Welcome

Vendor COP Meet

Welcome
Vendor COP Meet (VCM) Journey

 Importance of Timely Part COP Certificate Renewal.

 ID Marking Requirement & Importance

 Upcoming Regulation.
Today

VCM1 VCM2

2021-22 2022~23
Presentation Outline

COP Certificate Renewal

1 • Comparison in COP Renewal
• Last Minute COP Renewal

Vendor COP Meet-1 Recap

2 • Type Approval & COP – Requirement & Importance
• Adherence monitoring at MSIL
• COP Frequency

New Regulation
3 • WVSCOP Regulation
• Importance of Markings
• Dimensional inspection of parts

Learnings
4 • Concerns and learnings during internal checks
Comparison in COP Renewal
Jul 20 to Sep 21

48%
32%
17%
3%

30 days in advance 8 to 30 days 2 to 7 days Last day

Oct 21 to Dec 22
59%

28%

7% 6%

30 days in advance 8 to 30 days 2 to 7 days Last day

Shift can been seen from red zone to yellow zone

Last minute COP renewal consequence

Application submission for COP Application submission for COP

certification at last moment certification on time

Delay in renewal due to-

• Non-availability of test
schedule at test agency

• Non availability of test

Consequence:- fixtures
Dispatch Suspension
Production Stoppage

Renewal of COP Renewal of COP

certificate delayed certificate

Request to Vendor- Initiate COP renewal early

Training Recap
Homologatory Requirements

AIS procedure for Type Approval and Establishing Conformity of Production (COP)
PP Stage MPT Stage Pilot / SOP Stage After SOP
Suppliers Suppliers
AIS-037 Part Level Type Approval COP cycle starts

OEM OEM
AIS-007 Vehicle Level Type Approval COP cycle starts

Examples of Homologation parts:

Vendor Partners need to ensure - COP certificate renewal before expiry of Type Approval certificate
Type Approval Requirements

Part ID
Part Type Vehicle level
specification
Approval test with test
declaration to
certificate agency
test agency
(Component Supplier) (MSIL) (MSIL to Test agency)

COP requirements after SOP

Part COP Vehicle level ID Marking

renewal COP check

(MSIL) (Component supplier &

(Component Supplier)
MSIL)

Adherence to the specifications in mass production as per TA is mandatory

Regulatory Compliances

Type
Approval Mandatory markings on
Production Components
Certificate
Safety Critical
Components

COP Certificate
(1 Year /2 Year)

ID / Marking
verification

- Any Change of Location , Design or Marking needs approval

Type Approval Procedure (excluding BIS)

Application for Type Approval

Initial Documentary Appraisal

Pre-Test Inspection

Tests for Type Approval

Issue of Type Approval Certificate

Marking on Type approved Components

Type Approval certificate is for Specific manufacturing location

/Specific part
Type Approval Number

Clause 9.0 of AIS-037 defines the TAC marking requirement as follows

Important items of TA Certificate

ALXXXX 6 digit TAC No

Applicant Name

Manufacturing location

Markings on
ALXXXX component

First COP date

TA Certificate – specifies Marking & First COP requirement

Why COP?

 Verification of continued compliance by test agency

 Product checks

 QMS check

 To be done at Fixed frequency

Type of COP certificate & Renewal frequency

Type of Example of parts Certificate Renewal

certificate Frequency

Tire, Safety Glasses,

BIS (CM/L) License Wheel Rim etc. 1 or 2 year

COP Certificate Lamps, Fuel tank , Seat Belt- 1 year

(by Test Agency) Mirrors, Safety belt Other parts – 2 Year
etc.
Rules for COP

S No Standard Regulatory requirement Resp.

*Component
1 AIS-037 COP – certificate renewal
manufacturer

Central Motor OEM to assemble parts

2 OEM
vehicle rule with valid COP certificate

* Part related requirement – respective AIS

Create a RASI (Responsibility Accountability Support &

Information)
COP Certificate adherence monitoring at MSIL

Type Approval Obtain Homologation Share with MSIL MSIL

Stage certificate thru extranet Approval

Renewal mail alert to

COP Stage Certificate Renewal Vendor CEO

Online system usage :

1. Monitor certificate for renewal

2. Auto generated mail to supplier, 90 days in advance of expiry.

COP Certificate adherence monitoring at MSIL

Vendor
Extranet COP
supplier input
Do you have a monitoring mechanism in-place?
Renewal Rule (AIS-037)

Extract
from AIS-
037

COP renewal frequency One Year

Initiate renewal process 3

e.g. Part type approved month in advance 1st COP on/ Before
on 1st Apr’22 1st Apr’23

1st Apr’22 1st Oct’22 1st Apr’23

1st COP period

Request: Share renewed COP certificate before 30 days of expiry

Renewal Rule (AIS-037)

COP renewal frequency Two year

Initiate renewal process

6 month in advance
e.g. Part type approved 1st COP on/ Before
on 1st Apr’21 1st Apr’23

1st Apr’21 1st Apr’22 1st Apr’23

1st COP period

Request: Share renewed COP certificate before 30 days of expiry

BIS Certification for automobile components

S No Type of Change Supplier activity BIS Remarks

No change- Production data sharing with Fee

1
Renewal BIS payment
Review the
then
Agency test report – new documents
renewal
2 Part addition parts certificate
+ production data sharing

Initiate renewal process

e.g. BIS approval taken 2 month in advance BIS renewal on/
on 1st Apr’22 before 1st Apr’23

1st Apr’22 1st Oct’22 1st Apr’23

1st COP period
Markings as per Type approved component

• Each component should have the following marking

Trademark / Manufacturer’s emblem Unique ID code

Marking as mandated by relevant Type Approval certificate No. (6 digit)

standard and/or E-mark

Location of marking- Discretion of the Manufacturer (Location once fixed cannot be changed)
Size of the marking- Discretion of the Manufacturer (Shall be visible)

E/e marked component- TAC marking not required

ISI marked component- TAC marking not required for domestic sale
TA Test report : Regulatory marking confirmation
Rule – Regulatory marking

 Marking & its location should be same as defined during the Type approval

 If a component comprises of more than one part, the marking should be

provided on atleast one part.

 In the case of components, where marking is made on running length basis,

marking shall appear at least once on the finished components.

Reflective tape Hoses

Rule – Regulatory marking

 Exemption from markings ( as per AIS-037):

• Door Locks, Door Hinges, Metallic Fuel Tank ,
Wiper Blades, High Security Registration Plate (HSRP).
• Non Metallic Fuel Tanks: shall have only the trade mark.
Summarizing

 Type Approval is for specific Part & plant

 COP renewal to be started early

 Submit renewed certificate to MSIL 30 days before expiry

 Markings & its location to be maintained as per type approval

New Regulation
 Whole Vehicle Safety Conformity of Production
[WVSCoP]

Standard : AIS-017
Applicable for M & N category vehicles (w.r.t MSIL)
WVSCOP Overview

 Enactment date - Dec’2022

 COP cycle- 07th Dec’22 to 31st Mar’25

 Selection of sample randomly by test agency from plant stock

 Static & Dynamic testing by Test agency

WVSCOP applicable tests [External COP by Test Agency]
Dynamic test – 4 No’s

Vehicle Pass By Brake

Noise check Effectiveness
check

Speed Limiting
Steering Effort Function check
check
WVSCOP applicable tests [External COP by Test Agency]

Static test - 4 No’s

Dimension Check-
Part ID & Brake pad, Brake
fitment check as lining, Brake drum
per AIS-037 diameter and Disc
diameter

Wiper
Frequency & Horn noise level
Arm and Blade check
length check
Pass by noise test

• Regulation- IS 3028
• Method- Vehicle with speed of 50 Kmph must pass through point 1 to point 2
with wide open throttle.
• Parameters to be checked- Vehicle Noise
Specifications
• Noise level- less than 74
dBA

Important factors
• Tyre
• Muffler/pre-muffler 1 2
• Air intake system

Request to supplier- Conformance of the parts as per design

Brake test requirement
• Regulation- IS 11852 and IS 15986
• Method- Panic braking at 100 Km/h for M1 & 72 Km/h for N1.
• Parameters to be checked- Stopping distance and deceleration of the vehicle
• Vehicle condition:
• Service Braking
• Secondary Braking
Specifications
• Stopping Distance (Service )– 70 m ( max) MFDD : 6.43 m/s2 ( min)
• Stopping Distance (Secondary ) – 168 m (max) MFDD : 2.44 m/s2 (min)

Important factors
• Tyre
• Brake pad/lining
• Brake disc/drum

Request to supplier- Conformance of the parts as per design

Steering effort test

• Regulation- IS 11948
• Method- Rotate the steering wheel to the specified angle
• Parameters to be checked- Steering force and rotation time

Specifications
• Steering force less than
15 daN
• Time taken to steer- less
than 4 seconds

Important factors
• Steering column
• EPS motor

Request to supplier- Conformance of the parts as per design

Speed limiting function test

• Regulation- AIS-018
• Method- Accelerate the vehicle to check the lock speed in Taxi and N1 vehicle
• Parameters to be checked- Maximum speed reached by the vehicle

Specifications
• Maximum Vehicle speed
less than 80 Km/h

Important factors
• Engine ECU calibration

Request to supplier- Conformance of the parts as per design

Part ID check Emission vs WVSCoP

S No Component Name S No Component Name

Part ID check during
Emission COP 1 Spark Plug 9 CNG Interface Unit

CNG Pressure
2 Ignition Coil 10
Regulator

3 Air Filter 11 CNG Cylinder

4 Injector 12 CNG Injector
5 ECU 13 ISG Motor
6 Silencer 14 Battery Li ion

Front and Rear O2

7 Catalyzer 15
Sensor

8 Tyre 16 EGR

Currently Emission related Parts are being checked by test agencies

WVSCOP Part ID check Requirement
S.No Part Name M1 N1 EV Will be checked by Govt agency
1 HLLD √ √ X Check for fitment
2 Passenger hand hold √ √ X Whether fitted or not
Check for fitment & marking as per
3 Seat belt (All) √ √ X
type approval
Check for fitment & marking as per
4 Rear View mirror (IRVM , ORVM) √ √ X
type approval
5 Safety Glass’s (All) √ √ X Marking as per Type Approval
6 Lighting and light signaling devices √ √ X Marking as per Type Approval
7 CNG / LPG vehicles (Cylinder , Regulator) √ √ X Marking as per Type Approval
8 Tyres (All) √ √ X Marking as per Type Approval
9 Horn √ √ X Marking as per Type Approval
10 Reflective tapes X √ X Marking as per Type Approval
11 Traction Batteries √ √ √ Marking as per Type Approval
12 Brake pad, lining √ √ X Marking as per Type Approval
13 Air filter case and element √ √ X Marking as per Type Approval
14 Muffler and pre-muffler √ √ X Marking as per Type Approval
15 ECU CVN and Cal ID for SLF vehicles √ √ X Marking as per Type Approval

Request Vendor Partners – Ensure Part ID as per Type approval certificate

Marking requirements for WVSCOP

Head lamp- Rear combination lamp-

TAC or E-mark TAC or E-mark

Marking shall be as per type approval

Marking requirements for WVSCOP

Side Indicators- Inner Rear View mirror (IRVM)-

TAC or E-mark TAC or E-mark

Marking shall be as per type approval

Marking requirements for WVSCOP

Horn- LT and HT - Outer Rear View Mirror (ORVM)-

TAC or E-mark TAC or E-mark

Marking shall be as per type approval

Marking requirements for WVSCOP

CNG Cylinder- CNG Regulator-

BIS marking TAC or E-mark

Marking shall be as per type approval

Marking requirements for WVSCOP

Tires-
BIS Marking

Marking shall be as per type approval

Marking requirements for WVSCOP

Glasses-
BIS marking

Marking shall be as per type approval

Marking requirements for WVSCOP

Brake pad/lining-
ID Marking

Marking shall be as per type approval

Marking requirements for WVSCOP

ECU-Cal ID and
CVN number

Marking shall be as per type approval

Wiper related checks

Mode Cycles per

• Regulation- IS 15804 and IS minute
15802 High Mode 45

• Method- Check the wiper Low Mode 10 to 55

Minimum 10
frequency in wet condition Intermittent
Difference in High Mode Minimum 15
• Wiper arm length and blade and Low Mode
length check

Important factors
• Wiper motor and linkages
• Windshield profile
• Wiper arm length and profile
• Wiper blade length and profile

Request to Vendor Partners- Conformance of the parts as per design

Horn noise level check at vehicle level

• Regulation- IS -15796 : 2008

• Noise level spec- 87 dB to 112 dB
• Measurement shall be taken with battery voltage 13 +/- 0.5 V
• Measurement shall be taken at 7 m from the front of the vehicle using Sound Level
Meter in on open site.
• Maximum value shall be taken within 0.5m to 1.5 m above the ground.

Important factors
• Horn

7m 1.5
m
0.5 m
Note maximum value of sound dB(A)
between 0.5 m to 1.5 m above ground

Request to Vendor Partners - Conformance of the parts as per design

Part dimension check requirements for WVSCOP
Dimensional Check Requirement as per design & Type Approval
Brake pad Brake lining

Brake disc Brake drum

Request to Vendor Partners- Conformance of the parts as per design

ID marking check through IT App

All regulatory markings at MSIL are being checked through IT enabled apps

Major Limitations of checking marking manually

• No photographic evidence of the marking checks

Regulatory marking check through IT App

• Benefits- User friendly for the operator

• Environment friendly – Save printouts

• Photographic evidence available for traceability

Request to Vendor Partners - Develop IT enabled system for part ID check at supplier end
Regulatory Marking Confirmation

NG Part Outflow Prevention

• Process Improvements
• Regulatory marking a check point at setup.
• Record regulatory marking content as an evidence. (better traceability)

• Poka-Yoke implementation in Occurrence or Outflow

• E.g. Camera inspection, Barcode scanning, QR code scanning etc.
Target Till end Jun’23
Current Status 82%
Overall Poka-
57% Yoke Target
100%. – Dec’23

Poka Yoke in place Poka Yoke targeted by Jun'23

Regulatory Marking Confirmation
Process & Poka Yoke Control Example:
Process Control - Label is checked for content with master sample and pasted in log-book(Fig-1)
-Homologation label verification done at final inspection (Fig-2)

Fig-1
Fig-2

Poka Yoke Control: -At stitching station PY control available to check homologation label ,if
homologation label is wrong stitching operation will not start.
Regulatory Marking Confirmation
Process & Poka Yoke Control Example:
Marking Specification

Process Control – A E4
• 100% Visual Inspection at Nucleus Caulking by
B 12 V
Operator.
• 5 Parts Inspection during Job Set-up C Type 2B
(Changeover, Start of Shift). D 000085

E 000714

Fig-1
Poka Yoke Control: -
• 100% Auto inspection by vision
camera before EOL for confirmation
of all regulatory marking and
interlinked with next station.

Fig-2
Shifting of Wheel Rim from AIS to BIS approval

Mandatory BIS certification for Wheel RIM Suppliers.

• Implementation from 22nd Jun’23.

• Applicable both for Domestic and Overseas Suppliers.

• BIS marking will replace TAC marking.

Possibility of interchanging from AIS approval to BIS approval.

Learnings
Recent Learnings.

Approx
Reason of Vehicles cost
Item Root cause Learnings
recall Affected (Rs.
Million)
Replace
• Incorrect Setup
Incorrect manual
• Improper verification.
A Regulatory 20,000 25 inspection
Manual inspection at end of
marking with
line
automation
• No Marking validation after
tool Duplication Regulatory
Regulatory • Marking not mentioned in Marking to
B 40,000 50
marking miss Child part drawing be verified
• No system for periodic periodically
verification

Compliance to regulation is not a choice , we need to adhere

to have business sustenance.
Change Management of Regulatory Part

 Un-approved Changes are not allowed as per standards

 Changes cannot be done without approval

 Process Change
 Design change
 Location change
 Marking change

Need to adhere to the standard requirement

Rule – Change Management

• Changes in the specifications of the Component Already

Type Approved need to be communicated to test agency.

• Non technical change – Intimation to test agency.

• Technical change – new plant /location with same part

Test agency may consider whether:
• Component with the changed specifications still complies
with provisions; OR
• Any further verification is required to establish compliance.

• After verification – extension certificate will be provided by test

agency .
Expectation from suppliers
Expectation from Vendor Partners

Awareness of Process
Regulations thru- Automation
Dedicated to control
Training Modules R-marking
on parts

Ensure Change
Camera Based
Approval from
Inspection to
MSIL before
ensure outflow
any changes in
control
R- parts

Request to Vendor Partners- Build Strong Process Controls to ensure Compliance

Expectation from Vendor Partners

Regulatory part
Periodic review
validation-
of control plan
Validation of
as per drawing
regulatory parts as
(MIS-P/PCS)
per design

Monitoring Sharing of Valid

mechanism – COP Certificate
Timely Renewal to Maruti
of COP Certificate Suzuki regularly

Request to Vendor Partners- Build Strong Process Controls to ensure Compliance

Thank You