESS GONTROL STANDARD: (ro-re804) ou aT aa en Samra) enemys ar wm aintty moma | a | jromimial | tunes aa shy ‘owing i | das a roma EG swsuaneoy mmo ve Se oe MEPUBIS [OUD S820%d ‘VENDOR GUMLITY ABBURANGE MANUALMARUTI SUZUKI 'STABLISHMENT OF PROCESS CONTROL STANDARD, ace an eran PTET a mn a ee (Wnts assembly pars (in case of Apart, White: at Cremorne ar So aa aa a oui ao on cums oussenaate ie | sume REGENT MSPEGTION =[) RECEIPTINSPEGTION | a a 4) mmc nnane) — ) 2) Process sin Nara) @) Pam Sin Name) “Y! (Forovslae Proves, a) Pram emnare) (2) anun ‘ardor procane eee om Q) Pressssnnane) 4) Precam Sin Nara) PART NAME } (Prem Ras) by orceam sn Name) | FAL WSPECTION @ ano standare Corto ln Approval By Date vewoor (QA Incharge should alg here Descrbilon & Reason ‘Aporoved By Date Fevison Record (Format - 62) & ‘VENDOR QUALITY ASSURANCE MANUALSUBMISSION OF SAMPLES & EVALUATION BY MSIL CHAPTER 7SUBMISSION OF SAMPLES AND EVALUATION BY MSIL juce the samples on the fully tooled up © of super towing condton/ level ‘Sub the semples to MSI. (umbrs eokded In the specication meeting)‘SUBMISSION OF SAMPLES AND EVALUATION BY MSIL = maRUTI SUZUKI SUBMISSION OF SAMPLES AND EVALUATION BY MSIL’ 70 TA TAA TAQA 72 724 722 723 This chapier explains the necessary activities to be done for sample evaluation and approval Preparation of Sample Parts After the Speciation Meeting, Drawing Approval and preparation of draft Process Control Standard, the next step is to prepare sample parts (or samples) The aw material and grade to be used for preparation of samples must he procured for the ‘sources from which iis in ended ta procure fr mass production andor as dacded in Specification oeting with MSIL, Material test conificates from the raw matorial vendors chau be obtained without fall Incase raw material atfocts the and functional items of the part. raw material fr all these parts shall e procured trom the sources as agreed with MSIL in specification meeting. Also the child parts fr all a: and functional parts shall be procured rom the sources as agreed ith MSIL in Spucilicalion masting. (Refer Annexuia — 1, clause 5.3) ‘Samplas shal ba produced on ths fully tooled up fine and samplas shall be subritad as givan in 3. 100% twadinass of Tools, Jigs, equipment or as par the tooling condition !leval agraad in the spectication meeting for each siage of development, should be confirmed by the vendor atthe time of sample submission lin case samples are not prociced on the mass production line i.e OF Tool Off Process sample ubmission (rafer 7.3), then the reports related to mass praduction line ehall be eubmitted at [Mass pioduction stage or Plot production stage wth a prior approval of MSIL QAPO. Inspection of Samples Bofora‘Along wth the sampla inspection report, weredor shall propato the validation roport for jigs. ius and tools used for production af samples. The rave material used for pioaration of samples must cithor be testod by the wendor or shall be got testod fram a rocagnised laboratory as pravided by MSIL in specication meoting. Samples tor all Quality characteristics; appearance, dimensions. material (i.e. chemistry, hardness, microsiructure ele.) and palormanes: should be inupeciad, The decisions taken in the Specification Maaing regarding the nurber of samples ka be ranulaciuved and inspected should be fllowad, The inspection shall bs done on the basis of this MSIL approved drawing {nenection of 100% paramotore as por drawing], reatod etandards and toms decided duving the ‘Spectication Meeting. Inspection report of samples shal be propared giving the actual value ‘of characteristics tn individual pisces. When using multiple dies or mult cavity eins, dintoaty umes on each pide shal be marked and also his shall he mentioned i the insspaction report agains the inspection reul of the pisos. In case of proprilary pats, detailed avalualion of ‘acl and every child part going into tha main component shal be carried ou ‘VENDOR GUAT ASSURANCE WANA w73 81 732 7824 7022 MARUTI SUZUKI Submission of samples to MSIL The no. of samples shall be submitted as par specification masting. Following a for minimum number parts, inspected by MSIL: ITEMS TO BE INSPECTED @ bo o @ i} 0 Dimensional inspection'appearance inspection {Atleast tno, for each cay) Plating thickness, welding ponctation, heat tteatment Hubber. plastics, glasses, metal fspeciment Mechanical properties Salt spray, Ozone resistance, Weatherometar Each Funetion Performance heck ‘SUBMISSION OF SAMPLES AND EVALUATION BY MSIL the guidatines NUMBERS. Kindly submit the following documents along with the samples to MSIL: @ o @ we © ® oy o ® wy o Parts drauing (wiatinal) approved by MSIL Draft process control standart Hatetialcatificata tat reports Dimensional inspection roport of samplos (Min. 5 samples) Process FMEA and Design FMEA Reports for parameters raquasted during spacifcation mesting Appeatanca inspection reports Process capabiliy report as per the discussion one during Spec, meeting Measurement systam analysis report Contngsney plan Indigenisation report List of sub vendors supplying raty material & parts (Anpreved bill of material, child pal 8 rae alta ‘Any ethor document as asked by MSIL 1 Copy 1 Copy each 1 Copy 1 Copy 1 Copy 1 Copy 1 Copy 1 Copy 1 Copy 1 Copy These dacuments shall be signedappraved by warrdor side by and to be submited, The numberof parts for fist run to submit samples shal he 300, it production in MSIL is more than 100 per day. Honever if MSILs production is less than 100 per ay than an alternate hhumber, as decided by MSILs QAPQ in tha specication meeting, shall be folowed. If process capabiliy reports!MSA reports cannol he submited along withthe samples, a plan should be provided for cartying ou! process capabilty studyiMMSA study at adate not late! than Pilot fot submission date, Procoss capability study should include minimum 100 parts (tofor AIAG Manual for SPC), ‘VENCOR GUALITY ASSURANCE MARUALSUBMISSION OF SAMPLES AND EVALUATION BY MSIL MARUTI SUZUKI Note: The ragitiamant of Process capability index Ppk = 1.67 shall be applicable. to all newly selected vendors: and new piocassas/naiw machine setup al the extsting wandors. For others the requirement of Pk > 1 minimum along with the contingency plan will be accepted, 7.3.2.3 Maasuremont systam analysis study shall be catrlad out (tsfor AIAG Manual for BISA) for Paraimctors listed in the procuss control standards or as docided in Spociication mocting MSA shall also be carried ou for Altribiile lyre parameters CVisial defects or Appeareincs) as decided in Specification meeting, 7.8.2.4 Continganey / Bisk Plan is taquitad when procave capability {Ppk) or meauu arent uystare repwalabilly and raprod ucbilily {RAR} aren! satisfactory. Alba, 2 coulingsncy /risk plan should be available in cae of bollaneck at eriical machinas lools a. the machines / tools, which will affect the MSIL production ine in case of breakdown. 7.8.2.5 Incase the sample is net for a new part but for processidesign change in a part sshich is alreasly under supply. the relerence of the coreeponding change document (ie. ‘Engineering change notice’ of MSIL or the ‘Change approval request made by the vendor should be mentioned in the Sample inspection raporL. A copy olchatige docurrient should be allached io ihe inspection wepstt 7.3.3 Samples and Others 7.8.3.1 Othe than abows reports ter /3.2) the flowing should be submit: (a) Number of Samples: § set minimum ar as dociled try MSIL’: APO. (©) Master Sample: ‘One numbar fon which massuramente have been mada} to fe idenilied as master sammie, fe} Raw Material Sample: Ono numbar or ac decidad by MSIL: GAPO, (a) Tast Slabs I raquirod by MILs @APO. (9) Ghockng roaures: i roquirod by mISiLs Gara. (In case of assemblies; Samples of inner parts / Child Parts shall be submitted to MSI's Ae 7.8.3.2 The sample parle, West specirnans and documents should be submiltad ta the MSIL’ QAP. TA Process Audi FAA After submission of camples and talaled documants to MSI: OAPO shall viit the vendor's plant and conduct the process audit refer chapter 19) as pet the process control slandards and process few chart, forall: and functional parts, For other pars, it willie atthe descrction of Departmental Manager MILs QAPQ. 7.4.2 I process audit could not be conducted after sample submission then it willlke done atthe time (of Pilot production (t required) 7.4.3 While performing the process audit MSIl's GAPQ shall also verify the jias and fixtures used in production, 7.4.4 For the issues # Problam fourel during Pi MILs GAPQ along with timoting. In pine! ‘of Mass prueluetion bass aud, Vondor has to provide tho action plan to a. all paints shall bo closed by Vendor bofore Start ‘VENDOR QUALITY ASSUFANCE WANLAL A75 75.1 T5AA 78.2 78.3 75.4 758 5.8 S MARUT SUZ SUBMISSION OF SAMPLES AND EVALUATION BY MSIL Evaluation of Samples by MSIL The MSIL QAP willevaluata samples for matatial, dimensions, appsatanea and paifommance characteristies. Ir necessary, Parts Gualty membors will vist the vendor's premises to witness Performan tests anctior to check tooling and inspection fixtures In parts where functional performance evaluation is necessary, samples vill algo he required to be submitted to Enag department of MSIL for performance evaluation, This requirement may be concurrent to the evaluation of samples by MSI's GAPG and will normally be explained in the inal Spee. meeting. Howaver, extta samplas may be requested from vandor latar on by Engg during coursa of development MILs GAP wil chock ho opents submited by the vendor gwfor 7.3.2} inrolation with sample submited ard inspection done ky MSIL QAPO to orisure that inspoution at vendor's eri is corres Ii Ppk is <1.67 then contingency plan fim provement plan needs to he submited by the vendor to bring the process in desinad Ppl Knits. Thee plans wil be raven! verified during sSpociication raviow mouting 01 whon MSIL QAPQ porson visits the vorddors piumisos. IFMSIL's QAPQ judges that the samples or reports are not satistactory. the wondor will be given Copy of the"Sample Evaluation Report” indicating the improvement items and it willbe asked ‘to re-submit samples, Necessary improvements in tooling ete, should be marie and samples resubrmiled with inspeclion reporls al thi earlest keeping the development scherlule (refer Chapter 3) in mind, If samples ara accepted and reports are satisfactory, wardor shall prepare a daft Marulé Inspaction Standard for Part (MIS-P) and a Spscification Review Mesting ill bo held with the GA. inchaige of the vendor, [he primary purpose of this meeting will he 10 finalise inepection standard of part fc, MIS P), [he details regarding MIS P and ather items tn be discussed in the specication review Meeting aze given in Chapter 9. Meanwhile, MSIL's QAP willhand over the samples to Engineering department for endurance testing (iftis necessary) along vith necessary documents, MSIL shall carry out andurancstesting, con vahiclasiengines and avaluala parlormanes of the part under actual uee, If patlormance ia hot salisfactory tha vandor shall ba asked 1o maks improvements in tha samples.In such cases, samples are to he re-submitted by the Vendot to MSIL QAPO after nacessary improvement, If tho Evaluation of samples is found satisfactory, the wondor shall be givon a Copy of “Sample Exaluation Flenon'’, Then vendor shall he asked by MSIL to: (@)_ Submit cravings for final approval, if requived (datails have been explainedin Chapter al 4) and (bj Proceed for‘ Peak Praduetion: Vaificalion Trial PPVT} evaluation (efor Chapter ‘WENDOR GLALITY ASSURANCE MAN UAPEAK PRODUCTION VERIFICATION TRIAL CHAPTER 8PEAK PRODUCTION VERIFICATION TRIAL (PPVT)PEAK PRODUCTION VERIFICATION TRIAL Maaum suzuKr @ PEAK PRODUCTION VERIFICATION TRIAL (PPT) 8.0 The purpose af PEAK PAGDUCTION VERIFICATION TRIAL" or PPVT is lo capliare Qualily, Production or Process rolated problom, which may arise during ramp up ef production at SOP ‘of major volume inereasc, sn that these problems can be identified and countermeasures an: ‘akon Hell in advance. In principle, PPVT shall be carried ou aller approval af mass production sarnplaas by RISIL oF Tine readings wilhin MPP + 1 mouth subjacted to Off Teol Of process readiness MSIL’ QAPO & SC mem bsis can clioose fo participate & obsarve PPVT at vendor's premises: at thir discretion, 81 SCOPE PPVT needs to be conducted for i} All parts of new model ii) New line established iNew plant wetablishad or lacalion SPECIFICATIONS & PREPARATION OF MIS P ee (Seeeeaton Review weeing Prepare limit samples for key ( ‘characteristics like texture as decided in specification ‘stablish a procedure: jactment, revision and cor of MIS-P cord the details of the li ‘samples in a register Display the sample in final inspection area Prepare draft MIS P for the part ‘supplied after sample is okayed by MSILAGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF MS-P RAARIUTI SUZUKT CeGes ined PREPARATION OF MI 9,0 Beforo start of supply of parts to MSIL. itis important that a clear undaistanding is wachad bbotsweon the vondor & MSIL rogaiding the Quality of parts and tha mathods of muzsuring and judging various Quality characteristics and also regarcing the method of assuring Quality during trial and mase production, Thi is necessary nol only to ensure supply of good Quality parts but also to avoid unnecessary confusion and disagreements later on. Such an agreement regarding (Qualiy of parts ie mada by establishing "Maruti Inepaction Standard for Parte" (MIS-P) and for Such Quality characterises, judgamant for which is subjective, by establish ng limit saamplas: Wi pacae ees 9.1 MSIL Inspection Stanciards for Parts (MIS-P) ‘As explained in Chaptor 7, the vondor shall proparo MIS-P'immosiataly after the evaluation of samples and this shall bo finalised during tha Sparctication Pusiow Mooting. Horo, tho procodurs of proparstion, approval and novision of MIS [is explained in, detail The thor ftom to kre discussed in the Specification Feview Meeting are explained in 9.3 of this Chapter @4.1 Scope MIS-P shall be made forall indigenised parts devared to RISIL 4 must ba submitted lo MSIL. 9.1.2 Enactment & Revision The route and parsons responsible within the vendor's company fot formulation, approval, ‘enaeimant, control and lwvision of MIS-P standatd should be clacrly specified in a decumantead procedure. 9.4.9 Approval of MIS-P MSI's QAPG will call vendor's represenlaives lo discuss and finalize the drall MIS-P, before esrance i given for supply of the First Production Parts lol. ln principle, thes Principal QA, Inchargo of the vondor must apprums the MIS-P? on bohalf ofthe vandor. Horwovsr, tha Deputy GA Inchaige of the werdor can approve in the absonco of the foie. Trom MSIL sido, the Bopartment Manager of GANG: wll appreve the original copy of MIS P & it all ke givon 1 the vendor. MIS P shall be preslucad whenever asked by MSIL 9.4.4 Revision of MIS-P AIIRIIS-P should be revieniad and raviaad, whenever thave is a change in paul cue lo dasign ‘modification, Quality problems reported, process changes etc. Inall such casas, the ravised MIS-P should be submitted by the vendor to MSILS QAPQ elsatly indicating appropriate issue number, reason for revision & revision numer marked. MSILS APG shall scrutinize the revised MIS-P and return to vendor after approval Altarnatively, i there is a need for revision in MIS-P fell by MSIL, MSI's APO shall make a Tevision and sand a copy of the tavised MIS-P to the vender. Vendor shall sign the MIS-P ard shayo with MSILs QAPO. 9.1.5 Contents of MIS-P and how to use it MIS P shall bo made in the format 9.1 (a.b.c)MARUTI SUZUICI AGREEMENT OF OUALITY SPECIFICATIONS & PREPARATION OF MIS-P 9.1.5.2 MIS-P shall contain the following information: 1) Vendor Name and! Vendor Code Fil the name of the company and the vendor code assianed by MSIL, 2) Part Name and Part Number [As given in MSIL drawing or drawings approvad by MSIL, ifthe partis ® part,‘ stamp. Isto be affixed atthe ond of the part number. 3} Batch eode This space should he utilised ta indicate whether batch code requirements arthere for the parlor nol fas decidad in specification meting wth MSIL). lean be indicaled by manlioning ‘Yas i balch coda ie raquitad & *No" of tis not required. Further, in case batch code is required, an annexure shall be provided ta MIS-P indivatingy the draiving & exact location of the batch sode on the part 4) Serlal Number and Inspection items Quafily characletistics of the part are classi inthe following major calegories and are listed surial number wise, 8) Appearance bb) Dimensions ¢) Funetional er Performance characteristics A) Durability tests 9) Material fh Olhes, For dimensions a simple skateh is de ‘cottesponding setial numbers on the slestch, 5) Judgement Criteria The specication values of Cuaity characteristics giving tolerance limits or dear criteria for judgement of acceplanca’rejactian are fa he: mentioned ©) Inspection method The method to be tolowed for inapection of a characteristic Is specifi” briefly giving the: relerence af applicable standards (2.9.18, JIS. JASO ete), if available. or by spesihying inspection. reference points, surfaces. location etc 7) Inspection tool Tha inspection instrument, aquipment, igs, fhtura atc. usd for inspection are spectiod 8) Sampling Plan The sampling plan to he folowerd by the vendor is to he vation fog. n=5, 9) Inspection Stage Tha slage al which inspection fs can iad out al vendor's end eg. recap of raw material, in process inspection, final inspection, pre-dispateh inspection ate, should be mentioned. 10) Requirement of BOM Bill of Material conisining Child Part and Tiet-? Sources shall he attached. and dimengiong are marked on it, giving pe fl e YVENDGR QUAL TY “U=ANGE MAMUALAGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF MIS-P = > MARUTE SUZUKI 11) Remarks (i) For ia: tame of i parts“ ill bo marked in tho rom arks column, (i Sinolanly for Functional tems. F sll bo writen Ui) For traceabiliy tems, of which recorting is tn be done by vendor ‘will be written. (ie) For Poka- Yoke items, where roka-yoke is installed, ‘P vil he writen. 82 924 92.2 92.9 924 Limit Samples For those imporiant Quality characteristics, which are subjective and their judgement eriteria cannot be described pracisaly in inspection standards for exampla, text of surface, colour, profile, etching peter etc; iit samples wil be established, as dacided in Specifcation meting, te facilites uniform in judgement by the vendor as well as in MSIL, ‘When itis necessary to establish mit samples, MSIL's GAPO shall ask the vendor to prepare limit sampla(s) and submit them to MSIL, Limit samples vill be approved ky MSILs GAPQ by fixing Limit Sample Tag" to each of the sets. The tag wil have pia name, part number, vendor name, vendor code, and Gualy characteriatice abe judgerd, valdity period ofthe mt sample ‘and approval signature and date & ‘will bo givan back to tha vandor. rafar Format-9.2} Particulars of the limit samplo shall bo rovorded by the: vondar it a ogistor and the: sample should be displayod at the final inspoction ana wr at a place wher actual judgement of the ‘characteristic is done. The inspaction aroa shall havo proper lighting. The: porson carrying out this inspection shall be trained properly. Proper cantiol of the limit soenple is very necessary. The init sample should be protected from dus), heal and any other kindof desnaaning condition. Periodic inspection al ther erl of thesincicated validly period must bs cauriad oul and it should be re-approved by ths Pincipal or Dspuly QA, Ineharge of the company. In case the limit samplo hae doteriorated or is damaged it must be bolfshod and a new limit sample must be established aftor yetting the required approval rom NISILS QAPQ. In such cases, new entry should fie mado in the cartrol register 93 9a Specification Review Meeting Allitoms ciscussed during the Specification M Jecting {refer Chapter 9} shell be reviewed in the ‘Shecttication Review Meeting. In principle. Speciation review meeting should be conducted tone month bers thes Mass production Irials ? SOP Following points will ba discussed in detal by the MSIL's QAPQ with the QA. Inchazgs of tha vendor © Contents of the craft Process Control Standard submitted by the vendor with samples {in case they have been submitted) © Inspection and leat aquinmen! a be used forall Quality characteristics ofthe part and their readiness 'oSizo of the First Production Pauts lot to be manufactured and submitted, ingpection to be varried out for FPP lot (In case of mass production change). (© terns for which process capability and MSA need lo be cauried outPMARUTI SUZUICI AGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF IMIS-P © itil Flow Control (refer Chapter 11), © Tracoabilyroquitements.and lot control along with TIS-P document (Tiacoabilty Information Shoot Part) 19. Marking of Batch code and Yordor Gedo on the part tmethod. location ote) 59 Inspection reports ane data to be submitted by the vendor to MSIL at various stages (Le. FPP ol, Initial Flor, Conirol petiod and petiodieally during Mass Production} © Review of problems faced by the vanor and MSIL in eit parte during eampls praduetion and piawentiva maacutes (such as fool pioofing davioes) © Review of schedule 9.3.2 Inprinciple, in the same meeting, members of the Supply Chain Depertment and OPC Department vail discuss wih the vendor about the requirements related to packaging and handling. The following point wil be olariied during the discussions: |. Type of packing. whether reusable binsfteturnable tulleys ur cartons willie used |. Type of packing. whether reusable binedecturnable wolleys or eartans wile used |. No.of parts per packing unit IL. No. ef pats in a supply lt (usually) TM. Points of caution in handling, Yt Storage condition requirements (e.g. dust pratoction, protection from heat ete) VL Problems faced in the past regaming similar parts. VIL Labelling to bs done an packagias. (refer Chaplet 13) VIIL Pravantive maintenance echeekshest for uollay/ bin, to ba used by vendor after SOP @ NOE MANUALAGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF MIS-P MARUTI SUZUKI MARUTI INSPECTION STANDARD - PARTS Mis soar P [paen. a Nae ar KuMBER BATCH CODE ‘morsenon rem [carrera | "MeTHO0 Tool | “pan | stage No. PERFORMANCE vasi._[oare | venoon [are "APPROVED BY (Format - 9:12) ‘VENDOR QUALITY ABGURANGE MANUAL 6IMARUTI SUZUKI AGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF MIS-P MARUTI INSPECTION STANDARD - PARTS: ve = | ere | [en = I > [am = ame ramen earch cone :| ee | ee ee ee ee aoe [eon [a Az (APPROVED, A faa ae aE] mes se | one | escnron | wren w/e (Format - 9. 1b) « ‘VENDGA GUALITY ASSURANCE MANUALAGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF HIS-P MARUTI SUZUKI MARUTI INSPECTION STANDARD - PARTS: VENGOR'S WANE ‘VENDOR CODE Tyre aF /iSGue oxre mis seAnDARO P [issue wo. [BATEK CODE S| cmmearrname | cate, |reeemate PARTNO |anLocanion| "™ GRADE Twat [OATE | VENOOR [are TasiL_| veNOOR "APPROVED OY (Format: 9.10) ‘VENDOR QAIALITY ABSURANCE MANUALMARUTI SUZUKI AGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF MiS-P oO LIMIT SAMPLE TAG INSPECTION ITEMS TO BE JUDGED WITH LIMIT SAMPLE Contraine Date of Eetabiahment Motel Validity Period Fart No, Part Name ‘Wendor Namie Parson Incharge Verified By Approved By [Note:1) Before expiry af validity period, Limit sample should be sent forinspecton ane Approval. 2) Na renewal necessaryincase there is no valcty period, © RECORD OF PERIODIC CHECKS Check Resut | Acton Taken (Any) Checked By Dato of Check [aa manag oh endorse hae ater pare onck oi samp (Format - 9.2) ‘VENDOR QUALITY ASSURANCE MANUAL,ESTABLISHMENT OF OPERATION STANDARDS CHAPTER 10_ ESTABLISHMENT OF OPERATION STANDARDS lish a procedure for enactment, rev! | control of operation standards / Wi eration standards / work instru cess Stations (Ensure all requi ‘drawing, PCS etc. are captured) Indicate@)in the standard /WIS if the operation has a @)item or @)part eview the standard whenever there i a Quality WIS feedback ish job set-up verification standards tool changes and record the same. splay the sample in final inspection ar isplay boards at processing & i spatch area & storage racks)ESTABLISHMENT OF OPERATIONS STANDARDS $ manum suzuxa 10.0 The primary objective of making operation standards is: 10.1 Scope In principle, operation standards must ke made for all process stalions for such operations ‘whore their absonce would advatsaly affact product Quality Howes, inthe interest of good management, operation standards can be made on various aspects e.g. contral of machines, {good workmanship practioas, safty precautions during work, cortrol proceduves, acministativa [rocedures, in process inspection, materi handling et. 10.2 Enactment ancl Revision of Operation Standards The vendor shall make a clear documented procedure for enactmentievision of operation standards so as fo avoid any oversight in their enactment/exision. In principle, the head of the ‘cencerned department should formally approve operation standards and their revisions, 10.3 Hew to make Operation Standards? While raking operation standards, it should always be ensured thal all the requirements (ike sdatving requirements (latest approved dreerings}, process Sequence, measurable parainclet, te.) montionod in procoss corral standard aro addressid pruperly 103.4 Format Vendor can shone ary sulable formal for making Operation standards which gives detailed information Operation Method: ‘Write the operation conultion, operation proedurus and deset ar operation ina simple manos proferably through sketches. ye the cortwet way of performing ‘VENDOR OU8_TY ASSURANCE WANUAL 7i$ waRuT SUZUKI ESTABLISHMENT OF OPERATIONS STANDARDS Caution Pointe : Explain in an easily understandable way using pictutes, sketches ete. the caution points and don'ts" regarding the operation, Operation standards should be mao in English and Hindi of language easily understandable by operators lis alsvays baller to use pictorial description, skalchas or photographs lierall lo makes operations slandards nore fective, An example is shown in Formal-10.1 . Ihe operation stanclards are male in such a way which is easy to follow by operator and should take care of their convenience and ergonomics aspects also Process/Machine parameters: White the control parameters of the procassimachine and their conliol specifications for that station. The: contol paramatars given in the standard shall conform to MIS-PY Procass Gontral Standaud, ‘Quality Check Points : Wile the Gualty check lems, judgement criteria and check Frequency sles for thal sation. Abnormality Handling \Writa instructions for the operator, as to what he should do in case of abnoimaltias (a 9.Stop: Call Wait. Defect History: While details and causes of accurtence of critical Quality problems, whic have occurred al thes station oF af similar stations. so as to pravant recuranc of thuse probioms, 104 10.4.4 10.4.2 10.4.3 Points to be noted while making Operation Standards ‘The basic objective cf making an Opotation standard is to praduice good produets and not ust to chack products already mad. Therefore, past oxpelioned ef defect investigation & prover ory must be used to propare: eporation stand. Allthecttcal operations defined inthe operation standard, should te identitied by sutable means and delals of fool proofing used al ese: opealionss should be sted in operation slandarc Whenever an operation slaridard is revised or newly made it should be ensured that iis in fina with the lalest drawing 105 Implementation of Operation Standards The woik method definad in oparation standard should ba followed by operators perfor ming tha task, The supervisory offic of the vender should continually chack ifthe standards ae fllawod by the workers or nat, In case workers don't follow the operation standards, the supervisors must erucate them. Also, abnormality handling procedure to he intisted for suspected parts ‘here operation standard was not followed. They must also review the standards and revise than to eliminate any short comings, Worksts should be encouraged to givs that suggestions {or upgrading these standards. ‘VENDOR GUALITY ASSURANGE MANIAESTABLISHMENT OF OPERATIONS STANDARDS: @ manum suzuKi 10.6 Review of Operation Standards Whenever there is a Quality abnormality or a feedback ahnut Quality problem. it shall be ‘thoroughly investigated and curing this time all related operation standasc's must be critically reviewed. Based on investigation results, not only the directly relevant operation standards, but also the anes related to similar operstions must he revised and insraded, The altura "if a slandard is vol ungradad periodically i gradually becomas useless" should navar be forgotten Job Set Up Instructions ‘The instructions (gal up and verification of sat up) fa all jot job changes (ia charge, major tool change, model charge), affecting ertical Gualty charactaristics ete. shall bo made and record forthe: same shoul! be maintained Work inetruction Sheet ‘A Work instruction sheet could be used for describing various aspects of the operation dane al a slalion, The work instruction should canlain step by step details of the operation being dona at the station, charactoristics of the part achiaved af the station, cicalty ofthe part (A Functional. Genorall:safoty & Cualty details and alist of anticipated problems apait hom station, ‘name, model name and pat name. Use of phetogiaphs is highly advisable. Anvexample of Work Instruction stot is given on in Format 102 b. 10.9 10.9.4 10.9.2 4 Operators Inspectors potatorinspentr isa person, who postorms ar-oporation which atts Quali lool of A sm, However, fall siations ina process aflect Gualty Ievels of tems, then the last operator ‘who, assires Gully wil be called, operat, In case, the operations affecting lem are carried ont by hily automatic machines, then the person, who controls the operating condiions {Le settings} ofthe machines wl bs called operator inspector ‘Vendor must nominate only tho senior most and the ablost workers as ' of Their narnes should be entered in a register wih dato of nomination as i opotator finspoctar ‘Whenever ® operator / ingpocter is absont. his work should be carried out ky another A ‘operator ‘inspector only Muliple persane shauld be trained to handle A) slalion, incase of any requirement./A) operators Jinspactors must be distinguished hy making them wear special cap. ‘ar 8 bulge or aim band ele, Also Ihe pholagraphs of all ® operator {inspector should be deplayed al Ihe work salions: tors Inspectors, ‘GENGOR OUATV ASSURANCE WANUAL 7MARUTI SUZUKI ESTABLISHMENT OF OPERATIONS STANDARDS: 40.10 10.0.1 Expression in the work place: In principle, the folowing expressions must ba used in the work stations (1), Putup dlsplay boards with the folowing expressions writwn on them, at tho processing station of parts (Including casting. forging, heal treatment etc. here after indicated as “Process! anda the assembly process Parts ‘Colour : Red latters er White background PartNo, PartName ‘Size :in principle 250 x 1900 rm. (2) Put up display boards with the following exprassions writen on them af tha process stations and assembly procass of ‘8 items. A. hem Processing Station ‘Colour: Red letters on White background, Size in principle 250 x 1.000 min (9) _Put up display boards with the folknving expressions at the dispatch inspontion stage: A Parl Dispatch inspection aaa Colour: Red lattars on White background ‘Size :in principle 200 x #00 mm > parts storage 4} Put up-display boards withthe fallowing expression writen on them, on racks of boxes: ‘Colour: Red letters on White hackground Size :in principle 250 x 1000 mm. ® Pars Pat No. Part Name * ‘VERDOR QUALITY ASSURANCE WAKAESTABLISHMENT OF OPERATIONS STANDARDS ¢ Marun suzuki [SPECIAL ATTENTION 1G PECTOR jae: PAGE WO FORMULATED ON RO OF COMPLETE WOR AR BET REVISIONS FNAL BISPECTION [srennaRo CORYTE: TE JGLABSIFCATION : os [conernoL no. PEREONE parncraren mi nearring: | ATTENTION PLEAGEINFORN TOUR SUPERVISOR IF YOU FEEL ANY MODIFICATION RITHES”“WOS WOULD [GIVE BETTER RESULTS. OUR S&VGERE EFFORTS CAN LEAD TO BETTER "MOS pRartem ey [26 [REASON Pom news] Grom | Gare [| ENG [REAbOweOR nevibwn | GGn | ORE A A A & A A (Format - 10.18) ‘VENDOR QUALITY ABBURANGE MANUAL %marum suzuki ESTABLISHMENT OF OPERATIONS STANDARDS SPECIAL ATTENTION: wove _‘[paatno FORNUCATED OW [0 OF COMPLETE WORE AREA? [DEPT ni ReWIONs se Coro? rime [ELASSIICATION MOS | Nut steering column °°" "0-0 ightening [PERSON W-CHARGE OF OPN LINE SUPEREOR 1) Tighten the four nuts1,2,3,4 fully to wac| the specified torque. i 2) Tightening torque range110 to 170 Kgf-cm 3) Limit Wrench set torque :140 Kgf-cm 4) Put Red paint mark after torque check on steering Column. Follow the tightening sequence and torquing sequence as shown in fig. | Tighten the bolts 5 and 6 at 280 Kg -cm — Tightening torque range:210-300 Kgf -em. re Limit Wrench set torque :255 Kgf-cm anon Put yellow paint mark after torquing bolt-5 and bolt-6. onarnna: | ATENTON: GIVE BETTER REGULTS.OUR SINGERE EFFORTS GAN LEADTO BETTER-MOS™ DRarreo ey [SRO [REASON ron RESON | Sane | URE [SNOT | REASON FOR RENTON S| ORE az az Az zA jz AzA (Format - 10.1b) ‘VENDOR QUALITY ASSURANCE MANUALESTABLISHMENT OF OPERATIONS STANDARDS it Ho I io BRS i! 1 tia i el $ MaRUTI SUZUKI (Format - 10.2a) fi daly Hod |t : vt i Ils|e(el< i | 3 it | tafuals ; Bs i 5 3 | 3 ail i al 3 i! ees ‘VENDOR QUALITY ASSURANCE MANUALESTABLISHMENT OF OPERATIONS STANDARDS marun suzuct (ee'04 - ous) Ieldiaiq = ee ee —— a “SN oDNN SETS emu | vojaied Aseg ‘ayes « ynseu = = Ee © row | FOUS UONINNSU] HOM wor [giz ret mean me —— = ae] =a co &INITIAL FLOW CONTROL & PART SENDAI CHAPTER 11Initial Flow Control and Part Sendai Initia Flow Contr Part Sendai ‘SarP Senda perp a adress problems til FC completion (Flow Chart-11.1) NOTE Risto cat ie bt Ati Fl eon ct hp. Pa otro te cpl ape eld rene ct SL pinzns unewn =INITIAL FLOW CONTROL & PART SENDAI maruni suzuki CRM VDT ST 11.0 This chapter covers the details of special / extra control which should be exercised during the initial phase of mass production when the following occurs 1. New Product / Engineering Change (© Anew patt is manufactured 0 Modification in parts, 2. 4M Condition Change (© Installation or change in machineries / equipment © Major change in process, (© Start of manufacturing after a long lay-off (12 months) © Raw Material Change © Sub Vendor Chango © Operator Change (refer 11.5) 11.4 Objective Special control needs to be exercised during the initial phase of mass production when one of the above items occurs, with the purpose of collecting sufficient data in order to judge whether the mass production can be continued using the existing process or not. 11.2 Establishment of initial Flow Control 11.2.1 Vendor must clearly determine the parameters to be controlled during the initial stage and the ‘duration of such contro. In his, vendor should formulae clear documented guidelines by enacting procedures and necessary standards to establish all the requirements of intial Flow Control as entailed in this chapter. Some of the requirements for Intl flow control are as mentioned below: The following activities related to the pat (for which Ital Flow Controls being observed) shall be carried out during this period > Special inspection / Process Controls that is higher than normal controls, These could be ‘either added inspection points oF inspections at higher frequencies. Establishing Lot Control & Traceability (refer Chapter 16) ‘Sub vondor ausite (if the change happens to be from sub vondor) Process Capability check (important points to be specified: check items, check method, ‘check frequency should be decited along with MSIL QAPQ and implemented) ‘Systematic observation and recording of problem and taking counter measures and improvement actions quickly without undue delay. » Systematic confirmation of effects of countermeasures fr the problems which were observed Establishment and confirmation of proper inspection methods during the intial low period, ‘VENDOR GUALITY ASSURANCE MANUAL a@ manun suzuci INITIAL FLOW CONTROL & PART SENDAI 11.2.2 The initial flow period must be fixed » In principle, the inital flow period should be 3 months or Quanity of parts as decided rmutualy with stakeholder (whichever is later) for new nats. % Tartninalion condliion shall be decided before elat of Inilial Now eonlua, Tha Initial Flow: Control ean ba terminated, fa tha and ofthe inal flow pari, the folloaingy ‘ronson are satiate > Wit is confirmed that the capability ofthe process can fully salialy the specified tolerance: ecutaciy requirernents, > it fp confirmed thet the countermeasures taken for the problems occured during the production of production of mass production lot arr effective, » Ifthe countermeasures taken against prablems observed during initial low period itself are found to be effective, > Httisccntirmed thatrre repeated dofecthas beon toported at customerordfor Zeansocttive clays during intial flow pric > Mallcilsialisted abows are mel, vendor from MSILs QAPO. If any of the erkeria fisted above are rat mat, Iniial Flow Contal period shall be exterdod till the time all eiteria are met hall lake approvallat iilalflow contra lemination 11.3 _Itigessentialthat the person who shall declare & authorise the start & termination of Ina Flow Control period is clearly defined in the organisation. In principle, it shall he € Incharge of the organisation. 11.4 Also, thare should ke clear identtication & display on the process in the shor floor that hitial Flow Goutto is baing observed for the part in question along with the name of the customer, part name, duration ef initial flow control etc, This shal help the paople on the shop flaor to ‘wxercisy the auelod contiols on tha part as required during Initial ow canto 11.5. Qutof tha 4 typa of AM changes (Man, Machine, Material, Method), Man (operator) ralatad changes are the one which is often taken most lightly leaing to serious consequences later on Initial tye control must be observed for even this tyne of change. This becomes all the more important for operator related changes occurring in A’ stations & pracesses: The added or extta contin for such typa of changas could be © Thotugh training of the operator aheur the job, te Gualty and safety aspocts 19 Educating operator ahour the criticalty of his jah and impact of it tallure. © Skill assessment of the operator before putting him on the job. © Special extta check of opsialian carried out by naw opstalor al some dasfned frequency in a day by his supervisor. How: the period for which intial flow conta Is observed (especially the last vonttel), i ‘operator relates changes. could he of shatter duration, say, a few days, (OCR QUALITY ASSURANOE MANUALINITIAL FLOW CONTROL & PART SENDAI $ maruni suzuxi NOTE: Any man operator related change shal be recorded in 4M contol registor(rfor Format-16.1) 11.6 _Allrecords of tal Flow Control shal be retained by the vendor as agreed or conveyed by MSIL 14.7 Reports to MSIL on Process Capability Process capabiliy studies shall be carried out (refer latest “AIAG Manual” for SPC) forall jtoms & Functional items of part and for those characteristics as dacided by Parts Quality ddopartment and these should be submited to MSIL along with “Summary of Monthly inspection report” (SMIR). At any stage ifthe process show sign of instability or show less capability (Cp<1.67 and / or Cpkct.23), corrective actions shall be taken andthe plan shall be submitted to MSIL. Til the corrective action is implemented effectively, the inspection process should be strengtiened in order to ensure right Quali ofthe products. 100% check shall be ensured by the vendor forall such items til the corrective action is implemented. The report shall have the following also: > Analysis of Quality characteristic data/parametors > Sampling plan (size and interval) > Duration & lot size ofthe study 11.8 Deputation of Vendor Quality Representative at MSIL. For (| and Functional parts during the start of Mass Production at MSIL andl the time Initial Flow Controls exercised by MSIL, tis required to have a“Qualty Representative” rom vendor's Production depariment or QC department, at MSIL The "Quality Representative” shall be (© Well aware ofthe process 10 Capable of taking immediate actions (© Implementation of Countermeasures at the vendors end ‘The purpose of having a"Qualty Representative" to have a faster resolution of problem faced MARUTI SUZUKI Teave date NAGARE DEFAULT COUNTERMEASURE REPORT | °° """ ouRGAON J WANESAR I Nagare Default Det VENDOR ___VENDOR/CODE | MT Date of Default SL Partho Part Name Pant Model Qty betaut 5 e Preliminary Invoetigaion roauta: Face DAMON) Root coupe snelyeia: (COUNTERMEASURES PLANNED /IMPLEMENTED apy Dat R ie E no. COUNTERMEASURES BEE mweeenmon ome) § P 4 @ E N ¢ z aedrsion Bards, Psd, Conplor per es} occ Hend EFFECTIVENESS OF COUNTERMEASURES ome Hare sostamnsues en inpamerad wor ey sao 8 ° rerio siome [Seer Detrrton (Format - 13.2) ‘VENDOR QUALITY ABBURANGE MANUAL ®& MARUTI SUZUKI SYSTEMSTOBE IMPLEMENTED AFTER STARTING MASS PRODUCTION Manutacturing & Quality Control -Work Details and Authorities (Example) mcrae 1 | Partiatin be Pade react ewe, Pariciplna Prado pepsin plan ste cretion reeling. ‘Cmte aPretctenprapein set, Paricipt esi ri caoo? eperaneet anager snearse! Sipertoot Deparsnent Pana Manager 2 4 | PeicipatainPrary Proton 4 ‘ {na Martner ‘restos Ouslty Choo shoot ‘rasta O penton Sande /Moslorncton Bhat Proton Preparation 8 | prtetpteincuaty auch, nw Gon Detioyrnatio rEg Changs /ProssaChanges, "ihe ware poen rca oom proces ed pa Tp senagerer) cant th areal ice wag red pai Ba Irvmagrecainenandtcnoorecin store Irlomto Msi evitha Stands opr rocurercsno! rb, ae Formers pana ferietalrastayekedoroes, 0 + | eran mosings Proper Stan Work Cheek machines, Aandance andabeoreocan, pmartate) Provide lnpectoninarnante and coe, ‘Coroatnoraionande cpactontnatunerivandtoa elelae ‘Castander Corel hats Ieper cad, ‘Gheckandracon taproparfirctaningat Pom oho, uy on b Eval reduc Creed Cheha? Mand / Erie {Lage f= © Examinat/ Checteet 2 App (Format 13.3) 100 ‘VENDOR QUALITY ABBURANGE MANUAL‘SYSTEMSTO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION > MARUTE SUZUKI ‘Stancard Operation Inspection Sheet (Example) g-=0K ena RT 3 Operant pire rte Nae cranes mena rami Hoe Caat Sommer | Pot Seer, site setvalues are matching wan tht of nstucion Shes Operation standard ms | eee] lopsmmen |_| [anor 2 [Te condition indicstion values eg Tomp et., have been] |checkod and racordodon checkstioet, lopsratan 3. |The operation is being partormed in lina with he Procass| jseuores | [Operation Fw. [Operators are using all PPE (Perconal Protective] ser [Equipment tome provided thor, I= | Gually Chocks are being parormed aa per conial pian Merk Intnuclon sheet and are being recorded on Ghecl iy Shost = Te Trxstpiaceidonifcation's being done by puting tag on tha] piace [7 [inspections are being dona for operation and equipments |during operation and are being recorded, 5 | Pokavate voriication is being done periodically (in ait) lr Boing roped an Gneck soot (og. Al aro lequiprene | _[ancatterfunch) Jo |igsanaitqure inspection sbeingdone and recorded. [10 | Operaion mapecsona a inepacion Sauipmanl, measur ing instrumentend gauges are beingdone. lomosca |11|Toois are being replaced in accordance with theil Feriscomon | [procedures andsequences. (TealLila Mantoring) 2} Occurence of detects ereported iasupervisors, [Rarcing [18 [Abnormal pieces are ilentfed properb(eg. Wih led tag] lorpain} andare keptat the designated piace lection |14|The parts. meseufing instruments, gauges, tole and] |checkshosts cic. are placed althoirdfined place, 5] Unidenttied objects ere not pisced haphazardly. lpr Hiram ig |Pans are being stored Im container as par the Worl insttucion / Control Pa, (Format 18:4) ‘VENDOR QUALITY ASSURANCE MANUAL 101mMaRuUTI suzuUKI This Page Is Lett Blank ‘VENDGA QUALITY ASSURANCE MANUALREVALIDATION OF PARTS & RAW MATERIAL CHAPTER 14$ marumi suzuki Revalidation of Parts and Raw Material Ee documented procedures for | Parts, Raw Material and Pi (C Prepare yearly / monthly revalidation pian) (C Carry out Revalidation activity as per plan) documented procedures for Parts, Raw Material and Pr Non-conformity observed du revalidation to MSIL's QAPQ. (Flow Chart -14.1) NoTEThe ow carson it‘ Flow descroton ofthe chante Pens gee cugh he complete chap for Gta reqreerte of M ion ‘VENDOR QUALITY ASSURANCE MANUALREVALIDATION OF PARTS AND RAW MATERIAL MARUTE SUZUII 1 REVALIDATION OF PARTS AND RAW MATERI, 14.0 Flevaldalion is a dalailed verficalion of dimencion, melalkiny, appearance, performance, condurance tems a3 montionedin draving o including the MAIS I” Roms which comprise meme for regular chock. All yondor shall carry out rovalioton of parts and tevalcation af ray mora {in caseof % parte affecting ‘item. Inv ease of proprialary ilems, revalidation af inner parks shall ba cutried eu Vendors shall earry out revalidation of sub venders pats Flevalidation of Part and teu material shall be done as por ckawing requiramant 14.1. Establishment of revalidation system fa) Vendor shail haze a documented proced material bb) Vander shall have-a trained personridentifiad person torduing Revalidation activity ©) Mandar shall prepare Yaarly / Morihly Revalidation Plan for all parts and rawy material that are Supplied to MSIL through vesious chaniolsliks GE, KOG & Spares, af loast once in a ‘yuar Ifrequited, malidation at a higher frequency maby also be cated! cut dd) Vandar shall carty aut Revalidation of Process also 2) _llthe parts have ta be checked 100% as per aresving parameters, covering MSIL controlled drawings as well es internal detsiled drawings, covering all child parts and additional cimansions ifany. for camying out Revalidation of Parts and raw ‘The sample size tor checking is as per table below: ome. ‘Crier Serpe Ske (Min) ‘Appearance ‘As por ISP paramotars | 5 pats 3 pails per ine or por molds sable pear AsperMsiL approved | PAK souing For multiple cavity meld, atleast 1 a from each cavily -Asper frequency Mati! (Pertormance J Qurbity |A8PeMequeNey | aa f) Make a vabust internal review mechani effective actions for nan-confotmitias.. fo acura adnate ea le Plavalidation plan fa) Informalion of Non-conlormily abserved during Revalidation shoul! be promplly shared \dilh MS I’s QAPQ along with corrective actions, h) The Revalidation reports hawe to be submitted to MSI's GAPQ on monthly basis in the Formal give in end of thes chapter All the revalidation reports shall be approved bry vendor Quality head and Plant head before submitting to MSIL. YENSOMGLALITY ASS RANICE WARUAL 108REVALIDATION OF PARTS AND RAW MATERIAL, : MARUTI SUZUKI Repo of ravalidation shall be submitted to MSIL through extranet in on lina ravalidation reports 14.2 portal before the 10th of ewory month, + Reter Format: 14.1 for Revalidation Report + Refer Formal 14.2 for Revalidation NC-Information Report 14.3 Allthe material and performance test reports should be submitted by venrior through extranet fn retaliation portal along with dimensional reports and balloon drawing. tt ‘VENOGR QUAL TY ASSUBANCE MANUALAPPROVAL OFFIRST PRODUCTION PARTS & START OFMASSPRODUCTION > MARUTI SUZURCI Fash REVALIDATION REPORT barre uae nese [reer [Oo i ea z (Format - 14.4) ‘VENDGR QUALITY ABSURANCE MANUAL 107IMARUTI SUZUKI APPROVAL OF FIRSTPRODUGTION PARTS & START OF ASS PRODUCTION ‘Revalidation BOs internation Report ‘mst pte etn nas per ere te ‘eee men Sm He (Format - 14.2) 08 ‘VENDOR QUALITY ASBURANGE MANUALPACKAGING REQUIREMENTS CHAPTER 15$ marun suzuxi PACKAGING REQUIREMENTS MSIL shall decide the packagi cations and share with Evaluation of Packing ‘samples by MSIL. input batoh oodo in BIN Car ‘a system for preventive mainten jular checking) of trolley / bin. (Flow Chart - 15.1) NOTE Pi Aly Pw emer fe pi Pinas g tough te compet chap for ied erent WS. io ‘VENDOR QUALITY ASSURANCE MANUALPACKAGING REQUIRMENTS SEM ood a nee 15.0 Packaging af parts is very important in order to preserve Qualily of parte during rans fen the vendor's premises to MSIL and duting storage. This chapter gims quidelines for establishing a system for Dowslonmentof Now packaging, maintaining the existing packaging and Mocifications irvexisting packaging based on requirement. Before dociding the packaging of part, tis advised thal vendors personnel mee! the MSI's OPC: department (Operation Process Control) personnel for specific guidance, Packaging of parts shall be dane in reusable packaging (binsttolleys) unless spaciiad by MSIL. Parts of irregular sizes and weight shall be identified ard special purpose packaging shall ke devised for then, Definitions: Packaging: Any Material employed for transport of Parts from is: manufacturing location to MSILin a defact free condition ill a raquitad stage as dasined by MSIL. Example. Trolles, Bins, Separators and any protoction shests ote Parts- Somi finisher! or firished parts suppliod by vendors which aie to be used after Further processing or direct assembly in any vehicle manufectured by MSIL 15.1 Understanding MSIL Requirement related to Packaging: For new packaging development or Modification of exiting pacleaging: - MSIL guides Understood in coordination with deparlien! rasiponsible for padkaning (OPC Department 15.2 Preparation of samples Sampl of packaging to be prepared as per defined timelines and approval from RISIL 15.2.1 General Guidelines for designing of packagi |Whila designing packauina for a part following factors should ba considered i} Environment protection (Reuse. Recyole, retunable) n & handing ji) Potential damage to parts during transport ele.) and tequited protection ii) Impact of packaging on past during the roquired timeline til part will be in packaging ‘eondltions, iv) Interference (bets ch, tear, deform, slain en parts, parts and container. ete.) 1} Workabilty ( Easiness in toking out, easiness in holding, mix-up prevention) vi) Vibration Shacks to ba undargone during tansport- potamtial effects on parts and raquited cushioning vill) Total load to be cantor! an packaging considering Maximum stacking mquirements. vil) Strength analysis for stacking ix) Packaging ergonomics tke part picking, Wolley movemant ste$ marun suzy PACKAGING REQUIRMENTS: 15.2.2 15.2.8 x) Kind of protection required against weather conditions such as water, heal, air, light. dust, folsign pastas, stc.), during stotags and tiansportation. x) Maintanabiliy of packaging in teims of cleanness ete Zi) Lite expected tiom wearparts ike wher, naint & Veleto's ote xxii) Prevention of past problems ftom recurring. xiv) Eiicioncy of loading and tranpartation of pats 4) Aloguletions and policies with respect to containats of parts and products >evi) It should be sate while handling and during transportation, Colour of Packaging a For Birs- Bluse 6. For Tiolleys- Off White Packaging Identi Unique holley nov Bin no te bis mentioned on Tilloy’s or Bin's ion 15.3 Submission of New Packaging Samples to MSIL & Getting approval In case of new packaging improvement in existing packaging. Packaging samples alan ‘ith filed Packaging Approval Form to be submitted to MSI as per required meine in coordination ‘with OPC denarimant. The sample shallhe chackecl ky MSI . packing i not found salistactary, vendor shall re-suberil the sample aller nicer poraing changas Jim provements ais prapessd bp MSIL. Vondor ig pected fo cairy oul the nocosealy changas in the supply of noxt lot whicty shall again be subjoctod to evaluation. ‘Also\Vendor shall submit the Proventive Mairtenance system proposal Le, Schedule ot inspection. checks of packaging and applicable Check- Shesls for Troley / Bin alc. lo MSI In principal all davalopment related activilies ta ba completed by ana month bafora the cuL-att data of Pilot Production start date. Alt! approval, parta shall be supplied in approved packaging cy. Vendor shall submit the sample latin the approved jacking wth each containers identification tag marked PP;MPT/Plot Trial hlateral’. The MSIL’s GPC along vith MSI's GAPQdepariment and Shop stall check hs trial lot packing (Packaging chetkai) as per he appioved specificatio dawings and photographs. In caso the packaging is found unsatisfactory. the: same shall ba intimated to the vendo with required changes’ improvements. Vendor is expester to carry aut the necessary changes in the supply of next lot which shall again he subjected to evahuetion, 15.4 Day wise colour coding of labels: + Monday = While © Tuaselay = Magenta © Wednesday ‘Golden Brown VENDOR GUAL TY ASSUAANDE MaNALPACKAGING REQUIRMENTS $ manun suzuic + Thursday = Vile Green + Friday — Oranges + Saturday Process Blue Sunday — Purple In case of i parts, iA’ shall be printed on the label, 18.5 Necessary Information to be printed on Packaging Labels Folloving information shall be piinted on labels which should ba pasted / put on Catton ! Bin / Trolay i. Part Name ii. Part Number fof MSIL) ii, Box Number (Box numbstToal no, of boxes in thee supply) iv Mods! 8 Batch ode vie Vendor vi, Vendor Name Dates of Despatch Date of Supply in, Quantity (Pack quantity and Lot Quantity) x Challan No, xis PSL (Plant Shop Line) xii, Packing Gods 15.6 Routine Supply of parts During routine packaging of parts. folsing activities to be followed and implemented 1. Colour coring to be fllewed as persay-wise schedule described in point 15.4 2 Tea printing and eltaching as per items described in point number 15.5 {Inspection and maintenance of packaging as per approved system from MSIL (Note applicable rocordstu be stored at vendor end as evidence of maintenance activtios) 4. Rostiication of any aroblems ¢ abnormalities informed hy MISIL on piety {VERON SUALIT® ABELTANCE HARUAL 1p MARUTI SUZUKI 187 PACKAGING REQUIRMENTS Maintenance of Existing Packaging: Routine checking and audit of Packaging at MSIL MSIL shall be coingranciom vestcations checks of packaging a parts receipt stage. Problematic Packaging shall be Kentitied and a VPPCR (Vendor Packaging Problem countermeasure report) shall be issued 10 vendor {refer Format: 15.1). Vendor shal take appropriate Cowntermeasties and submit the VPPCR to MSIL as per the timeline informed by NISIL, andor shall check i any modification quired in Pravantiva maintenance systam Le, Schad of ingpection and chack-shaat as a countermaasuta for Packaging ploblem aril shall discuss ‘sith SIL Modified Preventive maintenance checksheet shall he approved by MSIL Ieeue of VFFCR Receipt of VPPCR oF Preliminary invetigation result —_— ‘Daciding sountermeasure for prevention of ee Tlarizontal application of caunarmeaauraa in similar models / processes / vendors (Packaging) “Approval of VPPCR by packaging incharge ‘of supplier Lot seppte, ‘Rscsipt and confirmation of countermeasures: “Submission of approved VPPCR to MSIL (Rep) eNDoR GAL TY waMUaL