QA Manual Supplier 2nd Edition 2014Y - Last Revise 20 Nov

PT.
Krama Yudha Tiga Berlian Motors
Quality Assurance Manual

for Suppliers
2nd Edition
December 2014
PT. Krama Yudha Tiga Berlian Motors

Production Engineering Division
Quality Control Departement
1
Introduction
This manual has been prepared for you as supplier of components or materials, or what we
usually refer to as “Parts” that are required for the production of Mitsubishi vehicles in Indonesia
both commercial vehicles and passenger vehicles. And you as supplier of components or
materials that we usually call “Supplier” are expected to understand the policies of the quality,
activities and procedures necessary for quality assurance and other principles.
In this case we mean “PT. Krama Yudha Tiga Berlian Motors” ask you directly or indirectly
involved in quality assurance to really understand the purpose and contents of this Manual and
try to keep and improve the quality of the Parts that you provide to us.
We ask you to understand and help to implement our quality policy that is “Continuous and
sustainable improvement in products and services, to achieve the first-class company with
international standards”. In other words “we always put a priority on quality and service in all
activities of our business including the Parts that the suppliers send to us.
We also ask the supplier to prevent leakage of the contents of this Manual to third parties
and others without the permission of PT. Krama Yudha Tiga Berlian Motors.
This manual can sometimes be corrected or added in order to follow the changes existing in
our company.
And we will try to improve the content of this Manual to make it more perfect and if you as
supplier want to give input for the improvement of this manual, please inform your input to the
Quality Control department.
December 2014
2
Document Change History
No Date/Month/Year Explanation of the Changes Remarks

1 November 2003 First manual published
2 December 2014 Second edition manual published
3
Table of Contents
Chapter I GENERAL
Chapter II Basic requirements of quality assurance
Chapter III Quality Assurance Procedures
Chapter IV New part preparation
Chapter V Production Part Approval Process (PPAP)
Chapter VI QC approval (Initial Product Inspection Result)
Chapter VII Inspection Agreement
Chapter VIII Control Plan
Chapter IX FMEA
Chapter X Process Capability
Chapter XI Determination of the person in charge of the quality
Chapter XII Production Code
Chapter XIII Initial Process Control
Chapter XIV Monitoring & Maintenance of Production Equipment
Chapter XV Monthly Report
Chapter XVI Notification of the change plan (4M change notive)
Chapter XVII Value analysis/value engineering
Chapter XVIII Vendor Audit
Chapter XIX Handling of Importing Parts (KD Part)
Chapter XX Handling of Local Parts
Chapter XXI Special acceptance
Chapter XXII Claim assurance service and Product Quality Report
4
PRELIMINARY
1.1. Aim
This manual prepared with the aim that the Suppliers/Vendors can understand and carry
out quality inspection activities to the manufacture of products, goods or components to be
sent so as to produce products, goods or components as shown in the drawings and
specifications submitted by KTB to the Suppliers.
1.2. Procedures
This “Quality assurance manual for the supplier” applies to all suppliers/vendors that
send the products, goods or components of the vehicles to KTB or Assy Plant designated
by KTB.
1.3. Contents of the manual
This manual consists of 21 chapters, which consists of one GENERAL chapter regarding
the agreement between the company (KTB and Suppliers) and 20 chapters concerning the
procedures that should be known by every suppliers/vendors and enclosing various
supporting tables. The procedures include:
0 Preliminary
1. Chapter I GENERAL
2. Chapter II Basic requirements of quality assurance
3. Chapter III Quality Assurance Procedures
4. Chapter IV New part preparation
5. Chapter V Production Part Approval Process (PPAP)
6. Chapter VI QC approval (Initial Product Inspection Result)
7. Chapter VII Inspection Agreement
8. Chapter VIII Control Plan
9. Chapter IX FMEA
10. Chapter X Process Capability
11. Chapter XI Determination of the person in charge of the quality
12. Chapter XII Production Code
13. Chapter XIII Initial Process Control
14. Chapter XIV Monitoring & Maintenance of Production Equipment
15. Chapter XV Monthly Report
16. Chapter XVI Notification of the change plan (4M change notive)
17. Chapter XVII Value analysis/value engineering
18. Chapter XVIII Vendor Audit
19. Chapter XIX Handling of Importing Parts (KD Part)
20. Chapter XX Handling of Local Parts
21. Chapter XXI Special acceptance
22. Chapter XXII Claim assurance service and Product Quality Report
23. Closing.
5
All of the procedures above may change from time to time in accordance with the
development of the situation, if there is change so KTB will send immediately information to
each supplier.
6
CHAPTER I
GENERAL
Quality assurance of the suppliers must be able to fulfill the requirements that exist in the
Purchase Agreement, including the principles for the quality assurance that consists of:
1. Agreement of Monitoring Procedures of Quality Assurance
2. Agreement of Assurance of Claim.
3. Memorandum of Agreement of Production Tools Procurement.
The agreement above as one package of inter-company agreement.
This manual is provided to explain the requirements specifically and consists of several
parts as below:
1) Chapter.II. Basic Requirements of Quality Assurance.
2) Chapter.III. Quality Assurance Procedures
3) Chapter.IV. New Goods/Parts Preparation
4) And so on until Chapter XXI
5) Closing.
1.1. Quality Principles

Management policies of PT. KTB regarding quality assurance are the same as the
expectation on the supplier. Nowadays the customers of automotive industry in Indonesian
are worldwide and not limited to the local level only. Four or more wheeled vehicles have
become a tool/need that can not be avoided by human life.
On the other hand, with the existing of the tendency of the customer taste that is always
changing, market demands and desires such as better vehicle endurance and energy
savings become stronger. Such conditions are usually used as a rule is required, and moral
responsibility becomes a very important thing in order to meet market demands and those
regulations.
To respond to such condition of society, PT. KTB is trying to publish an appropriate
corporate quality policy, namely “Continuous and sustainable improvement in products and
services, to achieve the first-class company with international standards”.
To get the public recognition of its product quality, so “the reliability, trustworthy superior
quality the customer” is expressed as the management basic policy, and PT. KTB is
implementing its quality assurance activities through the entire process of planning,
development, production preparation, mass-production, sales and after-sales service.
There is quite a lot of automotive components received by KTB derived from the
suppliers, and the quality of these parts plays a very important role in determining the
overall function of the vehicle.
On the other hand, from our record indicates that some of the cases that occurred in our
customers one of them caused by the problem of product quality, from goods sent by the
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suppliers that do not meet the quality requirements. The experiences in the past show that
just one quality problem occurs on a product/good, it will cause the claim of damages in the
amount to billions rupiah. So it is very important to develop the procedures for monitoring
quality assurance and to ensure the reliability of the quality in order of product loss
prevention. And it must be remembered as well that the suppliers have a very big moral
responsibility to the customers even for goods with a simple function.
PT. KTB is expecting their suppliers to create and implement a system that can ensure
and guarantee that all products are delivered to KTB have met all quality requirements.
1.2. Quality assurance

In the purchase agreement it requires the suppliers /vendors to ensure its production
goods “free” from the quality problems. The quality assurance contained in the agreement
of monitoring procedure of the quality assurance includes the agreement of assurance of
claim as a systematic activity of the manufacturers to produce a product with the
satisfactory level of quality that is required by the customer. Therefore the suppliers
(suppliers/vendors) are strictly not allowed to deliver troubled products to PT. KTB,
although it is only one claim good that has the quality problems. In order to achieve this
satisfactory quality assurance, then the quality must be built from a range of products
starting from the planning stage of production, development including design and trial stage
of production, then continues to the stage of mass production by emphasizing the basic
concept of “The quality is built by each individual” and “only making/producing a good
product and discontinuing products that do not conform to the specifications/fail”, including
carrying out inspection before delivery (pre-delivery inspection) as the final stage of quality
assurance. And one thing that is also important in the quality assurance is performing
analysis of the process and machine capability during the development period, the initial
process until the time of mass production.
To achieve the above objectives should be instilled reference of all the activity that is
"Building quality through the production process" and "Just making products with good
quality from the beginning and never send the product with quality problem at a later stage."
For the most important suppliers are set a complete quality assurance system that can
cover the entire process up to the delivery of goods which are already finished, and on the
basis of the above requirements is expected to create a working system that produces
quality products, which not only meet the requirements of PT. KTB but also certainly have a
high reliability of the item itself.
At the time KTB has to suffer losses due to product failures that cause claims from the
customers, where the product failures are caused by the negligence of the supplier, then its
compensation of all losses caused must be borne by the relevant supplier.
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1.3. Acceptance inspection and quality audit.

On the consideration that all goods delivered by the suppliers to PT. KTB should be
free from all of the quality problems, then PT. KTB can do inspection of the good
acceptance to confirm the quality level of the goods received from the suppliers. In
principle, the inspection is conducted by random/sampling method. Even if an item is
known having quality problems, then it is possible that all lots are decided having the
problem as well.
The suppliers are asked to not cause any disruption in the production schedule of
KTB, and should immediately take the necessary action that must prevent the quality
problems.
On the basis of mutual trust on both parties, if it’s necessary then KTB can perform
quality audits, with the aim of confirming the system of quality assurance and quality
control are implemented in the production process of the suppliers.
If at the time of the audit a discrepancy is found, the suppliers are required to fix the
problem as soon as possible according to the suggestions and advice given by KTB.
1.4. Feedback of quality problem information.

PT.KTB will inform the suppliers if found any quality problems of the goods received
by using Countermeasure Request Sheet (CRS). The suppliers are required to take
appropriate and immediate action to prevent similar problems and poured into CRS to
be sent back to KTB.
PT. KTB will issue monthly reports related to supplier performance connected with
the quality problems of parts that are found in assyplant and carpool of KTB to all
suppliers.
After receiving the result, the suppliers are required to take immediate action to
repair and improve its quality assurance system.
1.5. Closing record.

The principles of KTB for quality problems have been described above. On the basis
of the principles, KTB will make a variety of opinions and suggestions to the supplier
that the quality level of its products is under the standards required by KTB. It starts
from the discussion of the requirements until maintaining and improving the quality of
the products that eventually will get its own appreciation from the customer. Prevention
of the loss of a product (product liability prevention) will be improved and the action will
produce a brilliant prospect future through trust and mutually beneficial cooperation.
KTB is asking for positive cooperation from the suppliers and the suppliers who are
already performing activities for quality assurance appropriately and actively expected
to continue their efforts to achieve better quality.
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CHAPTER II
BASIC REQUIREMENTS OF QUALITY ASSURANCE
The suppliers are required to make an internal quality assurance system to meet the
requirements determined by the KTB also with the procedures to implement such a system.
Basic items required by KTB for their suppliers to the quality assurance are shown in Table 2.1.
In the table, (A) represents KTB and (B) represent the suppliers. On the other hand KTB
expects the leader from the supplier provides support for the procurement or investment of
resources (human, tools, etc.) that are considered important to support the implementation of
quality assurance activities.
The following are the requirements that must be performed by the suppliers related to the
quality assurance:
Table 2.1 Basic requirements of Quality Assurance
Items Decription
1. Quality Assurance System 1. The following points below should be determined to issue
Note : the quality assurance system.
(A) KTB a) Basic policy concerning the quality.
(B) Suplier b) Diagram of the system for the quality assurance.
c) Organization for the quality assurance.
d) People who handle (PIC) for the quality assurance
(as people with the full responsibility of the quality
assurance of the products to be delivered by (B) to
(A), a section chief and vice chief should be
nominated and introduced to (A).
e) Flow of standards and standard procedures for
quality control (QC).
f) Training program for quality control (QC).
g) Other things as may be necessary to improve the
quality assurance.
2. Activities such as the activity of small groups must be
improved to motivate quality safety and improvement.
3. Should establish a procedure for how to get a
confirmation of (A) for inspection procedure.
2. Controlling the There msut be a rule governing documents such as
specifications and other drawings, and the specifications for easy access whenever
documents needed.
3. Improving and developing 1) At the stage of development of new products, the system
new product for quality assurance must be implemented/ executed.
PPAP documents such as: APQP, FMEA (design and
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process), etc. is one effective tool in planning a quality

assurance system.
2) The facilities and capabilities must be prepared for the
test
4. Control in Initial Stage 1) There must be a procedure for controlling the initial stage
Note : of new products, design changes, changes in the
(A) KTB production process, etc.
(B) Supplier 2) When producing the goods designated by (A) in the initial
stage of a new product, the personnel of Quality Control
at (B) may call (A) for consultation stage between (A)
and (B). It is called the system of Quality Engineer.
3) In the case of design changes and changes in the
production process, it should be reported to (A) according
to the method determined by (A) through the Notice of
Change Plan form (4M change notice).
4) The first product must be delivered to (A) along with the
inspection report which has been determined by (A)
5. Inspection Procedure 1. Inspection procedures should be specified for
acceptance inspection, inspection during the process
(self- inspection) and delivery inspection (final inspection)
that depends on the characteristics of the quality,
capability process, etc. Such procedures shall include the
stage of initial inspection, daily examination and periodic
inspection separately.
2. The overall inspection (100%) must be made in respect
of goods which are categorized as (safety part) of goods
with the important quality characteristics, etc.
3. Periodic quality evaluation should be designed to
maintain and improve the quality by checking the level of
quality by processing data with statistical methods.
6. Precision control of the 1. The regulation for controlling the measurements must be
equipments. made by clearly defining the procedures for controlling
the accuracy of the measuring equipments, testing
equipments, etc.
2. The same procedures should also be performed to jigs,
molds, gauges, etc. such as no. 1 above.
7. Quality control of the goods 1) To assure the right quality of raw materials, the goods
purchased and supplies purchased by (B), the requirements for the
Note: supervision of the quality must be met by suppliers (sub-
(A) KTB contractors).
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(B) Supplier 2) The quality assurance procedures over suppliers (sub-

contractors) must be confirmed and advices must be
given when needed.
8. Control of important goods, To ensure the safety of a product, the procedures of specific
Safety Parts quality controls should be made for the important goods
(safety parts) with specialization in marking, identification,
confirmation of trustworthy quality.
9. Control of Production 1) To ensure the quality of a product it is needed: a stable
Process process, control of processes and products, as well as
Note: control methods for each process. It can all be explained
(A) KTB in the QCPC/Control Plan, SOP, Checksheet Process
(B) Supplier (Control Chart), etc.
2) Conducting an analysis of process capability/CPK to
determine whether the results of the process are still
within the specification or have been beyond the
specifications so that it should be improved in order to
achieve the ideal value.
10. Control of special Special production processes such as heat treatment,
production process welding, surface smoothness (surface treatment), etc. must
be controlled by making a regulation to control the existing
facilities and good working management. Most of control over
the facilities is for tools, equipments, and production
conditions.
11. Reliability test To ensure the reliability of a good, periodic test for reliability
Note: must be made on the characteristics determined by (A) and
(A) KTB other important characteristics. This test is done at the
(B) Supplier beginning of the manufacture of new goods and conducted
periodically at the time of mass production (in accordance
with the agreements in the Inspection Agreement)
12. Prevention of loss of quality 1) To prevent corrosion, contamination by dust, damage,
deformation, loss of quality and performance, etc. of the
materials, parts and products in storage, packing and
transportation, appropriate measures should be made
clear methods and work instructions are prepared.
2) Setting in and out of goods/first in - first out (FIFO) must
be executed carefully.
13. Actions to overcome the 1) The procedures must be made regularly that enable the
quality problems separation of troubled goods come into the production
Note: and inspection process so as to prevent the reoccurence
(A) KTB of problems ever informed by (A).
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(B) Supplier 2) When there are troubled goods found by (B) or its sub-
contractors, but it has been delivered to (A), then it must
be communicated to (A) immediately and corrective
actions should be taken as instructed by (A).
Quality Audit Quality audit must be conducted periodically in the system
Note: (B) and its sub-contractors. Corrective actions must be
14.
(A) KTB recommended according to its needs, corrective procedures
(B) Supplier must be improved, and the results should be confirmed.
Data collection and the use The quality information that is in the internal (B) and its sub-
of quality information contractors to the products delivered to (A), should be
15. Note: collected and analyzed in good ways and should be feed
(A) KTB back to the related section for the development and next
(B) Supplier production.
1) Lot Control on the products is very important, especially
in identifying or mapping the troubled parts so that they
Lot Control/Production
can be traced (traceability) until which lot the parts are
Code
troubled. For parts with a very important category
16. Note:
(safety & important) granting lot control is a must.
(A) KTB
2) Setting in and out of goods/first in - first out (FIFO) must
(B) Supplier
be executed, both in the warehouse of raw materials and
in the warehouse of finished goods.
17. Maintenance of Quality As evidence of the procedures and actions taken for quality
data recording assurance, the data must be stored for the period of time
specified as follows:
Storage Period
(after the model is
No Name of data finished)
Ordinary Safety
Part Part
a. Data Recording of 5 years 10 years
initial inspection
Storage Period
No Name of data Ordinary Safety
Part Part
a. Initial data of inspection
b. Inspection and
maintenance data for
production facilities and 5 years 10 years
testing equipments.
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c. Inspection Data
(including reliability test)
according to inspection
procedures for material
of goods and supplies 5 years 10 years
d. Control data for
production process
(self-check).
e. Recording data of
delivery inspection (final
inspection) including
reliability data.
f. Taking note the actions
taken to overcome the
quality problems. 5 years 10 years
g. Data recording of audit
quality.
h. Recording Control Lot
i. Recording of other
data’s that designated
by (A)
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CHAPTER III
QUALITY ASSURANCE PROCEDURES
3.1. Definition
The quality assurance procedures is a procedure that describes the steps that must be
performed by each supplier, especially from the section of quality assurance (quality
assurance Department/section) in ensuring the quality of the products from development
stage to mass production.
3.2. Aim
The quality assurance procedures are aimed as a guide to steps/actions to be done by each
supplier to maintain the quality of the products produced from the stage of pre-development,
during development, initial production to mass production (feasibility study, development,
initial production and mass production), including the documents that must be prepared and
submitted.
3.3. Procedures
The scope of procedures
These procedures must be executed by each supplier of KTB, as one of quality assurance
in accordance with the above aims.
The quality assurance procedures will be shown as follow:

Time of Execution
Document
No. Description Explanation Develop- Mass/Pro
submitted Feasibility Prototype
ment & Trial duction
1. Supplier The selection & RFQ
●
selection determination of
vendors for
localization of new
parts
Qualification audit
●
(system audit)
2. Confirming Confirming the
the following items:
capability - Process plan Breakdown ●
and - Capacity study chart ●
readiness sheet Production
of the - Detail of testing Capacity Form ●
vendor to specification Testing List
perform requirement
15
localization - Part sourcing ●

(Feasibility process and New Form
study) material
information
sheet ●
- Quotation (cost
detail) Form 1A ●
- Development &
Production AP QP Form
Preparation
Schedule ●
- Pallete Design ●
- Quality Pallete Design
Management Quality ●
- Determination of Management
the person in Form
charge of the QC
quality control Administration ●
- Material & Form
tooling ●
information Tooling List ●
- FMEA FMEA Form
- Drawing Proto Drawing
prototype
3. Prototype Manufacturing Check sheet
sample proto product using
temporary tooling, ●
hand made, wire
cut, etc.
4. Testing Testing report Testing report
Report & refers to the detail form
Analysis of testing ●
(Prototype specification
Part) requirements
5. FMEA Doing analysis to Process FMEA
Process various forms of Worksheet
Revision Revision/ Revision/
(Execution failure that are / Update Update Update
of FMEA potential to occur in ● ● ● ●

Process) manufacturing
process and
determining the
16
method in the
process to prevent
the occurence of
problem rejected
parts made.
6. Preparation Making/planning Floor Layout
of Floor layout process Drawing
Layout (from raw materials
Drawing to finished goods)
wherein includes
the location for ●
inspection,
repairing area,
placement of NC
(non-conforming)
products.
7. Production Making production Tooling list
Tools tools (dies, molds,
●
Manufacturi mandrel, jigs, etc.)
ng
8. Drawing The design of proto Drawing
approval drawing that has Approval
been confirmed and
●
approved by KTB,
submitted as
approval drawing
9. Pallete Making pallet in Palette
manufacturi accordance with Design/
●
ng for part the design that has Approval
been agreed.
10. Product Making the part/ Testing Report
Testing product testing that
Process is required both in
●
drawing and
Mitsubishi
specifications.
11. Creating Determining work Supplier’s
working standard and Form
●
standard procedure for doing
and training training operators.
17
the
operator
12. Confirming Verifying data such Consistency
and as dimensions, checksheet
verifying tolerance and other between the
drawing technical data in Drawing and
with the drawing whether it Records
Document/ is already same
Record that in the
(Confirming document (such as: ●
the check sheet,
consistency inspection
between standard, control
each plan, WI, etc.)
drawing especially for parts
and record) with safety
characteristic.
13. Part History Every problem Part History
Record occurs on each Record
during stage of
Developme development and
nt corrective actions
●
(Developm must be recorded
ent of Part and verified for
History repairement
Record performed whether
Document) it is effective or not.
14. Production Giving production Supplier’s
Code (Lot code is aimed to Form
Control/Pro ease the ●
duction traceability or a part
Code)
15. Part Quality Meeting between Minutes of
Meeting KTB and the Meeting
(Part suppliers
Quality discussing
Examinatio development ● ●
n Meeting) progress &
evaluation of status
of production
preparation and its
18
quality control tools.

16. Pre Production trial
Production before mass
production.
Performed in 3
●
stages, namely P1:
100 units, P2: 200
units, PP: 500
units.
17. Process & Verifying the actual Quality Audit
Product process of Form
Verification manufacture/produ
(Process ction by ensuring all
Audit & quality assurance
Join (QC Gate) and
Inspection) preventive actions
to NC product are ●
running well and
performing part
audit to ensure that
the parts are in
accordance with
the standard &
specifications.
18. Analysis of Analyzing process Supplier’s
Process capability to find out Form
Capability whether the output
of a process in
accordance with Performed continuously until mass production
● ●
the specification.
This analysis can
be done if the
process was
already stable.
19. Part Quality Quality approval of PPAP Form
Approval a product that
(Part submitted by the
●
Production supplier, where all
Approval requirements &
Process – specifications
19
PPAP) determined by KTB

have been met.
Part may be
produced and sent
if there is an
approval from KTB
QC.
20. Initial Controlling process Initial Process
Process specifically in the Control Result
Control first 3 (three) & Notification ●
months of mass
production.
21. Control & Maintenance and Supplier’s
Maintenanc control of Form
e of production
Production tools/equipments, ●
Equipment jig, tooling and
reporting abnormal
conditions.
22. Monthly Inspection data Monthly
report submitted to PT Report
KTB every month is
in accordance with
the parts ordered
for production need
of vehicles. The
●
content of the
inspection data
must be in
accordance with
the agreed
inspection
standard.
23. Change of Notification by the PRPP/D, ECR
Production/ supplier if there is a (if there is
Design change of process change of
Process of or design. design), PPAP ●
a Product (if it is
(Change requested by
Control) KTB)
20
24. Execution VA/VE program Supplier’s

of VA/VE performed by the Form, ECR,
(Value supplier is aimed to PPAP,
Analysis/ minimize the total PRPP/D
Value of production cost ●
Engineerin or it is also possible
g) Program as quality
and its plan improvement of a
detail part.
25. Quality Doing process audit Quality Audit
Audit and part audit Form
periodically or if ●
there is serious or
serial problem.
26. Handling of If found quality KDQR
quality problem for
problem of importing parts
Importing (CKD), KTB will ●
Parts (KD make claim report
Part) in the form of
KDQR.
27. Handling of If the quality CRS
quality problem found for
problem of local parts, KTB will ●
Local Parts make claim report
in the form of CRS.
28. Request of Supplier may Special
suppliers submit special Acceptance
(supplier/ acceptance for Form
vendor) to parts that are not in
be able to accordance with
accept the
exceeding standard/specificati
●
parts and on with the terms
so on that it’s not safety
(Special part, do not disturb
Acceptance installation in
) vehicle, do not
disturb the function
and not clearly
21
seen.
29. General Explaining Product
explanation generally if there is Quality Report
of Process a claim from (PQR),
Warranty customer regarding Warranty
Service part failure that Service Claim ●
Claim and occurs in vehicle (WSC), and
Product due to the quality of Technical
Quality the part. Report (TR)
Report
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CHAPTER IV
NEW PART PREPARATION
New part preparation is preparation that must be done by suppliers in order to manufacture
a new good/product. The activities to be done include confirmation of readiness/capability of the
suppliers to perform localization, manufacturing part prototypes and production preparation until
the local/supplier production goods approved by KTB.
New part preparation consists of 3 stages, namely:

 Feasibility Study.
KTB confirms the readiness and capability of the suppliers to perform localization. At this
stage the suppliers are asked to prepare some documents of Feasibility study to be able
to go to the next stage.
 Part Development (Prototype).
At this stage, the suppliers make a prototype good together with the results of part testing
and inspection of overall dimensions (ISIR data).
 Production preparation.
At this stage the suppliers can start doing production trial with quantity of the parts is
greater to see the stability of the process and also confirming fitting on test on the vehicle.
At this stage the suppliers are asked to prepare PPAP documents as a requirement
before the Final part of approval approved by KTB and continue to the stage of mass
production.
Here is an explanation for each stage,

4.1. Feasibility Study.
4.1.1. Aim
Confirming the readiness of the selected suppliers to perform the localization of new
parts.
4.1.2. Items to be confirmed:
 Development & Prod. Preparation schedule
Creating the schedule (master schedule) of the process of development, trial until
production preparation by using APQP form.
 Process Planning
Making the process order to make goods from the beginning to the final product and
delivered to KTB.
 Drawing (proto approval)
Making proto drawing refers to the specifications of control drawing.
 Capacity study sheet
Creating and analyzing the production capability & capacity, whether it can meet the
production needs in KTB.
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 Detail of testing spec requirement

Making a list and schedule for the testing of products and materials to do that refer to the
specifications and requirements specified in the drawings and MMC/MFTBC
specifications.
 Material & tooling information
Creating a list of materials used, including for small components (child parts) and making
a list for production tools that will be made related to the new parts localization, including
jig/pokayoke inspection.
 Part sourcing process and material information sheet
Making a component list used and informing the place where the material purchased,
where the manufacture of die/mold is done and where the process of each part is done.
 Quotation (Cost detail)
Making the price details proposed to manufacture the parts, including the testing and
pallet/packaging price.
 Palette Design
Creating a palette design that can maintain the quality of products starting from shipping,
storage in a warehouse until delivering the production line in assyplant.
 Quality management form
Making a list of the quality management system that has been applied on the suppliers
and the supplier performance during the last 1 year to be considered by KTB in observing
the supplier performance.
 FMEA `(Failure Mode Effect Anaylisis)
Aiming to take precautions so that the same problem does not occur. With this review,
errors in design,` process or during delivery can be avoided.
The problems made into a FMEA form (failure mode effects analysis)
4.1.3. Feasibility study (FS) approval
All of FS documents that have been sent to KTB will be re-verified and confirmed and
also at this stage decided whether this localization can be performed or not by the
suppliers based on the conclusion of the confirmation items above. If it is approved, then
KTB will issue LOI development that will be sent to the suppliers.
4.2. Part Development (Prototype).

If at the stage of Feasibility study it has been approved by KTB, the localization process is
continued to the stage of Part development (prototype).
4.2.1. Aim
At this stage, the suppliers makes the prototoype product and from the product an
analysis is done on the design both in terms of dimension, function and installation and
also the overall test. If a failure is found in which the prototype part does not fit design
drawing, the suppliers are required to directly making improvement, and that need to be
24
noticed is the allowable improvement is 3X, if at the third improvement the failure is still
found KTB will stop the localization process.
The documents are to be made and sent to the KTB at this stage:
 ISIR data
Inspection of all the data that made refering to the drawing.
 Detail testing result
Perform product and material testing based on the requirements and specifications are
determined by the drawing and MMC/MFTBC specifications. The results of these tests
are sent to KTB and the goods of the testing results stored by the suppliers for further
analysis (if needed). At this stage, KTB and the suppliers will perform Fitting On Test
(FOT) in vehicle to ensure the part design is not troubled.
4.2.2. Prototype approval
All data and results of FOT will be re-verified and confirmed and at this stage it is also
decided whether it is able to continue to the stage of preparation production, based on
the conclusion of the confirmation items above. If it is approved, then KTB will issue LOI
Production that will be sent to the suppliers.
4.3. Production preparation
This stage is the execution or implementation of all the plans that have been agreed at
the stage of feasibility study, starting from manufacturing tooling, product testing,
manufacturing pallets, until the production trial.
4.3.1. Aim
This stage ensures the stability of the process with more production, so as to reflect the
condition of massproduction later.
In order to guarantee and ensure the stability of the process is going well and the quality
of the product is assured, then the following items should be executed:
 Performing the stage of trial (P-try and Pre production) and evaluation of the number of
more production quantity. Part quantity is according to the agreement betwen KTB and
the suppliers.
 KTB will conduct the audit process at the suppliers refers to the control plan that has
been made.
 KTB will also conduct join inspection at the suppliers based on the existing drawing and
specifications.
At this stage, KTB and the suppliers will also do Fitting On Test in a vehicle with a larger
quantity to ensure the stability of the process and also confirm the installation prosess in
assyplant.
 The suppliers must submit PPAP (production part approval process) document to KTB for
evaluation and reconfirmation. Details of PPAP documents will be discussed in this
manual.
4.3.2. Final Part approval
25
After all items have been confirmed, then KTB will decide the status of parts through the
Final Part Approval, and then KTB Technical will issue EO (engineering order) to the
suppliers
Flow chart of Localization (new development )
26
27
CHAPTER V
PRODUCTION PART APPROVAL PROCESS
(PPAP)
5.1. Definition
Production Part Approval Process (PPAP) is the agreement of the quality of the parts that
will be mass produced and delivered to KTB.
5.2. Aim
 Ensuring the parts that will be sent already met all the quality requirements set by KTB
 The suppliers must submit an application for approval to the delivery of production parts
to KTB and will begin to deliver after approval.
5.3. Procedure
 If there is a manufacture of new products or changes in design/materials/processes,
KTB QC will inform the suppliers regarding the materials/ PPAP requirements that have
to be made and performed by the suppliers. This also applies if the changes of
design/materials/processes derived from the suppliers.
 Materials or documents for PPAP can be seen in “PPAP Submission Material Table”
 PPAP submitted to KTB QC after the pre production trial is completed.
 Delivery of parts for production can be done if there is approval from KTB QC. As long
as there is no approval, the suppliers should not deliver the parts.
5.4. Submitting PSW (Part Submission Warrant)
PSW (Part Submission Warrant) is a guarantee for parts that will be delivered. Before
applying for PSW, the suppliers must ensure that all quality requirements and
specifications set by KTB have been fulfilled.
Before the first delivery made, the suppliers are required to conduct an evaluation to
ensure that prior the delivery the parts condition is already in accordance with the
specifications.
5.5. Approval Notice
The inspection results of PPAP will be informed by KTB QC by sending a copy of PSW that
indicates whether the part is approved or not.
 Not Approved
Part should not be sent. KTB will explain the reason for the parts not approved and the
suppliers will be required to repair immediately.
 Conditionally Approved
Part may be sent with specific requirements.
If the requirements are met then the suppliers can resubmit PSW for unconditional
approval (Full Approved)
 Full Approved
Parts can be delivered
28
5.6. Form
See attachment regarding the form of “PPAP Submission Materials Table” and “PSW (Part
Submission Warrant)”:
PPAP Submission Materials Table

Supplier Code :
Supplier : Issue No.
To the Administrator Date of issue :
Quality Control Department.
Part No. <1> Approved Checked Prepared
Issue
Part Name.
Model.
Supplier due date submission
Date of submission by the supplier
<2> Approved Checked Prepared <3> Approved Checked Prepared
Reception
Submission
w hether Instruction of
Confirmation
No Submitted record name Form Remarks submission submission
by Supplier
is required by KTB
1 PPAP Submission Materials Table (this form) O O
2 Parts Submission Warrant (PSW) O O
3 Design Record (Drawing & Specification) O O
4 Engineering Changes Documents O O
5 APQP Schedule ( production preparation plan ) O O
6 Part History O O
7 Past Failures and Recurrence Preventive Measures O O
8 Design FMEA O O
9 Floor layout Diagram O O
10 Process FMEA O O
11 Control Plan (A/B/C ) O O
Consistency Confirmation Check Sheet between

12 O O
the Drawings and Records
13 Measurement System Analysis studies O O
14 QC Approval (Initial product inspection result) O O
15 Inspection Agreement O O
16 Initial Sample Inspection Result - ISIR O O
17 Material Performance Test Result O O
18 Process capability result (Ppk, Cpk ) O O
19 Certified Laboratory Documentation O O
20 Appeareance Approval Report (AAR) O O
21 Boundary sample (boundary sample photo slip) O O
22 Checking Aids O O
Fill in the date on which the supplier submitted it in the box of thick frame
* O : Essential item. (O) : KTB will instruct whether the submission is necesarry. – : Not required to submit
* On submitting the PPAP, submit the relevant materials, after confirming them with this form, together.
* If any material which was submitted before PPAP has been changed since the last submission, submit the latest version at the PPAP.
Route of forwarding record :
<1> KTB; Quality Control Dept. <2> Supplier <3> KTB; Quality Control Dept.
29
PT. Kramayudha Tiga Berlian Motors No.
To : Quality Control Dept. Date of isued
PSW ( Part Submission Warrant ) Supplier code

Part No. Supplier Name
Approved Checked Prepared
Part Name
Vehicle model / type

We herew ith declare :
We have confirmed that this product meets all the specifications set out in the drawings and
specifications documents and manufactured accordingly.
Remarks
Part division
Safety part Objective part of regulation Important parts General part
Objective division
Submission of initial product Design change Sub-supplier Material Packaging style
Work method and condition Equipment/jigs and tools Production plant Others
Modification contents ( only w hen actually modified )
Related EO No. Concurrently executed EO No. Schedule date of supply
No. Evaluation contents prior to shipm ent Evaluation result

1 Have the past design failures and manufacturing failures been dug up in the design FMEA ?
Development
2 Are all the measures identified by the failure mode in FMEA incorporated in the design w orks w ithout omission ?
3 Are all the problems on the design that occurred in the T0 sample, T1 sample or T2 sample solved all the w ay and
are all the measures incorporated in the actual parts?
4 Have all the past manufacturing troubles been dug up from the Design and Process FMEAs ?
5 Are the measures identified w ith the failure mode in FMEA incorporated in the processes w ithout omission ?
6 Is the preparation complete w ith respect to the hardw are such as the equipment, jigs and tools, inspection instrument,
and gauges, etc. ?
7 Is the preparation complete w ith respect to the softw are such as the Work Standard, Equipment Conditions Control Table,
and Check Sheet ?
Manufacturing
8 Have the operators received sufficient training and obtained sufficient learning level ?
9 Are all problems regarding the manufacturing that have occurred in the P0 ~ PP solved all the w ay and are all the
measures incorporated in the actual processes ?
10 Are the problems identified in the trial production solved ?
11 Is the sufficient process capability secured for the required quality ?
12 Are the flow -out preventive measures adequately taken for the total inspection contents ?
13 Are the quality assurance systems at the subsupliers firmly established ?
14 Did you make sure that the stable shipment quality is secured ?
Describe problems here, if any .
No. Ev aluation Ev aluation criteria
(when Δ, × is entered in the abov e colomns.)
Target is achiev ed. No problem.

Target is not y et achiev ed, but possible to take tentativ e
measures. It is also supposed that problems will be solv ed within
the initial f luctuation period.
X Target has not been achiev ed. It is a sev ere problem
N / A
Final Judgement Full approved Conditionally Approved Not Approved Date of conf irmation
Remark Approv ed Checked Prepared
( Note ) Inside of the thick-line f rame is f illed by KTB

Route of f orwarding this f rom : Supplier KTB ; Quality Control Dept. ( as s copy ) Supplier, Production Control Dept.
PT. Kramay udha Tiga Berlian Motors
30
CHAPTER VI
QC APPROVAL
(Initial Product Inspection Result)
6.1. Definition
QC approval is a request for approval of the quality parts or materials submitted by the
suppliers to KTB, in accordance with the standards that have been determined ( MFTBC
and MMC specification) so that the part or material can be produced and delivered to the
plant assy.
6.2. Aims
QC approval is intended that all parts or materials to be produced and delivered in advance
can be confirmed regarding quality issues ( dimension, appearance, installation in vehicle
and performance test ) so that can prevent the occurrence of damage parts and problem on
vehicles that will be produced.
6.3. Procedure
1. Scope of delivery
The suppliers are required to prepare and submit QC approval on the parts or materials
to be produced and delivered to the assy plant, as one of quality assurance in
accordance with the above purposes.
2. Time Delivery
Date delivery of QC approval is determined by the KTB-QC Dept. with a limit time
before the parts or materials are produced and delivered to the plant assy.
3. Submission procedures
Each QC approval to be delivered must meet the following requirements:
a. Total sample (sample)
The number of samples to be delivered at least 10 pcs for parts or material. If the
product or the item has more than one production tools (molds, dies, or jigs) then
parts are to be delivered each 10 pcs (minimum) for each of the production tools.
b. Identification of the samples (sample part)
Provide identification on each sample part in accordance with the numbering
sequence of sample part as stated in the QC approval, including the numbering
sequence of production are used. Below are examples of tags for the identification
of sample part:
Examples of labels (Sample Tags)
31
6.4. FORM
See the form 'QC approval'.
6.5. HOW TO FILLING

QC approval of the application form are as follows:
1. Type classification status of these parts are as follows:
 New = Approval for new goods.
 Design Change = Approval for design changes
 Proses Change = Approval for process changes, but may affect the quality of the
product, goods or materials ( if not significantly affect the quality of, then simply use
the form "4M Change Notice")
2. Select the type of classification desired production

 Preliminary Production = Approval for new goods at the time of development
 Mass Production = Approval for the old stuff at the time of mass production
that are changing the design / process
 Countermeasure = Approval as sheet goods inspection (check sheet) data
for corrective actions (countermeasures) problems that occur at the time of initial
production or mass production.
3. Select the classification of goods (goods on security / safety, essential goods / important
or unusual goods / ordinary part),
The types of categories of items to be approved (Approval) are as follows:
 Safety = Such goods include items that can affect the safety when
installed in the vehicle.
 Important Quality = The goods do not affect safety, but in terms of quality, need
special attention (rather functions in the vehicle).
 Ordinary = The goods does not affect the safety of a (rather Accessories)
4. Number and number of pages, enter the desired number of the appropriate standard
supplier (if the supplier has a numbering system on any proposed agreement). And fill
the number of pages to be filed.
5. Choose the type of processes used in the manufacture of products, goods or materials
and processes on a regular schedule to back a column that has been provided or attach
a schedule of the temporary (provisional process)
The type of process is::
 Provisional Process = The process is done in the manufacture of parts still
provisional / temporary, like the making with handwork or equipment (tooling) while
and still require adjustment.
32
 Regular Process = The process is done in the manufacture of the goods has
been put on permanent tool or tools for mass production.
6. Fill in the data products, goods or materials are required as listed below:
a. Supplier = Name suppliers that sends approval to the KTB.
b. Model = Vehicle category on the product, goods or materials to be
approved (approval)
c. Part Name = Name of parts or materials to be approved.
d. Part No. = Number of parts or materials to be approved.
e. E.O. = Engineering order number which has been issued by the
Technical Department KTB, as a condition of approval of such goods.
f. Drawing No = Last Drawing number.
7. Fill in the data required inspection items as listed below:

a. Measurement = Indicate the date of inspection on the parts or materials to
be approved.
b. Inspector = Indicates executor (inspector name) of the parts or
materials are examined.
c. No. of Inspect/Size of Lot = Indicates the number of items checked ( sampling
size ).
d. Material = Indicates the material used for the manufacture of parts.
e. Identification method of product = Shows the method of identification / approval
code on the production of goods to be delivered examples.
f. Weight = Shows the weight of the goods to be delivered.
8. Make a sketch or detail changes to the specified column, if the sketch or the change is
not enough detail in the column specified, then the suppliers are allowed to ake
sketches or detailed annex to the proposed changes, including the annex to the report
reliable test results and implementation schedule.
9. Enter the inspection items and standard used in the approval to be delivered
10. Enter the data in accordance with the results of the point checks
As an example calculation for x (the average / mean) and (deviation) is as follows
For X (Average/mean):
X = (data 1 + data 2 + data 3 ……. + data 10) / the amount of data
As for the (deviation):
= Highest value - lowest value
33
11. Once the data is loaded, then the suppliers are required to assess the results of the
measurement and checking of data over the existing standards in accordance with the
order of inspection items.
12. Having given an assessment of the measurement results and then checking, the
suppliers are required to give effect to the approval of the QC approval.:
 Checked = QC inspectors to approval to be filed {signatures from QC staff level)
 Accepted = Acceptance of the QC approval to be filed (signed from QC
supervisory level or similar ).
 Approved = Approval of the QC approval to be filed (signed from QC
management level ( manager).
34
QC APPROVAL
Classification of Classification of 2
Part Initial Production PILOT SAMPLE / No :
1
New Preliminary INITIAL PRODUCTS Received :
Production INSPECTION & TEST RESULT Month Day Year
Design Change Mass Production Page : ……….. Of …………
Process Change Countermeasure No.
3 Safety Important Quality Ordinary Provisional Process Regular Process 4
Supplier : Part Name : Schedule Regular Process
6 Model : Part No. : 5

First / Resubmit (No. ) EO / ECR No. : Month Day Year
Drawing No : Attached,Details of Provisional Process, ( Yes or No )
No. of Inspect/ Approved Accepted Checked
Measurement Inspector Material
Size of Lot
12
7
Month Day Year
Identification Method of product : …………………………………………………… ………….g
Weight : ………..g
Identification at initial product : ……………………………………………………
Judgement by KTB - QC Approved Checked In - Charge
Delivery Accepted Reasons or Conditions

Accept Delivery Accepted
Conditionally
Reject Resubmission Date :
Details of Change, Sketches, etc.

8 Attached reliability test reports (Yes or No), submission schedule ( month ____ day ____ year_____ )
COPY TO :
For items such as material, characteristics, performance test and endurance test results which are difficult to be described in this form,
TOTAL descriptions in any form may be attached.
35 TO BE FILLED BY KTB. QC.
(NOTE) HEAVY BLOCKS
No. : 044
Revision :2
Date : April 16, 2003
Inspection & Test Result

Part No. : Part Name : Page : …….... Of ……….
No Inspection Standard Judgement
1 2 3 4 5 6 7 8 9 10 X (OK/NG)
Item
9 11
10
(NOTE) HEAVY BLOCKS TO BE FILLED BY KTB. QC.

No. : 045
Revision : 2
Date : Nov 7, 2014
36
CHAPTER VII
INSPECTION AGREEMENT
7.1. Definition
Inspection agreement is an agreement made by the supplier in connection with the
inspection conducted on the product, goods or materials that will be delivered to KTB-QC
Dept., which describes the critical quality inspection, and confirmation of the periodic
inspection that is also equipped with a standard inspection, which must be informed to KTB
each month.
7.2. Aim
This inspection agreement is made with the aim that the suppliers are able to determine the
list of inspection confirmation (consisting of: a critical quality inspection and determination of
quality confirmation) and a standard inspection (consisting of: point, standards, tools,
methods and time of inspection) so as to maintain the quality, continuity of production and
delivery.
7.3. Procedure
1. Scope of submission
The supplier is required to create and send the inspection agreement for any products,
goods or materials that will be produced and delivered to the assy plant, as one of the
quality assurances in accordance with the above aim.
2. Time of submission
Date of submission of inspection agreement is determined by KTB-QC Dept. with the time
limit before the products, goods or materials are produced and delivered to the assy plant
(both for new parts and for design/process modification parts).
3. Procedure of Submission
The order of drafting agreements inspection that will be submitted are as follows:
A. Sheet I : Inspection confirmation sheet
B. Sheet II : Inspection standard sheet
The suppliers are obliged to confirm the inspection agreement that will be
submitted (draft) by facsimile or e-mail to KTB-QC Dept., once approved by KTB-QC
Dept., then the suppliers can send the original inspection agreement (signed by the
supplier) to KTB-QC Dept. prior to the first shipment.
7.4. Form
See the attachment regarding inspection agreement form ‘Inspection agreement’.
7.5. How to Fill in

The inspection agreement has 2 forms as for the descriptions are as follow:
37
7.5.1. Inspection confirmation sheet.

1. Select the category of part (safety, important or ordinary part), as for the category is as
follow:
 Safety = Such parts include items that can affect the safety when
installed in vehicle.
 Important quality = The parts do not affect safety, but in terms of quality it needs
special attention (the function in nature in vehicle).
 Ordinary = The parts do not affect safety at all (more accessories in
nature).
2. The agreement of critical quality that must be done by the suppliers in the column:
 Critical quality items = The inspection items that should be carried out by the
suppliers usually affecting the function, installation, capability/ performance and so
on, for example: Item of dimension that is affecting installation or item of certain test
performance. The items are on the drawing marked “ or ”, which marks one of
critical quality items. In this column give the mark “O” in the serial number that shows
the data of process capability.
 Standard/ attended items = An explanation of the standards used to assess
the quality, as it is written in the importance items of quality (‘critical quality items’).
 Remarks = An additional explanation of the important items of quality (‘critical
quality items’) and the ‘standard items/attended items’, if needed.
3. Enter your confirmation of periodical report/check sheet that must be submitted by the
suppliers as the Quality report (the data and test results) produced in the manufacture
of products, goods or materials at the time of mass production (delivery check sheet
and process capability) as for data as outlined in this confirmation of periodical
report/check sheet using the inspection data that is carried out by the suppliers/vendors
in accordance with the inspection period at the inspection standard, with the following
filling:
 Inspection/test items = Inspection inspection or test that must be reported to
KTB-QC Dept as the quality confirmation at the time of mass production (items to
be reported include in the “Inspection standard”), for example: apperance,
dimension, function et cetera.
 Sample size = The number of sample that will be reported in
accordance with the ‘inspection/test item’, for example: n = 5 pcs (minimum), n = 10
pcs etc.
 Confirmation period = Confirmation time of periodical report that must be
reported to KTB-QC Dept, For example: 1/1 months, 1/3 months etc.
 Remarks = Is an additional explanation to the Confirmation of
quality needed.
38
4. In addition to the items of the quality agreement it can be written specifically in the
special remarks column, in this section KTB-QC Dept. has required special addition as
it is written in item no. 1, as the quality assurance at the time of initial production (initial
product) so that the suppliers/vendors are required to report initial production (initial
product) in the form of check sheet on each production starting from the first month to
the third month of mass production
5. Enter the parts data needed including the name of related suppliers (supplier/vendor)
that send the parts to KTB-QC Dept.
 Supplier = The company name that send the products, goods or materials to
KTB-QC Dept.
 Model = Category of vehicle on products, goods or materials that will be
approved, for example: TD, FM, FN, CJM, SL, and so on.
 Part Name = Name of products, goods or materials that will be conducted the
quality agreement.
 Part No. = Number of products, goods or materials that will be conducted the
quality agreement.
6. Give the approval to the quality agreement that proposed to KTB-QC Dept by the
related suppliers, on the ‘supplier’ column ( with notes after it has been approved by
KTB-QC Dept )
Endorsement of the supplier column in the following positions:
 Drawn = Maker or arranger of the quality agreement that will be submitted
(signed from the level of staff).
 Checked = Inspector of the quality agreement that will be submitted (signed from
the level of supervisor or equal with it).
 Approved = Approval of the quality agreement that will be submitted (signed from
the level of management/ QC manager / QC administrator).
7 If there is a change to the inspection agreement that has been submitted, then the
suppliers must make the revision/improvement to such change and the reasons (such
change usually occurs because of the change in design/process so that the agreement
items need to be revised/improved). Such change should be written in the revisions
column, see the following picture:
In this column the filling is as follow:

 C.L (Change Letters) = Showing the sequence of changes that occur, the order
may be made in the sequence of letters, for example: a, b, c etc.
 Date = Date of making of these changes.
 Reason = The reason for the changes made.
 Reviser = The name of the changes maker.
39
 Drawing No = The number of the latest/newest drawing.

8 If the first sheet is not sufficient then the suppliers can use the form of continued
“inspection confirmation sheet (sheet continued)” as in the picture below,
7.5.2. Inspection Standard
The following describes the way of filling in the inspection standard, as follow:
1 Select the parts category (safety, important or ordinary Parts/Goods), as for the
category is as follows:
 Safety = Such parts include the parts that can affect the safety when
installed in vehicle.
 Important quality = The parts do not affect safety, but in terms of quality it needs
special attention (the function in nature in vehicle).
 Ordinary = The parts do not affect safety at all (more accessories in
nature).
2 Make the grade (grade of inspection, is a grade division in the Inspection of a good/part
for example: the largest/major or smallest/minor).
As the grade division is as follows:
 Major = It is an inspection number/point that is common, such as:
appearance, materials, size/dimension and so on.
 Minor = It is an inspection number/point that is specific, such as: performance
test and so on.
3 Enter the item of parts inspection in accordance with the “inspection confirmation sheet”
that will be submitted.
4 Enter the standard that will be used as guidance in the production and quality that is
usually taken from MMC/MFTBC drawings, MMC/ MFTBC specifications or the
drawings of the suppliers (supplier/vendor) that have been approved by KTB-Technical
Departrment.
‘5. Enter the type of inspection tools that are used to check the ‘Inspection item’
6 Enter the method of inspection that is done in accordance with the inspection item.
7 Enter the period of inspection that is done in accordance with the inspection item
conducted by the suppliers.
As the placement of inspection period is as follows:
 Initial = Checking period conducted by the suppliers during the initial period of
production/initial product ( the first month up to the third months of mass production.
In this initial product KTB-QC Dept. has required that each parts delivery during the
initial production ( initial product ) accompanied by check sheet, so the filling at this
initial part for example: 5 pcs/shipment (delivery) and so on.
 Daily = Checking period conducted by the suppliers after a period of initial
production (initial product) is performed every day at the time of production on
certain inspection items at random/sampling or the whole, for example: at the
function points all sizes/dimensions: 3 pcs/4 hours (hours) and so on.
40
 Periodic = Checking period that must be conducted by the suppliers after passing
the initial production (initial product) and is done for all of the inspection items
periodically. As for how to fill this periodic inspection for example: 5 pcs/month, 10
pcs/3 months and so on. These periodic inspection items are the data that will be
written in the report of “confirmation of quality” on the inspection confirmation sheet.
Especially for the appearance, size/dimension minimum sample 5 pcs.
8 Enter the manufacturing date of this inspection standard also with the wieght and
material used.
9 Enter the parts data in this inspection standard, includes:
As the data need to be entered are as follows:
 Supplier = Name of the company who send the products, goods or materials to
KTB-QC Department.
 Model = Category of the vehicle on the products, goods or materials that the
inspection standard will be made, for example: TD, FM, FN, CJM, SL and so on.
 Part name = Name of the products, goods or materials that the inspection standard
will be made.
 Part no. = Number of the products, goods or materials that the inspection
standard will be made.
10 When the first sheet is not sufficient then the suppliers (suppliers/vendors) can use the
form of continued “inspection standards (continued sheet)” as in the picture below.
11 If there is a change to the standard inspection that has been sent, then the suppliers
(suppliers/vendors) must make revisions/ improvements to such change and the reason
(the change in the design/process). Such change should be written in the revisions
column, see the following picture:
In this column the filling is as follow:
 C.L (Change Letter)= Showing the sequence of changes that occur, the order may
be made in the sequence of letters, for example: a, b, c etc.
 Date = Date of making of these changes.
 Reason = The reason for the changes made.
 Reviser = The name of the changes maker.
12 If all the columns on a Standard Inspection has been filled and has been approved by
the KTB-QC Dept. (in this case the sent draft approved), then the suppliers (suppliers /
vendors) shall authorize the inspection standard (standard inspection). When all of the
columns in the Inspection standards has been filled in and has been approved by KTB-
QC Dept. (in this case the draft sent has been approved), then the suppliers
(suppliers/vendors) must validate the inspection standard.
Approval of the supplier column in the following positions:
 Drawn = Maker or arranger of the quality agreement that will be proposed
(signed from the level of staff).
41
 Checked = Inspection of the quality agreement that will be proposed (signed from
the level of supervisor or equal to it).
 Approved = Approval of the quality agreement that will be proposed (signed from
the level of management/ QC manager / QC administrator).
42
INSPECTION AGREEMENT
Page : of
No :
I. INSPECTION CONFIRMATION LIST
Received :
* Supplier shall carry out the undernoted inspection at there own responsibility before delivering to KTB. Month Day Year
Category : X Safety parts Important parts Ordinary parts

(mark X in column )
1
1 Critical Quality Critical Quality Items and Standards/ Attended Items of the parts are as listed below.
Supplier shall exercise full control as per Inspection Standards, Quality Control Process Charts , etc.
attached hereto.
No. Critical Quality Items Standards / Attended Items Remarks

2
Note : Grasp of Process Capability :

As for the critical quality marked by "O", process capability shall be grasped during the period of
initial stage control and the results will be reported to KTB.
2 Confirmation of Quality Supplier shall perform the inspection and test listed hereunder and will submit one copy of the report
to KTB at the time given in the column of time for confirmation.
Sample
No. Inspection/Test Items Confirmation Period Remarks
size 3
3 Special Remarks
1. At initial product (the first 3 months production), vendors / suppliers must send check sheet for each production as initial
production report. 4
6 7
Approved Checked Drawn
KTB
Supplier
C.L Date Reason Reviser
Drawing No :
Supplier : Model : Part No. : Part Name :
5
No. : 043
Revision :2
Date : April 16, 2003
43
44
45
46
CHAPTER VIII
CONTROL PLAN
8.1. Aim:
 Explaining the process flow/ sequence process starting from raw materials until the
delivery and manufacturing place.
 Describing the method of quality control that involves the control of items, value control,
method, frequency, notes, people in charge (PIC), and so on, for each process that is
necessary to ensure the quality of the process.
8.2. General things to be regarded:

 Control Plan can be made for each parts supplied. For the part that has the quality
characteristics and process of making same, can be used as a general control plan and
procedures can be made based on one part of it as representative.
 For each characteristic of “safety quality” marked + +, as well as the “critical quality” or
that become the attention points of the suppliers marked S.
8.3. The things that need to be considered in the preparation and manufacture of
control plan:
8.3.1. The order of control plan

Control Plan A Process of Flow Chart & List of Applicable Parts
B Sketch & list of components
C QC Process Chart
8.3.2. Control Plan A (Flow Chart Process & List of Applicable Parts)
- As the front page of control plan
- Flow Chart Process:
 Clearly describing the whole process, including process, inspection, transport and
storage.
 The symbol used refers to “JIS Z 8206 Process Chart Symblos”.
- List of Applicable Parts :
If the control plan is used for some similar parts, the list is made consisting of the
name of the part and the number of the part.
8.3.3. Control Plan B (Sketch & List of Components)

- The sketch has to be able to explain the following information:
 The position of each component and the control point.
 The position and the way of reading the production code/lot number.
47
- List of Components:
 Containing the list of the components used to make one part/product. The list
describes the component names, part numbers, names and locations of the
suppliers of the components, and so on.
 If the control plan made for some of the same parts, then on the list the relationship
between the components of each part must be explained.
8.3.4. Control Plan C (QC Process Chart)

- Is an integration of the inspection standard and QC process table (QCPC)
- Control Plan C explains:
 Sequence of the Process
 In accordance with the sequence mentioned in the flow chart process.
 Name of process, equipments used, tools and jigs
 Characteristic control of the quality
 Related to the characteristics of the parts quality, so the following things need to be
explained, among other: the levels of importance of each characteristic, control
item, control values, and the method of measurement.
 Manufacturing Condition Control
 Explaining control item, control value and the method of inspection.
 Failure Handling
 Explaining the person in charge and the actions taken if problems are found.
 Standard/Reference
 Explaining the name and number of document used as the standard.
- The things need to be considered:
 The results of FMEA Process become the item control in control plan.
 Specification value and control value are written in terms of numbers.
 Control value should match with the value indicated in the drawing. If a control
value is determined based on visual control, it must be made “Limit Sample”.
 The measurement of outer diameter and inner diameter, using X-Y method (cross
direction)
 For the use of grease or oil, the control items need to be made for the amount and
method of application (filling, coating, etc.) of grease or oil.
8.3.5. Revision of Control Plan

Revision of control plan is conducted if there is a change both in the process and in the
product design.
Here are some examples of control items of the process/machine/equipment that are
made for some kind of process.
48
Manufacturing Conditions Control Table

Name of the Process Control Item
Casting Process Molten metal temperature, die temperature, cooling
condition, pouring pressure.
Forging Process Forging pressure, temperature
Sintering Process Temperatur, time
Plating Process Density, current density, temperature, time
Heat Treatment Process Process temperature, time of process, cooling condition,
gas flow rate
Press/Cut Process Pressing pressure, wrinkle-restrictive pressure
Injection Molding Process Forming pressure, temperature, time
Bonding Process Bonding pressure, temperature, time
Welding Process Welding current/ampere, voltage, diameter of electrode
tip, pressure, time
Coating Process Density, temperature, air pressure, drying time
Cutting Work Process Number o torque, feed rate, cutting fluid concetrate
Press Fit/Caulking Process Press-fit pressure, press-fit rate
Automatic Tightening Process Torque setting value, amount of coated oil
In-Line Measurement Process Measurement pressure, measurement time, setting of
judgement criteria, inspection accuracy
Washing Process Washing pressure, detergent, washer fluid concentration,
mesh filter
Soldering Process Temperature, time, flux
Sealing Agent Coating Process Coating pressure, coating rate
Electronic Beam/Laser Work Output, feed rate, degree of vacuum
Process
Stamping Process Stamping Pressure
Inspection Process (usually for Function Check
function check or completeness
detection)
Proses using fool proof method Function Check
49
CHAPTER IX
FMEA
(FAILURE MODES AND EFFECTS ANALYSIS)
9.1. Aim.
 Looking for the possibility of various forms of failure in the production process of goods
and to search for critical processes.
 Determining a process assurance method to prevent NG parts are produced and sent to
the next process.
 Design, such as engineering method can produce a process assurance, by entering the
assurance method into control plan and implementing the method in the production line.
FMEA can be applicable in all processes include: raw materials, process, assembling and
storage/delivery.
Implementation of the FMEA process should be supported by relevant departments namely
Production Engineering, Quality Control and Development (Cross Functional Team).
Precautions should be done if:

 RPN Value > 100, corrective actions must be taken for example design changes, process
improvements, increasing inspection, etc.
 RPN (Risk Priority Number) = “Severity” x “Occurrence” x “Detection”.
 RPN Value < 100, but it is high value of “Severity” and “Occurrence” (high grade). With
this condition it is suggested for doing corrective actions.
 After the corrective actions have been done, re-evaluation of grade and RPN must be
done.
50
Here is the flow diagram to make FMEA Process:

Start
Pick up all the work items and

Determining Working Item contents involved in each process
into a list.
Write evey failure mode possible to

Searching/digging the form of occur per each work content.
failure (Including the review of the design
FMEA and past failure instances
Evaluation Evaluating the result of “Severity”,

Execution of (Severity, occurrence, & “Occurrence”, & “Detection ”
Evaluation detection)
Calculating
RPN value
Considering corrective
actions through structural
inspection
Considering corrective
Using the method of fool proof
Consideration actions through inspection of
of corrective equipments
actions
Considering corrective actions Providing specific regulation that is

through engineering method able to operate
Considering the assurance Increasing the inspection if the method

by doing inspection of structure/equipments/engineering is
difficult todo
Re-Evaluation Including the corrective actions and

review of “Occurrence” and
(Occurence & Detection) “Detection ”
Execution of
Re-evalation
Recalculating Checking & ensuring that the
corrective actions that have been
RPN
successfully done are safe enough
for the quality assurance of the
process
Final Decision
Finish
51
9.2. Criteria for “Severity” evaluation

Effects on Production Process at Evaluation
Effects Effects on Users
Assy Plant Rank
Causing failures in vehicle that
related to the safety and
Endanger the operators and tools/
Major Risk regulations without any 10
production equipments without any
(without symptom) symptoms/signs of damage.
symptoms/signs of damage.
The result: Recall or corrective
actions
Causing failure that is preceded
Potentially endanger the operators
by symptoms/signs on vehicles
Major Risk and production equipments, but it can
and related to the safety and 9
(with symptom) be predicted by the appearance of
regulatory. The result: Recall or
certain symptoms/signs.
corrective actions
Causing the vehicle can not run or All products must be removed
Severe Risk part does not work. (cannot be used). It takes time to 8
The result: service campaign recover the production process.
Vehicle can run or part does work
It needs to sort the products and the
but there is decreasing in
Major Risk part of the result of sorting can not be 7
performance. The result: User
used (removed)
claim
All functions of vehicles or parts
can be operated, but the comfort No need to sort the products but the
Medium Risk or the use related to the function products could not be used 6
does not work. (removed)
The result: User claim
All functions of vehicles or parts
Doing the adjustment process to the
can be operated, but the comfort
entire product.
Minor Risk or the use related to the function 5
Performed outside the production line
is decreasing. The result: Claim
(off line)
from some users
Causing problems such as
It is needed to sort the products but
abnormal sound, appearance, etc.
Little Risk the products can still be used by 4
The result: Claim from the most of
doing adjustments (improvements)
users
Causing problems such as Allowing adjustments in the
abnormal sound, appearance, etc. production line.
Minute Risk 3
The result: Claim from the most of Most of the products have to be
users adjusted (still usable)
Causing problems such as Allowing adjustments in the
abnormal sound, appearance, etc. production line.
Ultra Minute Risk 2
The result: There is possibility of Most of the products have to be
claim from a few user adjusted (still usable)
None Not recognized by user Not influencing production process 1
52
9.3. Criteria for “Occurrence” evaluation

Evaluation
Posibilty Problems Frekuensi of Occurrence Failure Rate
Rank
Very High Failure must occur 1/10 10

(Continuously occuring) Failure need to occur 1/20 9
High Very often occur in the similar process in the past 1/50 8
(Often occuring) Often occur in the similar process in the past 1/100 7
Sometimes occur in the similar process in the
1/200 6
past
Medium
Several times occur in the similar process in the
(Sometimes occuring) 1/500 5
past
Rarely occur in the similar process in the past 1/1000 4
Very rarely occur in the similar process in the
1/2000 3
past
Low
Ever occurred 1 time in the similar process in the
(Rarely occuring)
past 1/10000 2
The same failure does not re-occur
The same failure has never been found in the
Rare similar process. 1/100000 1
Most of the failures are never happened
9.4. Criteria for “Detection” evaluation

Method of
Percentage Inspection/Confirmati Inspection/ Rank
Level
Detected on Confirmation Detect-ion
A B C
There are no items that need to be
Almost Zero No need inspection O 10
checked or confirmed
Almost impossible Conducting random (sampling)
Very Little O 9
for being inspected inspection
Conducting visual inspection by the
Little O 8
Low possibility for operators
being detected Conducting two times inspection in
Very Low O 7
the form of visual by the operators
Statistical control with the chart
Low O O 6
control, etc.
Possible for being
Sampling checking with a gauge or
detected
Medium O performing total inspection using 5
gauge limit in the next process.
Performing inspection in the next
The possibility for
Relatively process or performing an initial
being detected is O O 4
High inspection at the beginning of each
relatively high
production (per Lot)
53
Performing inspection in the area of

High The possibility working process or the next
for being
O O processes. 3
detected is
relatively high Small probability defective goods
delivered
Inspection has been integrated into
Almost possible for
O O the working process so that there 2
being detected
are no defective goods delivered.
Very High
The part design and process have
Definitely detected O prevented the forming of defective 1
goods
Method of Checking/Confirmation:
A : Using fool proof, and checking using automatic measuring tools
B : Checking by operator using gauge
C : Visual checking by operator
54
Form FMEA Worksheet
55
CHAPTER X
PROCESS CAPABILITY
10.1. Definition
Process capability is comparing between the process capability and the specifications of the
product/process. Process capability analysis can be done if the process is stable.
10.2. Aim
 Understanding the process capability index at each stage to ensure the quality of the
product.
 As one of the control methods to improve the quality of the product/process during the
mass prodution.
10.3. Procedure
1. The analysis of process capability is prioritized for process that has safety or critical
characteristic.
2. The suppliers are required to determine the points that will be taken for collecting data
based on the existing drawings and specifications with the approval of KTB QC, and QC
KTB has the right to request/add the points that are important to the suppliers.
3. In the process of collecting data, the number of part samples taken n ≥ 30.
4. At the stage of mass production, the process capability analysis must still be done to
determine whether it is still appropriate to the control/specification limit.
5. Checking whether there is a variation of the process.
6. If the process capability is still in the specification, the improvement continues to do so
its process capability becomes stable.
7. If the index value of the process capability is below the specification, perform analysis to
find the cause of the problem and make an improvement plan.
8. For product/process with specific characteristics (safety), if the process capability index
is below specifications, it must be conducted total examination (100% check).
9. Submission time
Development stage: as supporting data at the time of submitting the approval
Document ( PPAP ).
Stage of initial production: as attachment of the form “Initial Process Control Result”
Stage of mass production: sent if there is a request from KTB QC.
56
Table of process capability index.

Part Quality
Ppk, Cpk Control Method
Division Characteristic
Statistical Process Control (*1) or total
≥ 1.33
examination (100% check) (*2)
Safety Total examination (*2)
< 1.33 Showing inappropriate the process capability, it
Safety Parts should be improved
Examination method can be changed into
≥ 1.33
sampling
General Total examination (*2)
should be improved
Statistical Process Control (*1) atau total
≥ 1.33
examination (100% check) (*2)
Safety Total examination (*2)
General should be improved
Parts Examination method can be changed into
≥ 1.00
sampling
General Total examination (*2)
should be improved
Information:
(*1) : Using statistical method (including chart control, etc.) in improving the process
capability.
(*2) : Visual examination is not allowed.
57
CHAPTER XI
DETERMINATION OF THE PERSON IN CHARGE
OF THE QUALITY
11.1. Aim
To be able to create and enhance the effective communication relationship on the issues
related to the quality between KTB-Quality Control and the Supplier-Quality Control.
11.2. Procedure
In accordance with the aim above, so th suppliers/vendors are required for:
1. Determining 1 (one) person from the management level (manager) who has directly
responsibility and authority in addressing the problems of quality and authority in
endorsing the entire quality documents (hereinafter called QC-administrator).
2. Determining 1 (one) person of the level of supervisor/staff who is responsible for routine
quality control and must cooperate with KTB-QC Dept. in conducting quality activities
starting from the development stage until mass production (hereinafter called quality
controller).
3. Informing the name and position of QC administrator and quality controller by using the
form of ‘notice of QC administrator’. This form is submitted to KTB QC at the beginning
of development and if there is a change.
4. If there is a change of one or both of these people, then the vendor must immediately
resend a new notice to KTB-QC Dept. no later than 7 (seven) working days after such
change.
11.3. Form
See attachment of the form of ‘notice of QC administrator’.
11.4. How to Fill in

The filling of the form of ‘notice of QC administrator’ is as follow:
1. Selecting information regarding this change whether it is new/the change as in the
column,
Dear Sir,
Hereby it is notified that as the person in charge that related to the quality of the Product in our
Company, is as mentioned below:
(NEW / CHANGE)
Note:
New = Information explaining the conditions of new vendors or the company that
changes to another company.
Change = Information explaining the change of one of administrators that have been
informed to KTB-QC Dept before.
58
2. Write clearly the company name, company address and the effective date of the
information in the column,
[ New / Change ]
Company Name : PT……………………………
Company Address: Jl……………………………

Phone……………Fax………..
Effective date : ……………………………..
3. Write the required data in the column prepared, on:

Person in charge Name Position Mobile Phone E-mail
QC Administrator
QC Controller
4. If the two columns have been filled in, then it is immediately signed by the related
suppliers (suppliers/vendors) and send it to KTB-QC Dept. no later than 7 (seven)
working days after the validity of these changes.
Flow diagram for information of the Person in charge in Quality :
Start
Information of the Person in

charge in Quality
No
Is there
any change?
Yes
Writing in:
“Notification form regarding the
person in charge in quality
Send to KTB – QC Dept
Finish
59
Sample of Notification Letter of the person in charge in quality
PT. .............................( SUPPLIER/VENDOR )

LOGO
To : PT. Krama Yudha Tiga Berlian Motors

Attn : Quality Control Departement
Mr. ........................... (Manager)
Subject: Notification of the Person in charge of the quality
Dear,
Herewith we are informing regarding the Persons in charge relating to the problem of product
quality in our company, are as mentioned below:
( NEW / CHANGE )*
Company Name : .........................................................

Company Address : …..................................
Phone: ...............Fax............
Effective Date : .....................................
Person in charge Name Position Mobile phone Email
QC administrator
QC Controller
Thus we notice, we thank you for your attention and cooperation.
Sincerely yours,
Sign
QC Administrator
Note: (*) Mark that it’s unnecessary
60
CHAPTER XII
PRODUCTION CODE
12.1. Definition
Production code is tagging/marking/identification given to each good that indicates the
condition of the manufacture of such good, which includes: the production date, production
time/production shift, the machine used or other production information needed.
12.2. Aim
 Facilitate the traceability of a product starting from shipping, production to raw material.
 Identification and prevention of the spread of troubled products can be done quickly.
12.3. FIFO (First In First Out)

For the product movement either in the process, warehouse or at the time of delivery have
been using the FIFO system.
12.4. Marking the Production Code

 Marking on product
Giving of production code on the product should not be easily erased and easily seen
 Marking on pallet/box
If the production code can not be applied to the product so the production code imprinted
on the box/pallet in the form of product/tag identification. ( confirmed to the division of
production control & quality control of KTB).
12.5. Document of Material History and Manufacturing Process

Material history and manufacturing process, starting from receipt of materials, assembling,
inspection to delivery should be documented and stored.
Here is the manual to make the document:
1. Material documents
 Name of manufacturer
 Material name
 Date/month/year of manufacturing
 Quality record (mill sheet, etc.)
2. Document of Manufacturing Process (fabrication, assembling, etc.)
 The tools used
 Heat treatment (if there is this process or critical process)
 Manufacture condition (operational, condition, tools, operator, etc.)
 Inspection before and after setup the machine or change tooling.
3. Inspection documents (acceptance, production process, final inspection, delivery)
 Inspector (personel in charge)
61
 Measuring tools
 Lot number inspection, lot size inspection, frequent of inspection, inspections result.
12.6. Controlling for Delivery Lot

The following items should be recorded and stored to provide traceability information the
parts that have been sent (ranging from manufacturing to material lot
1. Delivery date
2. Number to deliver
3. Lot number of delivery (to be able to trace to manufacturing and material process)
4. Destination of delivery
12.7. Procedure
1. Scope of submission
The suppliers have to prepare and submit the ‘production code’ system to KTB-QC
Dept. as a reference in the production and perform tagging on each sample part that will
be sent to KTB-QC Dept. (marking on this good/sample part is position confirmation of
the ‘production code’, which will be applied in the next mass production). The form of
the ‘production code’ system is entirely left to the suppliers but still showing the
necessary production information, including the position of the marking on goods
sample (sample part).
2. Time of submission
The delivery of the ‘production code’ system by the suppliers is determined when the
suppliers do not have and build the ‘production code’ system or there is a change to the
‘production code’ system.
3. Procedure of submission
Any manufacture or change of ‘production code’, the suppliers are required to send an
official letter to KTB-QC Dept. as a notification letter. The form of execution of
‘production code’ is written on each sample part and the QC approval sent.
Increasing Period
Document Objectives
Mass Production
sent
Predevelopment Development
Initial Daily
Production Production
Form of Coding system that

vendor informs the
identification &
condition of a part
Placement of the
production code on the
sample part to be sent
Placement of the
production code on the
part of mass
production
62
Flow chart of the procedure of prodution code
Start
New part localization There is a change of

(Development) “Production code”
(Mass production)
Make, arrange & place

“Production code” on sample
part (if it does not exist)
Make a notification on
“Production code”
Send to KTB-QC Dept.
Make & re-

Information
No arrange
checking of
“Production
“Production
code”
code”
complete?
Yes
“Production code” has

completed.
Put “ production code ” on

production part ( Initial product &
Mass production )
Finish
63
CHAPTER XIII
INITIAL PRODUCTION CONTROL
13.1. Definition
Initial production control is controlling that conducted in the first three months of mass
production. Controlling that is conducted, is controlling of the process and the product. In
addition to new products, this controlling is also carried out for the product that experiences
the changes of design or process.
13.2. Aim
 Ensuring all quality assurances that have been defined in each process run according to
the procedures.
 Controlling the stability and the process capability.
 Performing special control and inspection of the products to ensure the quality
assurance of the products produced.
13.3. Period of initial production

In this period the suppliers are required to send the check sheet, the audit process and the
‘Process capability’ of each production process as the Initial product report to KTB-QC
Dept. in accordance with the above aim.
13.4. Extending controlling period

Controlling period can be extended (> 3 monts) if:
 Found a problem of quality in this period. (problems in the process or product)
 If a problem occurs, corrective actions must be done immediately and evaluate the
results of the correction, so the controlling period can be extended.
13.5. Period of mass production

In this period every year KTB will do ‘quality audit’ of all suppliers and the suppliers should
send the check sheet as the production quality report or periodical report on all parts
delivered and the process capability for parts, which include the category of important parts
in terms of security (‘SAFETY PART’) or other parts deemed necessary periodically.
64
The stage of Initial Product in the development process to production

Stage / Period
1
The period of preparation & arrangement of
Predevelopment Development plan
The period of development of new parts or old

2
parts that experiences the change of design or
Development process.
3 Three months production since the

Mass starting of manufacturing a new part or
Give the “Special an old part that experiences the
Marking” on new parts production change of design/process.
(Initial product) and
special controls for
production and parts in
terms of security (safety
item)
Daily
Mass production
Sample of special marking/ label on the pallet of parts ( initial product ) :

Quality Control Departement
INITIAL PRODUCT
Part No Part Name
Supplier's Name Lot no
Change description Relevant EO no
Remarks
65
66
CHAPTER XIV
MONITORING AND MAINTENANCE OF
PRODUCTION EQUIPMENT
After entering the stage of mass production, the suppliers shall establish a procedure regulating
the monitoring and maintenance of all aspects that can influence the course of the production
process. This chapter will discuss the aspects that need to be monitored and maintained.
14.1. Monitoring and Maintenance of Equipments.

The equipments in question are all equipments including jigs, dies, tools, etc. used to
produce KTB products.
14.1.1. Controlling system:

The supplier shall designate 1 person who is responsible for ensuring the implementation
of the following matters:
1. Making the procedure of control and maintenance of the equipments
 Containing the description, methods, and frequency of execution of a routine
inspection, periodic inspection by the maintenance dept., and external inspection
(by the instrument maker).
 Verifying the quality after repair and report if abnormal conditions are found.
2. Performing internal audit (self audit) to the status of maintenance and control.
3. For the equipments, dies/molds, jigs, tools that are KTB asset, there should be a
conversation between KTB and the suppliers related to the maintenance and control.
14.1.2. Inspection and Repair:

1. Control items of the equipments listed in the control plan must be carried out in
accordance with the frequency and methods listed in the control plan.
For the items that are not listed in the control plan, inspection is carried out in
accordance with the established procedures to ensure the functionality and accuracy
of the equipments is working properly.
2. Giving a clear identification for the equipments that is in the inspection process.
3. If the abnormal condition is found, corrective action must be done immediately.
14.1.3. Quality verification after repair:

1. After the repair is complete, the equipments must be rechecked (verified) in
accordance with the procedures of control and maintenance.
2. Notification of improvement should contain:
 Date of the repair
 The equipments repaired
 Detail of the repair
67
 Parts involved
 The results of parts inspection before and after the repair
 Date of parts delivery after the repair
3. In repairing that related to a big problem, the suppliers must provide information to
KTB.
14.2. Control of measuring instruments.

Measuring instruments that must be controlled is the measuring instruments used to
determine the suitability of the product against the requirements of quality, among other:
 Instrument (scale, thermometer, torque wrench, manometer, etc.)
 Gauges (JIS boundary gauges, standard gauge, dial gauge, etc.)
 Measuring equipments/instruments (calipers, micrometer, etc.)
 Measuring tools (jig inscpection, checking fixture, etc.)
 Detection tools (fool proof) for the specific characteristic of the product quality and
part dummy to evaluate the function of tools.
Control of measuring instruments:
1. Routine inspection.
Before using, the accuracy and function of the measuring instrument must be ensured.
2. Periodic inspection.
 Inspection and calibration period is determined by the conditions of the use of
each equipment.
 Each measuring instruments are given identification/ labeling of the period or
validity of the measuring instruments.
3. The placement of measuring instrument is not accurate (nonconforming equipment)
 The nonconforming equipments are given identification for further checks or
recalibration, or placed in a special place.
 The products are inspected using nonconforming equipment, the results of the
inspection need to be re-evaluated to take the necessary action.
For the ease in monitoring, the suppliers must provide a log book or a master list of
measuring instruments which among other things contains the type of measuring
instruments, the amount of measuring instruments for each type, the use, inspection
records, expired date, etc.
68
CHAPTER XV
MONTHLY REPORT
15.1. Definition
The monthly report is inspection data that submitted to PT KTB each month in accordance
with the ordered parts for the need of production of vehicles.
The contents of the inspection data should accord with the Inspection standard agreed,
which are listed therein regarding the checked points, the amount of data is retrieved and
the time of submission of the inspection data.
15.2. Aim
The monthly report is intended as an assurance from the vendor (supplier) of the product
sent to KTB that the conditions are in accordance with the required specifications.
15.3. Procedure
a. Scope of Submission
The suppliers are required to prepare and submit Monthly reports of the products or
goods are delivered to KTB, as one of quality assurances, that the goods delivered are in
accordance with the specifications.
b. Time of Submission
Time of submission of the Monthly reports, submitted to KTB-QC every month, maximum
on the 25th of the current month it has been accepted by KTB-QC. Checking data are
sent in accordance with goods or parts that are ordered by PCD-KTB in the order list.
c. Procedure of Submission
This Monthly Report must be written in the form of ‘Monthly Report’, the report may be
sent in a copy that has been validated and sent to KTB addressed to the Manager of QC
Department.
15.4. Form
See the attachment on the form ‘Monthly Report’
15.5. Others
15.5.1. Confirmation from KTB-QC
KTB-QC will confirm this monthly report in the form of letter to the vendor, which will be
submitted no later than the 10th of the following month.
15.5.2. Warning Letter
KTB-QC will send a warning letter to the suppliers (vendors/suppliers) if there is a delay,
lack of data items or do not send the monthly report. The warning letter will be sent no
later than the 10th of the following month.
69
3
Monthly/Periodical Quality Report
Attn : Mr. Ari Murahardjo (QC Manager)
Classification of Received date :
Part MonthDay Year
1 4
Safety/Function Important Quality Ordinary Report For : Page : …. Of ….
5
Sending date :
2 Supplier : PT. Part Name : MonthDay Year
Model : Part No. :
Tooling Confirmation Condition

Production OK Repair Replace
Vendor Validation
Inspection OK Repair Replace
6
11 Measurement Inspector Material Lot / Batch No Approved Accepted Checked
0
Deliver To KTB on
0 Base :…………
Month Day Year Finishing : ………..
10 Month Day Year
Sketches.
0
0
9 8 7
COPY TO : 12
1
1
REMARKS: ( If any deviation found) Disposition
OK
NG
Attached Supplier's checksheet for dimention/reliability / performance /function check result
TOTAL ( Item check should reffer to inspection agreement /std )
Date : November 13, 2014
Revision : 01
70
14
13
Inspection & Test Result
Part No. / Part Name : Page : ……….. Of ………….
Inspection Point Judgement
No Item Standard 1 2 3 4 5 X ( OK or NG )
(NOTE) HEAVY BLOCKS TO BE FILLED BY KTB. QC.
71
15.5. The way of filling

15.5. A. The way of filling of covering letter
1. Part/product classification; For example: Safety, Important or Ordinary (filled in by the
suppliers/vendors)
2. Supplier name, Model name, Part No & Part Name
3. Received date by KTB-QC
4. The number of pages in the monthly report
5. Delivery date from the suppliers/vendors
6. Validation from the suppliers (suppliers/vendors)
7. Production Code of the parts delivered for production in Assy Plant of KTB
8. Materials of the parts
9. The name of inspector that performs inspection
10. Date of checking/data retrieving
11. Tooling Cindition confirmation status
12. The entire supplied part status
13. Inspection Items and standard
14. The result of checking and measurement
15.5.B. Way of filling of data sheet

12. Items of inspection and the standard are following the content of Inspection
Standard that has been agreed in the QC approval
13. Enter the data of inspection result in accordance with the inspection points (the
amount of sample checked)
As the sample of calculating for x (mean) and R (range) is as follow:
For X (mean) :
X = (data 1 + data 2 + data 3+data 4 + data 5)/ amount of data
While for R (range):
R = highest value – lowest value
After the asessment of the results of the measurement and checking has been given,
then the suppliers must give validation to the approval of the quality control (QC
approval)
Give validation to the column of suppliers on the following position:
 Checked = Inspection of the QC approval that will be submitted (signed from
the level of QC staff).
 Accepted = Acceptance of the QC approval that will be submitted yang
(dsigned from the level of QC supervisor or similar with it).
 Approved = Approval to the QC approval that will be submitted (signed by the
level of QC management/manager/QC administrator).
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CHAPTER XVI
NOTICE OF THE CHANGE PLAN
(4M CHANGE NOTICE)
16.1. Definition
Notice of the Change Plan/4M Change Notice is the information of change plan made by the
suppliers that are related to the changes in 4M (Man; Machine; Methods and Materials) to
KTB QC every month. Any changes made have the risk that need to be managed together
so that the changes can be run well and provide mutual benefits.
The following table contains information of the changes both that should be reported and do
not need to be reported (from 4M method) to KTB:
Information to
Criteria Changes Specification
KTB
Tools/equipment Installation of new manufacturing
s changes equipments, renewal of existing O
equipmens.
Tools modification O
Modifications outside the production line
O
(power source, electrical source, etc.)
Modifications outside the production line
X
(safety equipments, etc.)
Changes of Bearings replacement (for machining,
O
parts/ assembly, unit of measurement)
tools/equipment Bearings replacement (conveyor system,
X
s components etc.)
Replacement of guide unit, sliding
contact surface (for machining, O
Machine
assembly, measurement)
Replacement of guide unit, sliding
contact surface (for conveyor system, X
etc.)
Replacement of Actuator (for machining,
O
assembly, measurement)
Replacement of Actuator (for conveyor
X
system, etc.)
Replacement of sensor (for machining,
O
assembly)
Replacement of sensor (for operational
detecting of the elements of the X
equipments)
Change of welding timer unit O
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Information to
KTB
(compensation timer, constant current
timer)
Change of sequencer or other instruction
O
units
Replacement of the components that in
direct contact with the product (guides, O
conveyor rollers, etc.)
Jig changes Die/mold modification O
Manufacturing new dies/ molds, or
O
reconditioning old dies/molds
Change of jig (locator, knock, pad, etc.) O
Simple change of jig X
Tools changes Change of tool equipments (machine
tooling, electrode, assembly tooling, O
fastener tools, etc.)
Change of fastener tools (pulse wrench,
O
impact wrench, etc.)
Change of standard operational tools
X
(screw driver, hammer, spanner, etc.)
Machine
Inspection Jig Change of inspection jig O
changes Replacement of inspection jig X
Changes of Change of automatic measurement
measuring insturments (automatic leak test O
instruments/gau insturments, etc.)
ge Change of manual measurement
O
instruments (air micrometer, dsb)
Change of measurement
instruments/ordinary gauge (dial gauge, O
QL wrench, etc.)
Replacement of the equipments of
X
measurement instruments
Change of the Casting condition (casting temperature,
condition of mold temperature, cooling condition, O
equipments casting pressure, etc.)
Method Forging condition (pressure, forging
O
temperature, etc.)
Plating condition (including pre-
O
treatment, density, temperature, etc.)
74
Information to
KTB
Sintering condition (temperature, time,
O
etc.)
Heat treatment condition (temperature, O
time, cooling, gas flow rate, etc.)
Kondisi press work (ram pressure,
O
holddown pressure, dsb)
Molding injection condition (molding
O
pressure, temperature, time, etc.)
Bonding condition (pressure,
O
temperature, time, etc.)
Welding condition (welding current,
voltage, diameter of welding rod tip, O
welding pressure, time, etc.)
Coating condition (including pre-
treatment, density, temperature, air O
pressure, drying time, etc.)
Cutting condition (spindle speed, feed
O
rate, coolant consentrate, etc.)
Staking condition, fitting press (pressure,
O
speed, etc.)
Automatic tightening condition
(tightening torque setting, oil application, O
etc.)
In-line measurement condition
(measuring pressure, time, limit setting, O
accuracy cheking, etc.)
Change of Cleaning condition (pressure, cleaner,
O
equipments consentrate, filter, etc.)
condition Soldering condition (temperature, time,
O
flux, dsb)
Sealant application condition (pressure
O
Method application, rate, etc.)
Pendeteksian proses
permesinan/perakitan ( termasuk
O
identifikasi model/tipe, kondisi
operasional, dsb)
Fool proof tools (operational condition,
O
etc.)
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Information to
KTB
Automatic assembly condition (speed,
X
time, etc.)
Marking condition (stamping pressure,
X
speed, etc.)
Change of Introduction of new fabrication method
O
fabrication (process, etc.)
method Casting design (puring method, cooling
O
method, etc.)
Forging design (heating method,
O
allowance, etc.)
Sintering design (blending, sintering
O
Method method, etc.)
Plating design (including pre-treatment,
O
plating method, etc.)
Heat treatment design (process, etc.) O
Press work design (method, etc.) O
Injection molding design (method, etc.) O
Bonding design (method, etc.) O
Welding design (method, etc.) O
Coating design (including pre-treatment,
O
method, pattern, drying method, etc.)
Cutting design (machining standard,
O
allowance, etc.)
Press-fitting/staking design (method,
O
etc.)
Automatic tightening design (method,
O
etc.)
In-line measurement design (change of
O
method, etc.)
Cleaning design (method, etc.) O
Soldering design (method, etc.) O
Sealant application design (pattern,
O
method, etc.)
Detecting machining/assembly process
(including model/type identification, O
detecting method, etc.)
Fool proof equipments (detecting
O
method, etc.)
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Information to
KTB
Automatic assembly method (order of
O
assembly, method, etc.)
Marking design (stamp method, etc.) O
Sticking design (method, etc.) O
Change of fabrication method on the part
elements/components with ordinary
X
classification. (universal bearing, bolts,
etc.)
Change of Change of fabrication method for
fabrication electronic parts/components(resistor, X
method capasitor, IC, etc.)
Change or plant/manufacture O
Change of Merging the operation O
process Adding the operation O
Stopping the operation O
Change of the order of operation O
Method Change of layout (including relocation of
O
tools)
Change of Change of sub-contractor O
Supplier Change from or to in-house/out-house O
Change of Work division X
working method Work procedures (where there is no
X
change of control plan)
Change of Change of limit of quality control
O
control limit
Change of Change of material source O
material Change from or to in-house/out-house O
Change of material quantity that directly
related to the products (paint, sealant, O
welding rod, etc.)
Change of form of material (forging,
O
Material casting, etc.)
The use of new material (chemical
composition, mechanical properties,
O
structure, etc.), change of
type/composition
Change of Change of additional materials that
O
additional directly used in the products (anti rust,
77
Information to
KTB
material coolant, cleaner, etc.)
Change of quantity of the use of
additional materials that used in the O
products (anti rust, coolant, cleaner, dsb)
Change of additional materials that are
not directly used/related to the products
X
(fluids hydraulic equipments, lubricating
oils, etc.)
Change of Change of the operator (heat treatment,
O
personnel welding)
Change of the operator (besides the two
X
processes above)
Man Change of the operator/ inspector
(performing product inspection that has O
safety characteristic)
Change of the operator (besides the
X
inspection above)
16.2. Aim
Notice of the Change Plan/4M Change Notice is intended that the suppliers inform
periodically to KTB-QC Dept. regarding a change or no change is made in the process of
product manufacturing. This information (especially when there is a change) can be used
for analysis by KTB-QC, so that losses can be minimized or avoided.
16.3. Procedure
 It is reported using the document of Notice of Change Plan/4M Change Notice that has
been completely filled and validated by the suppliers.
 The document must be sent to KTB no later than 1 month prior to the implementation
plan of the change.
 If it is related to the design changes, the document must be sent to KTB 1 week after the
suppliers receive EO (Engineering Order) from KTB Technical.
 For the change of the materials, fabrication method, change of part safety process, or a
quite big change in the process, the document must be sent to KTB 3 months prior to the
implementation of the change.
 When the change of process must be made immediately to anticipate the quality
problems or problems on the machine (or other reasons), the document must be
immediately sent to KTB.
 If the delivery of the first product delays of more than 1 month, then the document should
be revised and resent to KTB.
78
 KTB will provide answers to such information 1 week after the documents are received.
KTB will ask supplementary data related to the change such as PPAP, Pilot samples and
other supporting data prior to approval of the changes notified to the supplier.
 Delivery time of the document is maximum submitted every 25 of the current month to
th
KTB-QC Dept. to inform the condition of parts and production processes in the coming
months, even if there are no changes yet of 4M but the suppliers (suppliers/vendors)
still have to submit the report of the change of the process.
79
16.4. Form
See the attachment on the ‘Notice of Change Plan / 4M Change Notice”:
To: QC Department No.:
Date of Issue:
4M Change Notice
Notice of Change
Model: Part No.: Part Name: Supplier Code:
Part Classification [Check Appropriate box] Name of Supplier:

Safety part Important part
Applicable to regulations General part

Approved by Checked by Prepared by
Classification of Change [Check Appropriate box]
Related to Inspection
Design change Confirmation Procedure Equipment/Jigs & Tools
Material Processing method/ Production plant

conditions
sub-suppliers Style of packing Others. ________
Contents of Change: Reason for Change:
* if details are necessary, attached a separate sheet
Control plan revision Yes No Characteristics which will be effected by this change :
Change safety quality characteristics Yes No
Related EO No.: Simultaneous Implementing EO No.: Scheduled Date of Change:
We have already informed Mr./Ms. of your Scheduled Date of Delivery of Initial Part:
company of the above contents on:
(month) ________________(day)_________ (year) .
Note 1: Submit to the Quality Control Department at least one month in advance of implementation of the change.
2: Even when there is no plan of change in the following month, the supplier shall submit this form by 25th of
the current month concerned by describing “No Schedule” in the form.
3. For design change must be approved by PT. KTB Technical Dept. by EO (Engineering Order)
4: If the applicable parts exist in large numbers, applicable parts list shall be attached.
5: Where the changed part number differs from the delivery part number, both part numbers shall be filled in the part number column
column.
The boxes enclosed w ith heavy lines are filled out by KTB QC .
Instruction for Confirmation

Matters to be confirmed additionally by the supplier: Date of Receipt:
・
Control Classification:
Implementation
・ of PPAP Voluntary control
・
Number of Copies
Submission of pilot
Distribution
Yes No
・ samples:
First product inspection

Yes No
report:
Attachment of
Yes No
identification tag
Matters to be Notified to KTB : Related department in Charge:
・
Approved by: Checked by: Prepared by:
・
Distribution route: Supplier --> QC Dept --> Supplier PT. Krama Yudha Tiga Berlian Motors
80
CHAPTER XVII
VALUE ANALISYS / VALUE ENGINEERING
17.1. Definition
Value analysis/value engineering (VA/VE) is improvement efforts that are made to the
various aspects of the specification, production, process, quality and management, while
these aspects include:
A. Specification aspect
1. Too much amount of parts.
2. Parts are too big or too heavy.
3. Shape of the parts is complicated.
4. The appearance of the parts is too good compared with the function.
5. There was no change yet in a long time.
6. Material productivity is difficult and the materials used are over specification/too
good
B. Production aspect
1. Too many manufacturing processes.
2. Low efficiency of processing (not make sense, inconsistent products, not too
useful).
3. Have been made in the same way in a long period of time.
4. Equipments and supporting tools (such as: jig) already in bad condition.
5. Too much labor involved.
C. Aspect of execution process
1. Quite much parts in the execution process.
2. Bad form of the packaging.
3. High manufacturing costs.
4. Complicated transportation route.
D. Quality aspect
1. The quality exceeds the required specifications.
2. Too many claims arising.
3. Excessive inspection.
E. Management aspect
1. Too many types of parts.
2. Needed too much indirect material and too many sources of material.
3. It is not too good in terms of safety.
17.2. Aim
This VA/ VE is aimed to minimize total cost production spent on each production that doen
by the supplier/vendor.
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17.3. Procedure
1. Scope of Submission
If the suppliers want to do VA/VE program, then it is required to make the planning to
make program (schedule) of VA/VE, ECR (Enginering change request) addressed to
KTB-Technical Dept. (when related to design changes), the form ‘Notice of change
plan/4M change notice’, PPAP documents and other documents related to the idea of
VA/VE.
2. Time of Submission
The forms must be submitted before the VA/VE program is running.
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CHAPTER XVIII
VENDOR AUDIT
18.1. Definition
Audit is a systematic and independently inspection to determine whether the objects and
activities that are planned/defined/agreed have been implemented effectively.
18.2. Type of Audit

A. System Audit
Audit aimed to determine the suitability and effectivenes of the quality management
system that runs in a company by reference to generally accepted quality system such
as ISO9000, ISO TS16949, QS 9000, TQM, etc..
The scope of audit system includes:
a. Organization strategic, resources and management review.
b. Sales communication
c. Product and process development
d. Purchasing aspect
e. Production and PPIC aspect
f. Operational and manufacturing management
g. Preventive and predective maintenance
h. Quality aspect
i. Distribution and transportation arrangement
j. Ohsas aspect
Note: In addition as periodic evaluation (Vendor evaluation) this type of audit is also
done as a benchmark assessment, whether the suppliers candidates have been
suitable to become the permanent suppliers (vendor qualification).
This audit is usually done at the time of the selection for new suppliers and old suppliers
that is conducted periodically.
B. Process Audit
Audit is intended to determine whether the processes are carried out in the manufacture
of products in compliance/effectively executed in accordance with the agreement that
has been specified, refers to generally accepted standards such as JIS, JASO, ASTM
etc. and/or specifically standards such as Mitsubishi standards, Mitsubishi specification,
inspection standard, inspection confirmation list, QCPC, internal standards in each
company, or other agreements that have been previously determined between the
related parties.
This audit is performed at the time of:
 The development of new products
 Mass production (performed periodically)
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C. Part/Product Audit
Audit is intended to determine whether the parts that are made are in accordance with
the technical requirements specified and agreed between the related parties.
( Customers and suppliers, by always bilateral considering (feedback) from the
customer (end user), as a guidance for “continual improvement”).
This audit is performed at the time of:
 The development of new products
 Mass production (performed periodically)
D. Special Audit
This special audit is carried out, especially related to the troubled parts that quite disturb
the production in assy plant, so it is causing delivery stopping or the parts are delivered
but the parts are not in accordance with the specifications so it can not be assembled or
after it has been assembled in vehicles cause problems.
Note:
The documents related to the above four types of audits described separately in
accordance with the requirements and can be revised periodically as a continuous
improvement.
18.3. Procedure
1. Execution of Audit
PT. KTB consists of various related departments (includes: Supplier support
department, Quality department, Production control department, technical department
and procurement department) to the suppliers that have been approved (listed in AVL/
Approved Vendor List).
2. Time of Execution
Audit can be done periodically, as the evaluation program, but basically KTB may at any
time conduct an audit when it discovered the problem on the goods delivered, as the
investigation materials to the problems that occur.
3. Scope of Audit
The scope of the audit includes the quality assurance system, the process of
manufacturing parts and self-parts, which is directly ordered by KTB and all aspects that
influence it, where particularly the scope of the audit will be determined later adjusted to
the conditions and the need of audit.
Under certain conditions, KTB can perform an audit process in sub-supplier together
with the supplier.
Note: For candidates of suppliers where there are no parts of KTB made in related
companies, KTB can retrieve the audit object for other similar parts that are supposed to
represent the condition.
84
4. Notice of the Audit Execution

Matters concerning the execution of audit, time, scope, audit team members, the
documents that must be provided, etc. will be formally informed to the suppliers in a
letter that will be issued by KTB prior to the execution of audit ( For audit system the
letter is issued by the supplier support Department ).
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CHAPTER XIX
HANDLING OF KD PART BY ASSY PLANT
This chapter discusses the procedure of handling of importing parts (KD Part) found in assy
plant, including in it the procedure on the making of claim report.
19.1. Problems of Importing Parts ( KD-Part Problem )

 The product is visually no good (warped, dented, porous, different/changed color,
corrosion, etc.)
 The product can not function normally (not working, cannot be assembled with related
parts, noise etc.)
 The product is dimensionally incompatible with the standard (The size is too small or too
big, too long or too short, etc.)
19.2. Actions if the problems of importing parts are found (KD problem)
 QC assy plant informs the problem to QC KTB (in charge in the assy plant).
 QC KTB will verify the problem reported. If the part is really troubled, then QC assy
plant have to release the claim report using the form of KDQR.
 If it’s necessary, the handling of claim continued by doing checking to the stock of
importing parts in the assy plant and the warehouse of importing parts.
 KTB QC may also determine whether the troubled part can be repaired or not by doing
analysis and trial first.
19.3. Handling of importing parts when the problem is found in finished vehicle in car
pool of KTB
If the defective product is found in the car pool area (stock of vehicles), KTB QC will take
emergency action as needed.
1. KTB-QC will inform to the related assy plant should to take immediate action for the
inspection of the products together with KTB-QC Department for goods or materials
that are in the process of production and the warehouse of the assy plant. And KTB-
QC will check in the inventory warehouse outside the assy plant, such as in CKD
Warehouse.
2. KTB-QC will make/forwad and send the problem report using KDQR form (Softcopy)
made by QC administrator of Assy plant and has been approved by KTB-QC
Department in this regard is expected, the suppliers are required to be able to analyze
and find the cause of the damage and the actions must be taken to prevent the
reoccurrence of the same problem.
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19.4. KDQR (KD Quality Report) Claim Procedure

19.4.1. The form that is used to submit the problems that occur during the production process
for CKD parts (Import Part). With the classification of the claim or the claim code as
follow:
Tabel 19.1
Claim Code Problem
Description
Symbol Meaning Classification
Actual Part does not contain in Part List/Packing List
W Wrong Example:
strange/unknown parts
Part troubled is still contained in the Part List/ Packing
List, but not the part that it is supposed to be (required)
V Wrong Example:
Surplus in RH, minus in LH
Discrepancy
Part for A variant, B variant is delivered
(W)
Partial If the quantity received is less than that written on the
S
Shortage Packing List
Total If the item that is written in the Packing List is not sent
P
Shortage at all
The incomplete part component/component errors
U Wrong Example:
Double tape, clip or ornament is not installed.
The troubled part cannot be/ inappropriate used due to
Q Defect poor quality or standard (in terms of dimensions,
Quality
function or appearance)
(Q)
Rust in part due to less/not enough anti-rust
R Rust
applications. (good packing condition, no damage)
Rust in part due to damaged/not good packing
R Rust
condition
Damage in part due to not good / damaged packing
D Damage condition Packaging
 Scratch, patah, penyok, broken, dented, etc. (P)
Damage in part due to not good / damaged packing
D Damage condition
 change of shape, color, melted, etc.
19.4.2. Each KDQR used for damage or a problem only.

19.4.3. All information of damage written in the column provided. The information is written to be
as detailed as possible, so that only by reading KDQR, other related parties will
understand and be able to investigate.
87
- For the problem of Quality defect (Q) for example: the dimension is not the standard,
it should be written the NG size and standard size.
- For wrong sent (W) problem for example: the part received is different from the
order, then it should be made an actual photo of the part is received compared to the
ordered part.
19.5. Time of recording

Each Assy plant in making the report at the longest has been received by KTB-QC
department one (1) day after the problem is found.
19.6. Address of KDQR

Form KDQR that has been filled, sent to:
PT. Krama Yudha Tiga Berlian Motors – Quality Control Department
Jl. Jend. A. Yani Pulomas Project, East Jakarta 13210
19.7. Attachment of KDQR Application

Each KDQR application reported to facilitate the analysis of the problem, therefore it must
be attached to the following document:
1. Packing list
2. Picking Ticket
3. Vendor tag
4. The photo if the problem (problem of W, Q, D, R and U) does not include problems
regarding the functioning or not the parts for example the light problem.
5. Parts are not perfect (defective part, rust, uncompleted)
6. Unboxing statement (for any problems that require replacement of both goods and work
costs).
19.8 Procedure of Filling KDQR
1. Destination
Address of sourcing plant part in claim
2. Date
Date of claim report issued by assy plant
3. Report No.
Report number (Report No.) filled by KTB QC as data control for each KDQR.
4. Problem Classification
Problems are classified based on:
- Critical Problem: Problems occur in CBU (vehicle) that related to the safety or
function but it does not occur in all vehicles.
- Major Problem: Problems occur in CBU (vehicle) that related to the safety or
function and occur in all vehicles.
- Minor Problem: Problems that occur in CBU (vehicle) that is not related to the safety
and function of the vehicle.
88
5. Report Classification
Classified in 3 categories:
- Discrepancy :
The problems occur caused by incompatibility part (example: wrong part, shortage)
- Quality :
The problems occur caused by the quality of part (example: dimension is not
standard, etc.)
- Packaging :
The problems occur caused by the packaging process that is not good (example:
scratch, dent, etc.)
6. Model
Model of vehicle that uses claimed parts
7. Lot No & Case No
Lot No & Case No. filled in accordance with the lot and case part troubled based on
picking ticket, packing list and vendor tag.
8. Repetition
The claim includes the repeated problem or not
9. Frequency
Number of defective part compared with the total part in 1 lot
10.Claim to sourcing plant
Ensuring whether the part is claimed or not
11.Claim No.
Filled based on claim number in unboxing statement
12.Reference
If the problem has ever happened before (repeated problem) then this column is filled
with the claim number of assy plant for the same/repeated problem
13.Reply form sourcing plant
Request of claim reply of sourcing plant.
14.Assembler’s plant name
Name of plant where the part is assembled and registration number of plant.
15.Subject dan Claim code
Subject : containing the part name and the part number that is troubled.
16.Full description of problem & comments
Claim code: Determination of claim code based on the part problem (based on table
18.1)
Detail explanation on the problem happened
- Problem : Explain the problem finding related the parts
- Qty : Filled quantity of the parts problem
- Action : Temporary action related the finding problem
- Date : Occur date of the problem
- Where : Filled where the problems are findings, unboxing, line assy & etc
89
- When : Filled the process at the time found a problem

- Possible Cause: Possible causes of the problem
- Judgement : Judgment related the problems of parts
- Note : Important information which cosidered neccesarry
17.Description picture
Supporting data (pictures, dimension, etc.)
18.Action taken or other relevant information
Information regarding claim status made.
Part claim : request for replacement parts
Monetary claim : request for reimbursement of work costs
Information only : no need replacement of both parts and work costs
( part is able to be used)
Others : not included in the 3 above categories.
19.Photograph and Sample return
Photograph : photo of troubled part attached or not.
Sample return : returning of claim part.
Categorized in 3 choices:
- Enclosed : if part claim sent together with KDQR
- Separately sent : if part claim sent separately with KDQR (sent after KDQR
issued)
- Nothing : part claim is not sent
20.Plant incharge
Person in charge in assembling plant to make KDQR
21.Reported by dan Signature
Contains the name of complainant (KTB QC) and validation.
90
Form KDQR
(1) AIRMAIL TO: (2) WINDOW PERSON (3) INVESTIGATED BY: (4) WINDOW PERSON REPLY DEADLINE
Overseas Production Support/Management Overseas Production Support/Management
ACCEPTANCE ISSUE NO. ISSUE NO.

20-Jan-00
1 NO.
DATE DATE DATE
PERSON IN PERSON IN PERSON IN (5)

REPLY TO ASSEMBLER　　　
CHARGE (TEL) CHARGE (TEL) CHARGE (TEL)
DATE REPORT CLASSIFICATION

D: M: Y: 2 KD QUALITY REPORT 3 REPORT NO.
DISCREPANCY
6 QUALITY
COUNTRY NAME OF ASSEMBLER PROBLEM CLASSIFICATION PACKING
CRITICAL MINOR
Indonesia PT. Kramayudha Tiga Berlian Motors 4
MAJOR
MODEL Parts No. Parts name

OR SUBJECT FINDINGS OF MFTBC INVESTIGATION AND COUNTERMEASURES TAKEN BY MFTBC
5 MMO 15
LOT NO. FULL DESCRIPTION OF PROBLEM AND COMMENTS: ACTION TAKEN OR OTHER COUNTERMEASURED
OR CLAIM CODE : RELEVANT INFORMATION: LOT AND P.C.I NO.
MMO NO.
7 Problem :
16 Part claim
CASE NO. QTY : Monetary claim
Action : 18 Information only
REPETITION YES Date : Other
8 NO Where :
When :
FREQUENCY 9 Possible Cause :
Judgement :
CLAIM TO YES NOTE :
10 SOURC. PLNT NO
CLAIM NO. 11
REFERENCE
17
12
DESCRIPTION PICTURE
REPLY FROM SOURCE PLANT
13 REQUESTED
19
URGENTLY REQUESTED PHOTOGRAPH
NOT REQUESTED ATTACHED
ASSEMBLER'S PLANT NAME NOTHING Status Of Problem (Circle)
SAMPLE RETURNED Approved Disapproved
ENCLOSED Problem Cause Category (X)
PLANT INCHARGE SEPARATELY SENT 1 Man
NOTHING
14 2 Machine
20 3 Material
4 Method
IF YOU NEED DEFECTIVE PART RETURN PLEASE INFORM TO: sus-ulanto@ktb.co.id 5 Environment
REPORTED BY 　： REMARKS (Input at MFTBC)

NAME 21 Defect contents :
： Delivery date :
TITLE Supplier :
：
SIGNATURE
：
91
CHAPTER XX
HANDLING PROBLEM OF LOCAL PARTS
BY ASSY PLANT
KTB expects that any parts/products (local) sent by the supplier to assy plant have been assured its
quality assurance, so that the quality problem caused by the local parts is unexpected to occur. But if the
quality problem caused by local parts is found, KTB will follow up the problem in accordance with a
specified procedure.
Here will explain the procedures for handling the problem of local parts that are found in assy plant or
area of KTB vehicle stock, along with the media that is used to inform the problem to the suppliers.
20.1. Local part problem:

Local part called troubled if:
a. The product is not good visually (warped, dented, porous, different/ changed color, rust, etc.).
b. The product cannot function normally (not working, cannot be assembled with related parts,
noise, etc.).
c. The product is dimensionally incompatible with the standard (size too small or too big, too long or
too short, etc.).
20.2. Action of problem found in local part:

20.2.1. Found in assy plant.
 QC assy plant informs the matter to QC KTB ( in charge in the assy plant ).
 QC KTB will verify the reported problem. If the part is indeed troubled, claim report will be made
using the form CRS (Countermeasure Request Sheet) and informed to the suppliers.
 If there is an indication that it is a serial problem, the handling of claims followed by checking the
existing inventory at the supplier and assy plant (both in the warehouse, production or vehicle
stock).
 KTB QC can also determine whether the troubled part can be repaired or not by first analyzing
and trial (only under certain conditions, for example not safety part, do not interfere with the
function, invisible, etc.).
 If the troubled parts found or installed on the vehicle so that the vehicle needs to repair, then the
cost of the repair will be charged to the supplier.
20.2.2. Found in the area of vehicle stock (carpool)
 KTB-QC will inform to the related suppliers and have to take immediately actions to check the
products, goods or materials that are in the production process and the production stock both in
the suppliers and in the assy plant.
 If there is an indication that it is a serial problem, so the handling of the claim continued by
performing inspection to all stocks of vehicles.
 Claim report will be made and sent to the suppliers in CRS form.
92
 All costs of the part repairment/replacement on the vehicle will be charged to the suppliers.
20.3. Procedure of filling CRS.

CRS is the media use to inform the problems of local parts found in the assy plant and in the area of
vehicle stock. CRS is also used as the media of handling problem from the supplier to KTB.
The procedure of filling CRS is as follow:
1. Claim Approval
Approval Column for the report/claim information consists of:
A. Approval column by the Assy Plant where the problem occurs
In this column to be filled are: Name, signature, name of Assy Plant
B. Approval column by KTB.
2. Claim Information/Report
In the information sheet/claim report ( filled by assyplant ), the item to be filled is as follow:
Description:
 Address (destination)
In the column of address to be filled are: Name of Vendor and Person in Charge/PIC
 Name of part, Part number and model of vehicle
The name and number of troubled part must be written completely in accordance with KTB
order. Model/type of the vehicle included in accordance with the parts used by the model.
 Amount and Lot
In this column the amount of troubled parts and part lot must be written, so the observation of
the problem and preventive actions taken are correct.
 Grade of problems
Grade of problems can be seen from how big the problem can disturb the production in the Assy
plant, and how serious the problem occurs. As for the influence are among others:
- The amount of troubled parts
- The relation to the safety (safety part)
- Etc.
Description:
Serious : The parts include the parts that can affect the safety of the vehicle when installed
Heavy : The parts do not affect the safety, but in terms of quality needs to get
Minor : The parts do not affect the safety at all (more accessories in nature)
 Plant issue No. and Plant issue date
Plant issue number is the column of claim registration number issued by the assy plant, while
Plant issue date is the column of claim time description made or issued by the assy plant.
 Description time and place of the troubled part
In this column it is written the description related to time of the problem occurs, place of the
troubled parts and the delivery date of the parts.
93
3. Detail of Problem
In this column the problems occur are written as specific and as clearly as possible, and should
include images/sketch/photo. It is expected that the vendors can understand easily and clearly.
Description of symbol:
Q (Quality) :
The troubled parts cannot be/inappropriate used due to poor or non-standard quality (dimension,
function and appearance)
R (Rust) :
The troubled part is rusty, due to substance of antirust not enough (good packing condition, and no
signs of damage).
The troubled part is damaged due to packing/imperfect packing/damaged. (thus resulting in rust,
mildew).
W (Wrong Part):
Part sent does not match the required parts.
D (Damage) :
The troubled part is damaged due to packing/imperfect packing/damaged. Damage, scratch, dent,
broken, change of shape, change of color, melted.
Disposition of reject parts :
Description:
Return : The part is returned to the vendor
Segregation : The part is separated / rejected
Use : The part is still used by repairing it first
In the column of KTB-QC comment due to upon occurrence problem (include status of reject
parts), KTB-QC should comment on the status of the problems that occurs and also the part that is
broken/not standard.
4. Filling the Answer Sheet to Claim ( Report problem solving )

This column is filled by the vendors/suppliers, where the problem happens has to be analyzed and
known the cause so that it can be searched and known the ways to overcome the problem.
Furthermore, the vendor is obliged to prevent the same problem happening again in the future.
Description:
 In the column of flow process, the vendor must describe the flow process of manufacturing parts
briefly and show on which station the troubled part occurs.
 In the column of problem investigation, the suppliers are required to investigate the problem
properly using tools such as Fish Bone Diagram and after investigated using Fish Bone Diagram
the supplier shall conclude the root of the problem occurs in the column of Root/Primary Causes
of Problems and then fill in the column of Problem Cause Category (5M +1 E) in accordance
with the root of the problem that occurs.
94
 In the Column of Problem Analysis (5-Why) the suppliers are required to analyze the problem
using 5 - why method to analyze why the troubled part was made and sent to the customer.
5. Column of countermeasures / problem solving (Filled in by the vendor)

 In the column 4A. Countermeasure of Problem (Temporary Action), the supplier must fill
temporary countermeasure of the existing problems in the assy plant and the conditions of stock
parts and the process in the suppliers.
 In the column 4B. Countermeasure of Problem (Permanent Action), the supplier must fill
permanent countermeasure of the existing problems in production area and delivery area so there
is no problem in the future.
If in the countermeasure/problem solving resulted in a change of the work process then the vendor
must describe in detail the changes in the column of flow process after improvement.
6. Identification of parts after countermeasure

Description:
 The column of Identification of Parts After Countermeasure filled by the vendor/supplier in the
form of tagging in part after the vendor improves the problem occurs. (Part identification after the
improvement process made by the vendor/supplier)
 In the column of First Countermeasure Product Delivery, the vendors/suppliers should fill in
the column by providing information on time and lot number of the product, which has been
repaired.
 In the column of Status of Problem, the suppliers/vendors shall provide the status of part claims
submitted by KTB (if the claim is due to an error in the process of vendor/supplier then the
supplier fills in the column approved and vice versa if the claim is due to an error in the process
of the supplier then the supplier fills in the column disapproved).
 In the column of Validation the vendor/supplier must provide a sign as the sign of validation of
claims submitted by KTB and include in detail the related company name and address.
7. Answer Approval
In this column written the approval for analysis and response from the vendors, which further the
answer is copied to KTB-Rep and Assy Plant ( This column is filled by KTB )
95
Form CRS
1
QUALITY CONTROL DEPT.
Approved Checked In-Charge KTB-REP
1
COUNTERMEASURE REQUEST SHEET Issue No.
Vendor Plant Issue No. 4. Countermeasure of Problem

Part Name Plant Issue Date A. Temporary Action PIC / Date
Part No.
Model 2 Found by
Found at
At supplier
Quantity Delivery on
Lot. Size Occurred on
Grade of Problem Serious Heavy Minor
Assy Plant Approved Checked In-Charge 1. Flow Process
At customer
1
- Detail of quality problem ( How found, Status, Assumed caused, Photo, etc ). 5
Problem ( Q , R , W , D ) B. Permanent Action PIC / Date
Production
Possible Cause 2. Investigation of Problem - Fish Bone Diagram

( Man, Machine, Methode, Material, Environment )
Temporary action
3 4
Photos
Delivery
5. Flow Process After Improvement
Root / Primary Causes of Problem
Disposition of reject parts :

Return Segregation Use
KTB-QC comment due to upon occurrence problem (Include status of reject part):
Problem Cause Category (X) First countermeasure product delivery Identification of Parts after Countermeasure (Photo)
Man Machine Material Method Environment Date
3. Problem Analysis ( 5-Why )

Prod Code.
6
Step 1 2 3 4 5
Status Of Problem (Circle)
Why "Problem
Occurred"
Approved Disapproved
ATTENTION :
REPORT FOR REOCCURRENCE PREVENTION MUST BE RECEIVED BY KTB LATEST 5 DAYS
Content
AFTER RECEIVING THIS FORM

4 From : Date Approved Checked Prepared
Why "Delivered"
7
ATTENTION : Confirmed result of effect of countermeasure by KTB-QC Dept. : Approved Checked Prepared KTB-REP
REJECTED PARTS MUST BE TAKEN OUT FROM…………....BY LATEST 2 DAYS AFTER RECEIVING THIS FORM AND
REPLACEMENT PARTS MUST BE RECEIVED BY………..3 DAYS LATER
96
CHAPTER XXI
SPECIAL ACCEPTANCE
If delivery of the parts that do not meet the requirements of quality specifications (hereinafter referred to
as “Difference of part specifications” or parts out of specification), it is decided to be able to use/accepted
by ensuring the final quality with a corrective action or such as the parts as they are, then the suppliers
(supplier/vendor) may request acceptance with special conditions by submitting a “Request of Special
Acceptance” (attached) to KTB-QC Dept. through KTB-Procurement Dept. first.
21.1. The basic requirements for Special Acceptance

21.1.1. The suppliers may submit special acceptance only if the suppliers wished to complete the
condition:
A. The following items below should not be affected by special acceptance:
 Safety
 Function of parts related to the emissions and the capability.
 Product liability.
B. The effects of most functions, the value of parts, replacement ability and so on are very small,
C. Corrective actions to prevent similar problems have been done.
21.1.2. If the differences of the specifications of a part is found but has been delivered to the plant assy
(third party), then KTB-QC dept. will not accept the request of Special acceptance can not be
approved.
21.1.3. Special acceptance for goods with the same difference specifications is only valid for one time.
21.2. Preparation of Request for special acceptance

The form of “Request for special acceptance” is prepared by regarding the following matters:
1. Detail of the existing quality problems
Location, condition, etc. of the differences in the specification described as much detail as
possible and to be easily understood, it is more expected when using a sketch
2. Cause of the quality problems
The cause should be explained clearly and concretely.
3. Actions
The actions that need to be done to use the differences of the part specifications should be
explained
For example:
A. Used as it is
B. Used after there is action/additional work
C. Used after confirmation of the suitability of the counter part
97
4. Corrective actions to prevent the recurrence of the same problem

Corrective actions shall be done to the root of the real problems and explained with concrete to
prevent the reappearance of the same problem. If the temporary/impermanent action is taken, it
should be mentioned clearly.
5. Enclosed documents
If there is confirmation for inspection and testing, etc. so at the reports of the results must be
presented in an applicable form and if possible along with the actual finished goods.
6. Others
All the important information should be filled in the provided column on the form that must be
completed by the supplier (suppliers/vendors).
21.3. Delivery of Parts with the Special Acceptance

The parts must be confirmed based on the “Approved acceptance”, actual parts must be identical
and marked as a “Special accepted part” and must be sent simultaneously or in succession.
21.4. Responsibility for any additional expenses

Additional expenses due to Special acceptance must be paid in full by the suppliers with the
following rules:
1. Expenses for confirmation of quality test, etc. to determine whether it is accepted or rejected.
2. Additional work
3. Expenses for the separation of the parts that have quality problems.
4. Other expenses for special control
21.5. Reconsideration
If the suppliers (suppliers/vendors) are objected to the decision that has been assigned to the
Special acceptance, they can propose reconsideration to KTB-QC department.
98
REQUEST FOR SPECIAL ACCEPTANCE 1

29
Attn : Mr. Sakti Wiranto ( QC Manager ) Date : Y ……... M……….. D…………
2 9
Page : ………….. Of …………
Condition for Acceptance or reason for Non Acceptance : Date Issue No.
27 28
Judgment
25 ACCEPTANCE / NON ACCEPTANCE
Approved Checked Incharge

22
26
Comments from Departments and examiners concerned : Result of Inspection / Testing :
23
24
1 Details (sketched description), 2 Cause, 3 Countermeasures, 4 Recurrence preventive measures, 5 Attached documents.
5
8
2. Encircle either " ACCEPTANCE " or " NON - ACCEPTANCE "
No : 1. Insidethe fine line is filled by applicant
Identification / Marking of special acceptance product : Expected due-date Order no :

of judgment :
10 19 21
Copy to : Identification of corrected product : Delivery Date of corrected product: Purchasing dept. Concerned :
12
11 17
Type of special acceptance : Order : Machinery model Applicant : ( Supplier or Mfg. Section )
Used as Used only - Checking 13 used :
it is "after special of every work
20 18
additional work"
16
Amount of Quantity : Unit price : Amount of loss due to disposal :
14
15 Manager Seal
7
Model : Part No.: Part Name : Part category :
………………………... - No Inspection / Safety / Essential quality/
6
TOTAL 3 4 5 History control / General.
Date : October 9, 2002
Revision : 00
99
The Way of Filling the Form of “Request for Special Acceptance”

1. Form of “Request for Special Acceptance”
2. Form addressed to the incumbent manager of KTB-QC Dept.
3. Model of vehicle
4. Part Number
5. Part Name
6. Part Category
a. No inspection
b. Related to Safety
c. Essential quality
d. Part control history
e. General
7. The number of parts that requested for special acceptance
8. Detail of the parts
a. Scetch, drawings, photos, etc.
b. Cause of the problems
c. Countermeasure
d. Preventive measure so that the same problems do not reoccur (reoccurrence preventive measure)
e. Supporting documents that need to be attached (attached document)
9. Date of issue of “Request for Special Acceptance” by the supplier
10.Position of tag/label on the product for special acceptance
11.Date of delivery of the correct parts (products that meet the specifications)
12.Identifying the correct parts (products that meet the specifications)
13.Type of special acceptance requested
a. To be used as it is
b. Used after additional work/special treatment
14.Price per unit of the product
15.Number of losses due to incompatibility
16.PIC that applies for a request (manager level)
17.Purchasing dept. of the supplier (name and signature)
18.Machining model used
19.Date of issue of official decision from KTB-QC Dept. that expected by the supplier
20.Amount of total order for the part (with the same part number)
21.KTB order number
22.Condition to be accepted (acceptance) or the reason if it’s not accepted (non acceptance)
23.Opinion from the department and person in charge that are concerned
24.Result of the test or inspection
25.Decision of acceptance or non acceptance
26.Person in Charge from KTB
100
27.Date of issue of the decision

28.Decision number
29.Number of the letter and the date of acceptance of the form “Request for Special Acceptance”
Note:
 That must be filled and met by the supplier of the form is the parts that are not bold underlined; these
are no. 2 to no. 21.
 That will be filled by KTB is the parts that are bold underlined; these are no. 22 to no. 29.
101
BAB XXII
WARRANTY SERVICE CLAIM
&
PRODUCT QUALITY REPORT
22.1. General Explanation
22.1.1. Definition
Warranty service claims (WSC) is the invoice of cost of labor {(Labour charge (LC)}/ Spare
parts/Postage of parts that submitted by the dealer to KTB-Svc Dept for the expenses spent by the
dealer to repair the vehicle of the customer because of the problems are included within the limits
of the warranty and within the warranty period and the problems caused are relating to the
part/installation process by the suppliers / assy plant.
Product Quality Report is an attachment of WSC in the form of report of the problem that occurs for
the first time and if the same problem reoccurs in the future it is included in the List Quality Report
Supplement (QRS)
22.1.2. Aim of Warranty

To promote and ensure that the quality of the parts produced are original (included in the
specification), strong, good and trustworthy in prime condition, so that the customer gets optimal
satisfaction and confidence to Mitsubishi vehicles.
22.1.3. Period of warranty / Limit of warranty

For quality assurance of the quality of the vehicle, PT. KRAMA YUDHA TIGA BERLIAN MOTORS
as the Sole Agent of Brand Holder (ATPM) of Mitsubishi vehicles provides the following warranty:
PERIOD OF WARRANTY
Warranty of power train components and in addition to the power train is valid for 24
months or 50,000 km mileage, whichever is first reached since the date of submission
by PT. KTB to the first buyer.
Unless Battery is valid for 12 months or 20,000 km mileage, whichever is first reached
since the date of submission by PT.KTB or official dealer of PT.KTB to the first buyer.
Warranty for paint or rust arising from within, valid for 24 months from the date of
submission by PT. KTB or Official dealer of PT. KTB to the first buyer, specifically
applies to standard body pick-up and bus/minibus of PT. KTB (to another body of a
car please contact the seller dealer or related workshop of the body of car body).
102
22.2. Flow of WSC process and its billing
Remarks :
Issue Faktur Pajak : Issue of Tax Invoice
Issue kwitansi receipt : Issue of receipt
Debit Note & Faktur Pajak : Debt Note & Tax Invoice
103
WSC Sheet
104
WSC data completeness as follows (see numbers in circle):

1. Name of Dealer (WSC manufacturer).
2. Name of vehicle owner.
3. Dealer Code (6 digits) example:100026
4. WSC sequence number (6 digits) example: 000001~ keep continue
5. WSC Sheet (2 digits) example: 01, if there are a lot of the replacement and type of work/provided
pages are not enough, so it is written in the new WSC with the page number of 02.
6. Delivery date to customer; filled in accordance with the delivery date/date of submission to customer
as written in Service Booklet. Example: 10.02.2007 (Date, Month, Year).
7. Date when the damage occured. Example: 10.02.2007 (Date, Month, Year)
8. Machine number. Example: 6A13820285 (without space and punctuation marks)
9. Chassis number, write down that in printed on the chassis of vehicle. Example:
MHMEA5ASRYK000285.
10. “X” mark for vehicle that assembled in Indonesia and clear for CBU vehicle.
11. 11. Code of damaged position in accordance with the manual on flatrate manual.
12. Mileage of vehicle in the event of problem according to Odometer on the vehicle, example: 1870.
13. Column of part name that is damaged/replaced with the amount and price.
14. Short description on: Symptoms of damage, inspection/cause of damage, repairment and the result
and the production code of part on the column that has been provided.
15. Approval from QA Dept.
16. “X” mark if there is secondhand parts/documents included.
17. Invoice date issued.
18. Production date of vehicle
19. Lot & Serial number of the vehicle.
20. Delivery date of the vehicle to customer.
21. WSC Notification Number (10 Digits) Example: 1401000001 ~ etc.
22. Notification date/ WSC issued.
23. WSC status A = Accepted and D = Rejected. Round one of them to give status (QA).
24. Code of the reason if WSC D Status (QA).
25. Comment of Assy plant/ Vendor on the problem of WSC
26. Total invoice of the accumulation of work cost and cost for part replacement.
27. PQR/TR Reference Number from dealer and KTB-Service.
28. Filled by KTB-QA In accordance with designation.
105
22.3. PQR/TR process flow and issuing IRS
22. 3. 1. Following up IRS to Assy plant/Vendor

IRS consists of 1 sheet, which consists of 2 main parts, namely:
1. Column of claim information, and problem analysis made by PT. KTB QA. This is directed to the assy
plant or vendor of part manufacturer.
2. Column of investigation result and following up to prevent reoccurrence of the problem, and the
problem status, that filled by the related Assy plant or vendor.
106
IRS Sheet
To: PT.Kra m a Yudha Ti ga B erl i a n M ot ors

Qua l i t y A s s ura nce Depa rt m ent
1 Approved Checked In Charge

2
Abi K Ranto Mu'alim
Investigation Request Sheet
Please investigate Causes and take countermeasure for undernoted quality problem and return the Report for
Reoccurence prevention upon filling in properly by
TR or PQR No. Model Chassis No Engine no Vehicle Type
3 4 5 6 7
Mileage Received Date * CBU Date Sold Date 12 Trouble Date 13 Part No Part Name
8
9 10 14
Subject : Issue Date : 16 URGENT
19 Issue No : 17
REGULAR
18
This problem already happened ( Qty ) :
Description of Problem at
Customer/Dealers
20
21
22
Copy
Mr. Catur
Mr.Yoshida
Total
Dealer :
Sent type : Email 23
Sent date : 0-Jan-00 107
Filling IRS data by QA

1. Filled in the name of the assy plant or vendor of destination and the manager name
2. IRS approved by KTB QA Manager before sent to the assy plant vendor of destination
3. Filled in the TR number or PQR claim information from Service Dept.
4. Filled in the model of the vehicle claimed
5. Filled in the chassis number of the vehicle claimed
6. Filled in engine number of the vehicle claimed
7. Type of vehicle
8. Mileage when the problem occurs
9. Claim information officially received by KTB QA
10. Production date of the vehicle claimed (date/month/year)
11. Selling date of the vehicle (date/month/year)
12. Date of the problem occurs (date/month/year)
13. Filled in the part number for the main problem
14. Filled in the part name for the main problem
15. Problem subject claimed
16. Date of issuing IRS (date/month/year)
17. Filled in the serial number of IRS issuance,
Example: 001/IRS/CV/IX/07 (for CV vehicle claim)
001/IRS/LCV/IX/07 (for LCV vehicle)
001/IRS/PC/IX/07 (for PC vehicle)
18. Status of the problem (Important or General)
19. Amount of problems that have ever occurred
20. Explanation of the condition claimed
21. Investigation result of part claim (completed with drawings if necessary)
22. Column of the aim of copy IRS
23. Description contains the media of delivering IRS, TR document acceptance and delivering
IRS to the assy plant or vendor.
Note: Filling of IRS is adjusted with PRQ/TR data and separate investigation result by QA
108
Filling the investigation answer on IRS by Assy plant/Vendor
Address : From : Approved Checked In - Charge

PT. KRAMAYUDHA TIGA BERLIAN MOTORS
QUALITY ASSURANCE DEPARTMENT
26
Jl. Jend.A.Yani Proyek Pulo Mas 24
Jakarta 13210
PO BOX 1482/JKT Phone 4891608 ( hunting )
Telex 48964 JKT KTB, Telefex ( 021 ) 489-9453 25 Issued Date :
Atten: Mr. Catur Darmaw anto Issue No : 27
REPORT FOR REOCCURRENCE PREVENTION
1. Investigation
28
2. Action 29
Status of problem found

30
Approved DisAp.
ATTENTION :
REPORT FOR REOCCURRENCE PREVENTION MUST BE RECEIVED BY KTB BY LATES 7 DAYS AFTER
RECEIVING THIS FORM
Identification of CBU after Countermeasure First Countermeasure Person In - Charge Person In - Charge
product delivery date of Promotion Enforcement
31 serial No.:
Confirmed result of effect of countermeasure Section : Approved Checked In - Charge

by KTB-QA Dept
33 Data Confirmed : 32
109
24. Name of related assy plant or vendor

25. Answer of IRS sent to KTB QA Dept.
26. Validation of the answer of IRS before sent to KTB QA.
27. Filled by the related assy plant or vendor in accordance with the standard performance.
28. Investigation result of the assy plant or vendor.
29. Follow up taken by the assy plant or vendor to prevent the reoccurrence of the problem.
30. Status determination of the problem informed (Agree or not agree).
31. Time limitation to the assy plant or vendor to answer the claim.
32. Data of the vehicle after countermeasure performed
33. Result of the answer of IRS confirmed by KTB-QC/QA.
110
CLOSURE
By having this book PT.KTB expects the commitment of the Supplier to follow all the
provisions contained in this manual. And we hope this manual can be a bridge of
communication between PT.KTB with the supplier so it can avoid misunderstanding of
information in the future and have the same understanding. And in the end all goals shared
between PT KTB and its supplier can be achieved in accordance with the rules covering it.
We realize there is still a shortage of this book and it is possible there will be a revision in
the future , we also expect input from various parties to the contents of this manual may be
better.
There is no idea or concept that is useful, if not applied truly and seriously. We really
wanted to evolve and move forward together between PT KTB and its suppliers.
And finally we thank you for your attention and cooperation.
Best Regards
Jakarta, October 2014.
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QA Manual Supplier 2nd Edition 2014Y - Last Revise 20 Nov

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QA Manual Supplier 2nd Edition 2014Y - Last Revise 20 Nov

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PT.

Krama Yudha Tiga Berlian Motors

Quality Assurance Manual

PT. Krama Yudha Tiga Berlian Motors

Document Change History

No Date/Month/Year Explanation of the Changes Remarks

1.1. Quality Principles

1.2. Quality assurance

1.3. Acceptance inspection and quality audit.

1.4. Feedback of quality problem information.

1.5. Closing record.

process), etc. is one effective tool in planning a quality

(B) Supplier 2) The quality assurance procedures over suppliers (sub-

The quality assurance procedures will be shown as follow:

localization - Part sourcing ●

of FMEA potential to occur in ● ● ● ●

quality control tools.

PPAP) determined by KTB

24. Execution VA/VE program Supplier’s

New part preparation consists of 3 stages, namely:

Here is an explanation for each stage,

 Detail of testing spec requirement

4.2. Part Development (Prototype).

Flow chart of Localization (new development )

PPAP Submission Materials Table

1 PPAP Submission Materials Table (this form) O O

2 Parts Submission Warrant (PSW) O O

3 Design Record (Drawing & Specification) O O

4 Engineering Changes Documents O O

5 APQP Schedule ( production preparation plan ) O O

7 Past Failures and Recurrence Preventive Measures O O

9 Floor layout Diagram O O

11 Control Plan (A/B/C ) O O

Consistency Confirmation Check Sheet between

13 Measurement System Analysis studies O O

14 QC Approval (Initial product inspection result) O O

16 Initial Sample Inspection Result - ISIR O O

17 Material Performance Test Result O O

18 Process capability result (Ppk, Cpk ) O O

19 Certified Laboratory Documentation O O

20 Appeareance Approval Report (AAR) O O

21 Boundary sample (boundary sample photo slip) O O

PT. Kramayudha Tiga Berlian Motors No.

To : Quality Control Dept. Date of isued

PSW ( Part Submission Warrant ) Supplier code

Vehicle model / type

Modification contents ( only w hen actually modified )

Related EO No. Concurrently executed EO No. Schedule date of supply

No. Evaluation contents prior to shipm ent Evaluation result

Target is achiev ed. No problem.

Remark Approv ed Checked Prepared

( Note ) Inside of the thick-line f rame is f illed by KTB

6.5. HOW TO FILLING

2. Select the type of classification desired production

7. Fill in the data required inspection items as listed below:

X = (data 1 + data 2 + data 3 ……. + data 10) / the amount of data

As for the (deviation):

= Highest value - lowest value

6 Model : Part No. : 5

Delivery Accepted Reasons or Conditions

Details of Change, Sketches, etc.

Inspection & Test Result

(NOTE) HEAVY BLOCKS TO BE FILLED BY KTB. QC.