MSIL - Vendor Quality Manual (VQM)

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Q VENDOR
QUALITY ASSURANCE
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MANUAL
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Third Edition
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MARUTI SUZUKI INDIA LIMITED

Quality Assurance Business Vertical
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MANUAL
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Third Edition
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COPYRIGHT MARUTI SUZUKI INDIA LIMITED. All rights reserved.

All information provided herein is solely the Intellectual Property and Proprietary of
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Maruti Suzuki India Limited and cannot be produced,

reproduced or copied in any manner or form without the prior written consent of
Maruti Suzuki India Limited

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PREFACE
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Indian automotive industry is passing through a critical phase of transformation. With ever increasing
sensitivity of customers towards product Quality, introduction of newer safety and emission regulations
and adoption of newer technologies, the need of the hour is to introspect and upgrade our quality systems
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so that we are always able to live upto customer expectations.
Also the new set of MSIL Quality requirements needed to be reflected in our Vendor Quality Assurance
Manual.
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With this objective, this revised edition of “Vendor Quality Assurance Manual” is being brought out. It
emphasizes MSIL’s increased expectations regarding Quality Assurance Systems from its vendor partners
in line with the current and future business needs. It majorly covers important aspects related to process
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controls, rework control, change management, traceability, and compliance to regulations.
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The activities discussed in this manual form a part of the requirements that have to be fulfilled by the
vendors to provide the assurance that Quality of Products is being consistently delivered.
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MSIL requests all vendors to utilize this manual as a guide and move together on the path of continual
improvement, thus fulfilling our quest of providing high Quality products to customers. Also, all vendors are
requested to extend the requirements prescribed in this manual to their suppliers to ensure that Quality
is consistent throughout the supply chain.
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The journey to Zero Defect will require high level of team work, commitment and engagement and we
request the support of our vendor partners in this endeavor by ensuring 100 percent adherence to the
requirements of this manual in letter and spirit.
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T. SUMINO D. K. SETHI
Senior Advisor Executive Advisor
(Quality Assurance) (Quality Assurance)

VENDOR QUALITY ASSURANCE MANUAL i

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CONTENTS
CH. NO. DESCRIPTION PAGE NO.
1 Introduction .......................................................................................................................... 1
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2 Management Responsibilities.............................................................................................. 13
3 Starting Development of Parts............................................................................................. 21
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4 Preparation & Control of Drawings...................................................................................... 29
5 Production Preparation........................................................................................................ 35
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6 Establishment of Process Control Standard........................................................................ 39
7 Submission of Samples & Evaluation by MSIL.................................................................... 47
8 Peak Production Verification Trial......................................................................................... 53
9 Agreement of Quality Specification & Preparation of MIS-P................................................ 59
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10 Establishment of Operation Standards................................................................................ 69
11 Initial Flow Control & Part Sendai........................................................................................ 79
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Inspection Reports & Data to be Submitted to MSIL During Mass Production................... 87
Systems to be Implemented after starting Mass Production............................................... 91
Revalidation of Parts & Raw Material................................................................................ 103
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15 Packaging Requirements................................................................................................... 109
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16 Lot Control and Traceability............................................................................................... 117

17 Maintenance of Inspection & Production Equipment......................................................... 127
18 Quality System Audit......................................................................................................... 135
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19 Process Audit..................................................................................................................... 143

20 Education & Training.......................................................................................................... 149
21 Skill Development.............................................................................................................. 155
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22 Quality Abnormality Measures........................................................................................... 161

23 Horizontal Deployment and Re-occurrence Prevention..................................................... 169
24 Rework Control.................................................................................................................. 173
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25 Continual Improvement ..................................................................................................... 177

26 Change Approval............................................................................................................... 185
27 Approval of First Production Part ...................................................................................... 195
28 Vendor Rating.................................................................................................................... 203
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29 Sub vendor (Tier-2) Control............................................................................................... 209

30 Risk Assessment............................................................................................................... 215
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Annexure – I Policy Guidelines for Vendors (Supplying Parts to MSIL)....................... 221

Annexure – II Working Procedure for Inspection of Parts(After Machine/Die/Mould.... 224
Maintenance or Die Duplication)
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Annexure – III Dispatch Suspension System................................................................. 226

Annexure – IV Guidelines for Documentation requirements and its Control.................. 227
Annexure – V Guidelines for Sub-Assembly/Process Shifting...................................... 229
Annexure – VI Guidelines for Environment Regulations................................................ 231
QA Manual ...................................................................................................................... 239
List of Acronyms ............................................................................................................... 241
VENDOR QUALITY ASSURANCE MANUAL ii

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CHAPTER 1
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INTRODUCTION
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INTRODUCTION
1. INTRODUCTION
1.0 The purpose of this manual is to explain the expectations and requirements of Maruti Suzuki
India Limited (MSIL) from its vendors in delivering Quality products and attaining higher level
of Quality by doing continual improvement.
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1.1 The basic requirements of MSIL and definitions of key words and phrases have been sum-
marised in this chapter. These would help vendors in conducting Quality Assurance activities
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according to the explanation given in each chapter of this manual.
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1.2 The basic Quality specifications of the parts purchased by MSIL from vendors shall be defined
through one or more of the following documents:
a) Standards, Drawings, Specifications, Mutually agreed standards, in accordance with this
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manual and / or any other document made by MSIL and provided to the vendors.
b) Drawings, specifications and documents made in accordance with this manual and other
documents made by the vendors and approved by MSIL.
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c) National or International standards such as IS, JIS, JASO, SAE etc. which are mutually
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acceptable to the vendors and MSIL (in such cases where items mentioned in a & b) are
not available but National / International standards are available).
The latest version of the manual can be obtained from MSIL’s Vendor Extranet or Enovia.
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1.3 Definitions of words and phrases used by MSIL.

1.3.1 Symbol:
is pronounced as ‘Maru A’. The word MARU in Japanese language means circle. Thus Maru
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A (or literally Circle A) means the letter A, which is the first alphabet, encircled to emphasize
importance. Thus MARU symbolizes something which is the first in the order of importance.
MSIL uses this symbol to designate safety of its customers, which indeed must be our first
and foremost concern. In other words, MARU parts are such, which if defective can pose
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a great danger and safety hazard to occupants and pedestrians causing accidents and/or fire,
jeopardizing human lives.
1.3.2 Part:
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part is defined as , those parts and components which are essential for the safe operation
of vehicles under normal use, and if defective, could result in incidents of personal injury or
fatality by causing loss of vehicle control or fire.
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1.3.3 Item:
items are those Quality characteristic of part, which if defective, could result in incidents
of personal injury or fatality by causing loss of vehicles control or fire.
VENDOR QUALITY ASSURANCE MANUAL 3

INTRODUCTION
1.3.4 Functional Part:

Functional parts are defined as those parts and components of the engine and transmission
which, if defective, could result in a reduction or a total loss of vehicle motive power and per-
formance.
1.3.5 Functional Item:
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A functional item is defined as a Quality characteristic of functional parts which, if defective,
could result in a reduction or total loss of vehicle motive power and performance.
1.3.6 General Parts:
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All the other parts of a vehicle, which are neither nor functional, are called general parts.
1.3.7 Parts:
Parts which are having backend traceability are denoted by symbol.
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1.3.8 Process:
Processes having Poka-Yoke are denoted by symbol.
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1.4 Quality Assurance of Parts:
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MSIL’s Quality Assurance system for bought-out parts has been explained with the help of
a flow chart, which is given in pages 7-11. Vendors are required to plan & promote Quality
Assurance activities for MSIL parts within their companies after thoroughly understanding the
overall flow of activities in all stages of a part’s life cycle.
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1.5 Documents to be submitted to MSIL:

Various documents need to be submitted by the vendors to MSIL at different stages, as
evidence of Quality Assurance activities. These documents are given in Table-1.1 Vendors
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are advised to follow this chart. For details of each of the documents, respective chapters of
this manual are to be referred.
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1.6 Model Codes:

Model codes used by MSIL for its products shall be provided to its vendors by respective
Engineering departments of MSIL.
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Note: Status of part i.e. , Functional or General for new developments shall be informed during
the specification meeting by MSIL. For parts already under supply, clarifications (if any) may
be sought from MSIL’s Parts Quality department (hereinafter called as MSIL’s QAPQ) for
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& Functional parts / items.
1.7 Vendor Acknowledgement:

Vendor Top Management (CEO) shall submit the below signed acknowledgement document
to MSIL (refer Format-1.1).
4 VENDOR QUALITY ASSURANCE MANUAL

INTRODUCTION
Vendor Acknowledgment:
We hereby undertake, declare and confirm:
• That we have read and understood the Vendor Quality Assurance Manual (VQM) and agree
to meet the requirements mentioned therein and to deliver quality products to Maruti Suzuki
India Limited (“MSIL”);
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• That the contents of VQM are subject to change without prior notice and thus we shall at
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all times, agree to refer only to the latest version of the VQM which is available at MSIL
Vendor Portal (Extranet/Enovia Portal);
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• That we shall ensure compliance with the VQM in all our dealings with MSIL and shall also
ensure compliance of VQM by our sub-vendor’s and sub-contractors also;
• That VQM is the confidential and proprietary document of MSIL and we shall not make any
unauthorized disclosure, reproduction in whole or in part of VQM.
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• That MSIL makes no representation or warranties with respect VQM and shall not be liable
for any damage, losses, costs or expenses, direct, indirect, consequential or special, arising
out of, or related to the use of VQM and any information contained therein.
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QMANAGEMENT
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RESPONSIBILITIES
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CHAPTER 2
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MANAGEMENT RESPONSIBILITIES
2. MANAGEMENT RESPONSIBILITIES
2.0 It is vendor top management’s responsibility to implement Quality Management System in the
organization. Top management has to communicate, to their organization, the importance of
meeting customer requirements as well as regulatory and legal requirements. They should
conduct regular management reviews and discussion meetings of the Quality System.
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2.1 Key Role of Management
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The key role of management is to build a Quality organization structure. This can be achieved
by 3 key elements:
→ Quality Planning
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→ Quality Control
→ Quality Improvement & standardization
Quality Planning:
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Develop and define Quality organization structure
Define vision and Quality policy.
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• Define Quality targets in line with customer expectations.
• Develop Quality Standards, procedures, processes and work instructions in line with the
requirements mentioned in this manual. (Refer Annexure-IV, Guidelines for Documentation
requirements and its control).
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• Focus on human resource development, develop and maintain training procedures.

• Give focus on training of manpower and develop system for upgradation of manpower
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skills.
• Conduct management review focusing on Quality System.
Quality Control:
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• Develop customer feedback monitoring and handling process.

• Develop and maintain Quality plan and control plans.
• Implement mistake-proofing techniques
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• Implement a system of Quality gate i.e. no defect should pass on to next process and in
turn, to end customer.
• Implement a system for Quality and process control by individual employees.
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• Monitor cost of Poor Quality.

• Develop and maintain change notification procedure.
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• Adhere to problem containment and traceability procedure

• Root cause analysis and team involvement

Quality Improvement
• Develop a system for continual improvement
• Develop a standard system for tracking Quality abnormalities.
• Document and adhere the WIS / procedures / standards.
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• Follow a standardized approach of PDCA to solve Quality issues.
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• Take feedbacks from customer proactively and introduce improvement in product
• Develop a kaizen team and motivate them by giving recognition time to time
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• Implement Quality circles and focus on improvement of Quality culture.
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2.2 Management Review
The vendor’s Management with executive responsibilities (CEO/MD/Directors/Presidents etc.)
shall review:
Quality Planning:
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Quality system requirements of MSIL (as specified in this manual)
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• Customer satisfaction
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• MSIL related performance measures

• Process performance & output product
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• Internal / External audits results or findings

Data being generated at the company level shall be reviewed and used to improve the performance
continually. Frequency of such reviews should be defined in a documented procedure.
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2.3 Nomination of Quality Assurance Incharge

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In order to ensure smooth working of Quality Assurance System and its continuing suitability
and effectiveness, vendors are advised to ensure the following:
2.3.1 Nominate "Principal Quality Assurance Incharge" and a "Deputy Quality Assurance Incharge"
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and inform their names to MSIL. The following explains regarding the qualification of Principal
QA Incharge and Deputy QA incharge and the method of informing about their nomination and
change to MSIL.
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2.3.2 Qualifications and selection of the QA Incharge:

2.3.2.1 Principal QA Incharge:
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The Principal QA Incharge is a person, who has been delegated the overall responsibility and
authority regarding Quality Assurance by the Chief Executive Officer (i.e. President or Managing
Director) of the vendor. In principle, the Principal QA Incharge should be an officer of a level
equal to or above General Manager. In small companies, one of the owners or a senior person
should take this responsibility. In principle, the Principal QA Incharge should be independent of
Production in taking decisions regarding Quality.

2.3.2.2 Deputy QA Incharge:

The Deputy QA Incharge is a person, who has the functional responsibility regarding Quality
Assurance in the company. In principle, he should be an officer of Manager level or above.
2.3.3 Method of informing MSIL regarding QA Incharges:
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2.3.3.1 The format "Quality Assurance Incharge Nomination/Change Notification Form" (refer Format-2.1)
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for first nomination is to be used and submitted to MSIL's QAPQ. In case of organizational
changes in the company etc, the form is to be filled once more with the updated information
and submitted to MSIL’s QAPQ in duplicate within one month of the change.
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How to fill up the “Quality Assurance Incharge Nomination/Change Notification
2.3.4 Form”:
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(1) Purpose of Submission:
If the form is being submitted for the first time, "Nomination" is to be encircled and "Change"
is to be struck out. Vice-versa needs to be done in case of change.
(2) Vendor Name:
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Enter the name of the company and also the Vendor Code assigned by MSIL. Also mention
the company's Email ID, Telephone No. / Fax No. along with the S.T.D. Code.
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(3) Address:
The company's full address, where the vendor’s QA Incharge is normally available is to be
written.
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(4) Type of business:

Write the main business of the company, e.g. sheet metal parts, rubber parts etc.
(5) Date of nomination/change of new Q.A. incharge(s):
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Write the date of nomination or change of the Q.A. incharge(s).

(6) Principal Quality Assurance Incharge:
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The name and designation of the person nominated as the "Principal QA Incharge" is to be
written. He should put his specimen signature in this column above the word "Signature".
(7) Deputy Quality Assurance Incharge:
The name and designation of the person nominated as the "Deputy QA Incharge" is to be
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written. He should put his specimen signature in this column above the word "Signature".
2.3.5. Duties of QA Incharges:
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The Principal QA Incharge and Deputy QA Incharge have to be explained that they, besides
discharging their other duties, are expected to ensure the following:
(a) Receiving, safekeeping, proper control and timely updation of Quality related documents
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received from MSIL.

(b) Participation in Quality Specification meeting and understanding MSIL’s Quality requirements.
(c) Timely submission, safekeeping, proper control and prior intimation regarding modifications
to MSIL for those documents which are prepared by the vendor and approved by MSIL.
(d) Timely and proper corrective action in case of Quality abnormalities and intimation of the
same to MSIL.

(e) Adherence to the provisions of these manual and other instructions from MSIL regarding
Quality Assurance.
(f) Establish system of conducting VQM training and its effectiveness check
(g) Regularly monitor the & functional items of the parts & the processes, & ensure that
the same are in proper order.
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(h) Prepare SMIR (as specified in ‘Submission of documents’ Table-1.1) & maintain a record
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in plant & also send a copy to MSIL; (refer 12.1 of Chapter 12).
(i) Present Quality data to Management for review.
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2.4 Organisation Chart
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An organisation chart shall be made & maintained which defines clearly the responsibilities &
authorities of different personnel who are involved in assuring the Quality. This chart includes not
only the personnel from Quality but also from production, inspection, purchasing, despatching,
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engineering etc. The chart must show the Inter relation of the personnel, their level and reporting
level. (i.e. which person is reporting to whom) clearly.
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2.5 Communication of Requirement

Vendor should implement a system to communicate MSIL requirements and change in MSIL
requirements within their organisation and at sub vendor's end. ( Refer Chapter 29).
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2.6 Quality Management System Expectations

Vendors shall have effective Quality management systems and must ensure adherence as per
this Manual provided by MSIL.
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Area Requirement
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Quality Management Systems IATF 16949:2016 / ISO 9001:2015

Customer Specific Manual and Standards communicated by
Requirements MSIL time to time
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2.7 Emergency Contact Information

A contact list shall be provided by vendor to MSIL. This list shall contain name of person,
designation of person and his contact number that can be contacted if required during non-
production hours or in case of extraordinary situation.

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Q STARTING
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DEVELOPMENT
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OF PARTS
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CHAPTER 3
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STARTING DEVELOPMENT OF PARTS
3. STARTING DEVELOPMENT OF PARTS

3.0 A Letter of comfort (LOC) / Letter of Intent (LOI) will be issued to the vendor by Supply Chain
department of MSIL. Part development activities may be started after the receipt of the LOC /
LOI.
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3.1 Part Development Stages
Normally, a new part shall undergo following stages of new model development in MSIL:
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The stage wise status and requirement of MSIL are explained in Table 3.1
The following documents / items shall be issued by MSIL to vendor:
(a)
(b) 3-D CAD Data (if required)
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MSIL Drawing or Specifications (in case of new concept design or proprietary parts)
(c) Applicable standards (in the form of SES / International standards)

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(d) Applicable inspection and testing standards (if available, for reference)
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3.2 Technical Review Meeting

In principle, a Technical Review meeting shall be held by Engg / SC department of MSIL with
vendors (before or after issuing LOC / LOI). The agenda and requirements of Tech. review
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meeting will be informed to vendor, normally, 7 days in advance.

Tech. review meeting, in principle, shall be held for all proprietary parts / parts which have
functional / performance requirements. However Engg. may request for Tech. review meeting
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for other parts also in case of need. Vendor shall submit all relevant details and presentation to
engineering 3 days prior to technical review meeting.
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3.3 Specification Meeting:

3.3.1 After the LOC / LOI is received, it is very important to understand clearly the function, specifications
and other requirements of the part to be developed.
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3.3.2 A specification meeting will be held with vendor’s new product development team and MSIL’s
Supply Chain (SC), Engineering and Parts Quality departments soon after the issuance of LOC/
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LOI. In principle, this meeting shall be held within 15 days of receipt of specification / concept/
final drawing from MSIL.
The items to be discussed in this meeting are given below
o Function of the component (purpose of the component, use conditions, its relation with mating
parts)
o Criticality of the component: , Functional or General part / characteristics

o Requirement of vendor drawing / prototype approval

o Design FMEA requirements
o Rig testing and other performance testing requirements to be conducted by vendor
o MSIL Testing requirements
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o Regulatory requirements if any (i.e. CMVR, ECE, ADR etc.)
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o Indication method and location of vendor identification marking and batch code on parts
o Previous part development history
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o Process FMEA requirements
o Process capability requirements
o Measurement system analysis (MSA) requirements
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o Appearance approval requirements
o Details of Sub Vendor for child parts including special outsourced Processes like Heat
Treatment, Plating etc.
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Die/ Mould information & their source selection
List of approved raw material/outsourced vendors & Sub-Vendors
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- Vendor’s control plan on Sub Vendors
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o Discussion on Traceability Information sheet (TIS-P) for Traceability Level for items i.e. up
to Tier-2 or up to Tier-1
o Manufacturing requirements (i.e. accuracy desired, production techniques etc.)
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o Flow of manufacturing process and important process control parameters

o Inspection & test methods and equipment to be used for inspection of important Quality
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characteristics
o Development schedule to be followed (i.e.for dies, tooling, jigs, fixtures, equipment, training
of manpower etc. for production of new part)
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o Submission of Process Control Standard (PFD (Flow Diagram) & PCS (Control Plan))
o No. of samples to be manufactured and inspected by the vendor and inspection and test
reports to be prepared
o No. of samples and test specimens to be submitted to MSIL for evaluation by vendors of
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critical inner parts & raw material.

o Evaluation of child parts in case of proprietary parts
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o Peak Production Verification Trial (PPVT) requirements

o End of life vehicle (ELV) requirements (Refer Annexure-VI, Guidelines for Environment
Regulations)
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o Classification of , functional & general parts / items

o Requirement of limit samples
o Raw material vendor finalisation
o Inputs for making proper jigs & fixtures required for manufacturing

o Identification / Marking (special tags / bar code / colour coding etc.) of trial part shall be
decided in spec. meeting.
o Past failures in similar parts and their countermeasures
o Packaging and handling requirements (to be discussed with OPC department of MSIL, for
details refer Chapter 15)
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o New Design/New System/New Vendor/New Process parts to be clearly identified during
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Spec Meeting.
o Identifying foolproofing (Poka-Yoke) areas and their schedule for implementation
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MSIL shall decide a mutually convenient date and time for these meetings.
Note: On the basis of discussion done regarding laws and regulations, vendor shall ensure that
the products fully comply with all the applicable laws and regulations. The vendor shall ensure
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that all the parts supplied to MSIL, conform to requirements that define the structure, function
and performance of parts with respect to regulation, environment and safety.
In case, if some child parts of regulatory parts are procured from Tier-2 vendor, then regulatory
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compliance of parts and child parts supplied by Tier -2 vendors shall be ensured.
Documents required during Process Specification meeting:
• Drawing of dies, jigs and manufacturing facilities.
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• Schedules of various activities (e.g. design of dies, jigs, fixtures, their manufacturing
schedules, trial production schedule etc.)
3.3.4 The items discussed shall be recorded in the “Specification Meeting Record” and the part
development schedule shall be recorded in the “Part Development Activity Chart” by concerned
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Engg department.
A copy of the Specification Meeting Report and Part Development Activity Chart shall be provided
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to the vendor by MSIL.

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3.4 Development Monitoring

3.4.1 Vendors shall constitute a project team comprising of personnel from Engineering, QA, Process
Engineering and Production in their organisation for carrying out development activities of
MSIL. This shall be informed to MSIL at the time of Specification Meeting. In due course of
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development stage, if there is any change in the structure of key vendor’s person, then same
should be communicated to MSIL.
3.4.2 Vendors shall plan & align their development schedules to meet MSIL development milestones
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(such as production proto trial, mass production trial, Pilot and SOP etc.) as decided in the
specification meeting.
3.4.3 An internal monitoring system shall be devised by the vendor’s project team to monitor & review
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the progress of activities against MSIL development milestones at fixed intervals.

3.4.3.1 These internal reviews shall be conducted by the project / development head of the vendor.
3.4.4 Vendors shall have a joint development review with MSIL before MSIL landmark milestones.
3.4.5 Vendors shall adhere to the initial development schedule, as agreed with MSIL, and shall inform
MSIL in case of any delay along with the reason and salvage plans.

3.4.6 CAD data shall be submitted to MSIL and approved before the start of tooling process at the
vendor’s end.
3.4.7 Vendors shall carry out process design simulations to the extent possible to minimise process
related defects at later stages of development.
3.4.8
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Development activity must be reviewed by the vendor’s top management after completion of
each stage/phase.
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3.5 Part Development Problem History
3.5.1 Vendors shall keep a chronological track of all major problems / defects encountered during
various stages / phases of the part development (till SOP at MSIL) along with the countermeasures
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taken, the implementation date of countermeasure & a status of the effectiveness of the
countermeasures.
(An example of a format to be utilised for this purpose is presented in Format-3.1)
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This chronological summary shall be utilised to check the criteria for termination of initial flow
control (refer chapter 11) and as a knowledgebase for minimising trial stage defects for similar
part developments in the future.
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3.6 Proper Storage of Trial Parts & Handling of Pre –ECN Parts
3.6.1
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Vendor shall identify the separate storage area for trial parts. They should have identification
system for Trial Parts & Production Parts like Tag / Colour marking / Bar code. Identification
method for trial parts should be discussed in specification meeting.
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3.6.2 In case of any ECN received during development trial, Vendor shall properly scrap the Pre- ECN
Part (as per ECN). Also, vendor has to add this checkpoint in his internal monitoring. Vendor
shall establish internal guidelines for handling of Pre ECN part and their scrapping (based on
ECN).
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3.7 Colour and Grain Approval

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3.7.1 All color and grain approvals must be achieved prior to mass production and in accordance to
the schedule agreed with MSIL’s QAPQ.
Any change from the approved schedule and plan must be communicated and approved by the
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MSIL’s QAPQ.
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QPREPARATION
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AND CONTROL
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OF DRAWINGS
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PREPARATION & CONTROL OF DRAWINGS
4. Preparation & Control of Drawings

4.0 Drawings are required to be submitted to MSIL in the following cases:
(i) When the part to be supplied by vendor is of proprietary design as per SOR (Statement of
Requirement)
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(ii) When any change requested from the MSIL in Drawing / specifications is required
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(iii) When specifically requested by MSIL to submit drawings or as discussed in specification
meeting.
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(iv) When design countermeasure / design change is done by a proprietary design vendor.
4.1 “Design Failure Mode & Effect Analysis”, shall be carried out as per “AIAG Manual for FMEA”
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for proprietary parts / concept design parts or as discussed in specification meeting.
Note: FMEA shall be carried out by a cross functional team(Cross functional team (CFT)
means a team which have members from different areas like Engg, QA, Production, Production
Engineering and Purchase etc.). k i In
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4.2 If required, detailed drawings for parts shall be prepared. The drawings required by MSIL for
checking include:
(1) Vendor Part Drawing:
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Drawings showing the basic details of a part’s assembly e.g. drawing should have, in
addition to the full detail dimension of the outside surface and fitment dimensions, Regulatory
Compliance Notes, a cut section showing the arrangement of internal parts, a bill of material
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giving name and material of each part and performance specs which the part is required
to meet.
(2) In case of concept design, any outside shape / form developed jointly shall be the property
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of MSIL. This shall not be passed on to any other party without prior approval of MSIL.
(3) Assembly / Parts Drawings:
Part Drawings: Drawing of internal parts as mutually agreed between vendor and MSIL.
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4.3 Vendors shall prepare their drawings based upon the spec. drawing / 3-D CAD data / concept
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sheets and other items mentioned in 3.1, issued by MSIL and their own technical know-how
and experience.
Vendor shall prepare the drawing as per MSIL “SES D2335” and get it checked by MSIL.
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4.3.1 Identifying parts drawing

All the drawings of parts shall be clearly indicated by “ “ in the title column.
Apart from indicating symbol for part drawing, parameters like, welding / spots,
torque etc. should also be clearly identified in consultation with MSIL Engg. department.

4.4 Drawings shall be submitted through MSIL approved platform already informed to vendors.
In principle, vendor shall submit the copy of DFMEA (wherever required) to MSIL’s Engineering
department.
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Vendor shall submit child part drawings based on MSIL Engineering’s requirement. These child
parts drawings shall be received by concerned engineering department.
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4.6 After registration, a copy of the registered drawing shall be shared with vendor by MSIL. This
drawing is to be controlled as the original and any modification in it shall be done only with the
consent of MSIL.
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4.7
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MSIL Engineering is authorized to make necessary changes in the drawing submitted by vendor
in accordance to MSIL requirement and mutual agreement with the vendor. All such changes
shall be specifically marked by MSIL and the revised accepted drawing shall be shared with
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the vendor for necessary action.
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4.8 Samples can then be made based on the drawings and submitted to MSIL for evaluation.
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4.9 Modification in MSIL approved drawings:

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4.9.1 Modifications initiated by MSIL:

4.9.1.1 If a design modification is proposed by MSIL which requires a change in the MSIL approved
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drawing, then the concerned Engineering department of MSIL will prepare an “Engineering
Change Request (ECR) and it will be discussed with the vendor. After coming to an under-
standing regarding feasibility and time frame for implementation of the modification, Engineering
department will issue the Engineering Change Notice (ECN). In some cases ECN can be issued
directly.
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The ECN will contain:-

o Contents of Modification
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o Reason in brief
o Current and new part numbers
o Likely date of implementation
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o Interchangeability of new and current parts

o Whether sample approval or First production parts evaluation is required or not required
o Advice regarding old parts usage

4.9.1.2 In case the modification is minor, i.e. for which sample approval is not required or which can be
implemented in a short time, modifications is proposed by MSIL based on the agreement with
vendor. Modified drawing (denoted by ‘S” mark) shall be registered in the MSIL system and
officially shared with vendor.
4.9.2 Modifications initiated by Vendor:
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4.9.2.1 In case the vendor wishes to make a change in the approved drawing, the format “Change
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Approval Request from Vendors” should be used to intimate the proposed changes to MSIL
(refer chapter 26).This form is to be submitted to the concerned Supply Chain department of
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MSIL. If MSIL agrees to the proposal, concerned Engineering department will issue an ECN.
4.10 For Proprietary parts, drawing updation is mandatory in case of design countermeasure taken
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by vendor.
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CHAPTER 5
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PRODUCTION Lim
PREPARATION ite
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PRODUCTION PREPARATIONS
5 PRODUCTION PREPARATIONS
5.0 Before the start of mass production, the following activities need to be carried out for ensuring
smooth running of production line and manufacturing of defect free components.
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5.1 Process design:
While designing manufacturing process, “Process Failure Mode and Effect Analysis (PFMEA)”
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(refer AIAG Manual for FMEA) shall be conducted, as decided in the specification meeting. In
case of process changes also, PFMEA shall be carried out. Following points should also be
taken care in order to avoid problems during mass production.
Note: PFMEA shall be carried out by cross functional team at vendor (CFT-Engg/QA/Prod/
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Production Engineering and Purchase).
(a) Vendors shall carry out process design simulations using standard simulation software
to extent possible to minimise process related defects at later stages of development.
(b)
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The accuracy requirements of the part should be clearly understood and it is to be ensured
that adequate process capability is achievable for meeting them.
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(c) Quality problem history of similar parts shall be reviewed and fool-proofing methods (Poka
Yoke’s) shall be considered in the process design stage itself.
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(d) Proper consideration should be given to the process flow. As far as possible, the length
of process flow should be less and in-process inventory should be minimum possible.
Vendors should, in principle, have a Single Piece Flow process. The flow should be
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so arranged to avoid mix up of parts and to minimise the material movement and
transportation.
(e) Proper location should be defined for inspection points, placing visual aids, repair station,
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rejected & OK parts.

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5.2 Schedule monitoring

5.2.1 In order to produce and deliver parts at the required time without delay in mass production and
to stabilize Quality at the earliest, it is very important to carry out thorough planning and control
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of the schedules of procurement and installation of machinery , dies, jigs, fixture, inspection
equipment etc.
5.2.2 In order to adhere to the “Part Development Activity Chart” (refer 3.3.4), it is advisable to use
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schedule monitoring techniques like gantt charts, network analysis etc. This will help in checking
the progress during meetings and on other occasions.
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5.3 Communication of information within the company:

A fail safe system (refer 2.5) should be established by the vendor for communication of Quality
related information like control items, inspection items etc. which have been discussed with
MSIL during Specification Meeting and also modifications etc. to the concerned departments/
personnel within their organisation. For this purpose:

PRODUCTION PREPARATIONS
(a) Information flow routes shall be clarified using flow charts etc.
(b) A documented system should be established whereby it is possible to confirm whether
particular information has been properly communicated to the necessary departments/
agencies without fail.
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5.4 Vendor shall submit the Design & Process Poka Yoke’s in Maru & Functional Parts based
on Past learnings/ Process FMEAs (refer 3.3.2).
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5.5 Vendor shall carry out the validation for tools, jigs & fixtures etc, used for production, during
development stage.
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5.6 Contingency Plan to handle risk
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Vendor shall have a contingency plan for handling any unexpected abnormality / extraordinary
situation / circumstance like manpower shortage, key equipment failure, process insufficiency
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etc. This plan should be communicated to all the concerned people so as to handle any abnormal
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/ extraordinary situation within time and to control the extent of impact.

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PROCESS CONTROL
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ESTABLISHMENT OF
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STANDARD
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ESTABLISHMENT OF PROCESS CONTROL STANDARD
6 ESTABLISHMENT OF PROCESS CONTROL STANDARD

6.0 Why is Process Control Standard necessary?
6.0.1 Quality can never be achieved only through inspection of finished parts. It has to be built into
the process. For building Quality in the process, it must be carefully planned and controlled.
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This can be done by establishing standards for controlling the process in all stages from receipt
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of raw materials to shipment of parts. A properly planned and effectively implemented process
control standard will help in:
(a) Achieving stable Quality by controlling variations
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(b) Knowing if stable Quality is being maintained or not
(c) Knowing if defects are being detected quickly or not,
(d) Knowing if further processing/despatch of defective product is to be stopped or not after
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detection.
6.0.2 Verbal instructions to workers, making judgement by intuition and working with only common
sense are some of the basic reasons for generation of defects. The method to avoid defects is
6.0.3
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to make a Process Control Standard or operation standard and implement it thoroughly.
Process control standard shall be prepared before sample production. As it is difficult to meet
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all conditions during sample production, the process capability shall be studied and carefully
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examined. The process control standard must be modified suitably on the basis of sample
production results.
6.0.4 Check sheets should be carefully designed to record data of various checks on the basis of
the Process Control Standard. The check sheets should contain check items, specification,
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measuring instrument/equipment used etc. so that they provide handy data which can be used
for investigation in case of defects and also for up gradation of process.
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6.1 Procedure for formulation and approval of Process Control Standard

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6.1.1 Enactment & Revision

6.1.1.1 The route and persons responsible within the company for formulation, approval, enactment,
control and revision of Process Control Standard should be clearly specified by the vendor.
6.1.1.2
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In principle, Process Control Standard should be approved by the Principal QA Incharge or in

his absence by the Deputy QA Incharge of the company.
6.1.1.3 It shall be ensured that whenever a standard is revised / newly made based on Quality problem,
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feedbacks etc all the requirements of drawing should be captured. Also, latest drawing shall be
referred while revising or preparing new standard.
6.1.2 Process Control Standard shall consist of two parts, PFD (Flow Diagram) & PCS (Control
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Plan). Both the parts of Process Control Standards i.e. PFD (Flow Diagram) & PCS (Control
Plan) should be prepared by the vendor for all parts ordered by MSIL, including the inner parts,
sub-assemblies. Process control standard shall specify ,functional and critical parameters
(identified in specification meeting and FMEA) for each part. In case of raw material for parts
affecting item and critical inner parts, bought-out by the vendor, sub-vendors should be
guided by the vendors to make Process Control Standards and include their important control
parameters in the main Process Control Standards made by the vendor.

Also, the important items to be checked during receipt inspection by the vendor should be
included.
6.1.3 For carrying out the inspection of both raw material and child part, at incoming stage and in
process stage, the inspection frequency and equipment to be used, shall be discussed with
MSIL’s QAPQ.
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6.1.4 Submission to MSIL:
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6.1.4.1 Vendor is advised to submit Process Control Standard (Flow Chart & Control plan) to MSIL for
approval in case of parts, functional parts and those general parts, for which MSIL’s QAPQ
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requests during specification meeting.
6.1.4.2 The following documents must be submitted to MSIL’s QAPQ (refer to the flow chart):
(a) For new parts, draft Process Control Standard copy along with samples shall be submitted.
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(b) After finalisation of the Process Control Standard (at the time of sample production) the
original Process Control Standard should be submitted with one copy for approval of
MSIL before/with supply of new part or changed part sample.
(c)
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In case of design changes initiated by MSIL through “Engineering Change Notice” or
changes in process or sub-vendor approved by MSIL through the “Change Approval
Request from Vendors” (refer Chapter 26) submitted by the vendor, the Process Control
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Standard should be updated and submitted to MSIL up to one week before the supply of
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new parts or change part.
(d) For revisions other than the above mentioned, submit one copy giving clear explanation
of the reason for revision, along with the “Change Approval Request from Vendors”.
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(e) In case of complete revision of the Process Control Standard, vendor to submit the original
with one copy to MSIL for approval.
(f) Revision history of Process Control Standard should be maintained. E.g. Change in PCS
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because of ECN, CARV, process change etc. along with revision date. All these type of
changes should be traceable.
6.1.5 Approval by MSIL:
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For new parts or complete revisions, the original Process Control Standard submitted by the
vendor shall be returned to the vendor with approval signature after the details are checked by
MSIL’s Parts Quality department.
6.1.6 How to prepare Process Control Standard?
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6.1.6.1 Format
The Process Control Standard should be prepared as per the format 6.1 and 6.2. If the vendor
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wants to use their own format (Format shall meet minimum requirement), MSIL’s format should
be attached to the Process Control Standard of the vendor as the cover page.
First sheet of Process control standard is a Flow chart, (Format 6.2) , which explains the entire
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manufacturing sequence along with the flow of bought-out parts / subcontracted processes. It
is to be noted that this first sheet is a mandatory requirement of MSIL in the Process control
standard.
Serial number 1,2, etc., should be given to each part/sub part (child part) on the PFD (Flow
Diagram), PCS (Control Plan) of each part /sub part (child part) shall be made on individual

sheets giving the same serial number to the corresponding sheet.

6.1.6.2 Process Control Standard - Flow Chart (refer Format - 6.2)
Items to be recorded:
1) Vendor Name: The name of the company to be written
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2) Model: The name(s) of the MSIL model(s) (in which the part is to be used) to be written.
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3) Issue Date: Issuance date to be written.
4) Part Number: MSIL part number as indicated on MSIL drawing/MSIL approved drawing
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should be recorded. For assemblies, it is not necessary to write part number of each
inner part, if the serial number has been written as per the flow chart. For parts, is
to be written and for Functional parts, “F” is to be written at the end of part number.
5) Part Name: Part name as indicated in MSIL drawing/MSIL approved drawing should be
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written.
6) Process Flow Description:
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(a) All the activities / steps should be captured against Sr. no. 1, 2 etc. The same
serial numbers should be used on the corresponding sheets of the main Process
Control Standard (Control Plan) for the part/sub part.
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(b) For each step indicated, in case the process is carried out by a sub vendor, provide
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sub vendors name. Tier-2 / Sub-Vendor check points should be added in beginning
of process control standard of Maru-A and functional parts.
(c) Write or “F” at the end of process name, for processes which are related to
and Functional items respectively.
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(d) Write “Sub-contracted” within brackets below the Process name, if a process is
subcontracted / outsourced.
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(e) For and functional parts write for processes having Poka-Yoke.
(f) Write for processes having backend traceability.
(g) Critical to Quality parameters to be clearly highlighted in PCS.
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6.1.6.3 Process Control Standard - Control Plan (refer Format - 6.1)

1) Items to be recorded:
Items vendor name, Model & part number, should be filled in the same ways as described
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in respective sub clauses 1), 2), 3) & 4) of clause 6.1.6.2.

2) Process Description: Write the name of each manufacturing process in sequence and
also indicate if it is carried out in-house or by a sub-vendor. Please write or F at the
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end of process name, for such processes which are related to and Functional items
respectively. If a process is subcontracted / Outsourced, write “Sub-contracted” within
brackets below the Process name.
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3) Process Machine: Write the name, type and capacity etc. of machine/equipment used
for the process.
4) Control Parameter: Enter process parameter(s) and also Quality characteristic(s) of the
part, which need to be controlled in that process.
5) Standard and Control Specifications: Write the specification values and also tolerances
without fail for each of the control items. Control specifications shall be tighter than the

standard or engineering specifications.

6) Inspection Method: Write briefly the method of checking the control parameter e.g.
visual, gauging etc. Also write the name of measuring instrument/test equipment used
for checking e.g. micrometer, plug gauge, thermometer etc.
7) Transportation Method: Write mode of transportation of part from & to other stations.
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8) Control Incharge: Write level of the person who is incharge of checking e.g. operator,
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supervisor, inspector etc; use the codes explained in the format.
9) Sampling Scheme/Frequency: Write check frequency in the manners explained in the
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following examples:
a) n=5, c=0, if start up (i.e. check 5 pieces at the time of process setting and start only
if none is defective)
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b) n=3, c=0/hour (i.e. check 3 pieces every hour and continue if none is defective)
c) n=100, n=3, C=0 (i.e. check 3 pieces for every 100 pieces produced and continue
only if none is defective)
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and so on. i In
n=10, c=0/lot (i.e. check 10 pieces in each lot and accept only if none is defective)
Recording: Write the name of format used for recording check data e.g. register, shift
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report, control chart, automatic recording etc. If data is not recorded, write “Not recorded”.
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11) Remark: Write remarks e.g. for what to do in case of abnormality etc.
12) Poka–Yoke: Identify the critical operations while establishing the process flow and indicate
the operations where poka-yoke will be used for fool proofing. Indication of Poka-Yoke
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operation shall be done with .

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6.2 While preparing operation standards, it should be ensured that all the operations and
their sequence are defined as per the process flow chart.
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Q SUBMISSION OF
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SAMPLES &
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EVALUATION BY MSIL
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SUBMISSION OF SAMPLES AND EVALUATION BY MSIL
7 SUBMISSION OF SAMPLES AND EVALUATION BY MSIL

7.0 This chapter explains the necessary activities to be done for sample evaluation and approval.
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7.1 Preparation of Sample Parts
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7.1.1 After the Specification Meeting, Drawing Approval and preparation of draft Process Control
Standard, the next step is to prepare sample parts (or samples).
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7.1.2 The raw material and grade to be used for preparation of samples must be procured from the
sources from which it is intended to procure for mass production and/or as decided in Specification
Meeting with MSIL.
Material test certificates from the raw material vendors should be obtained without fail.
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7.1.2.1 In case raw material affects the and functional items of the part, raw material for all these
parts shall be procured from the sources as agreed with MSIL in specification meeting. Also,
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the child parts for all and functional parts shall be procured from the sources as agreed with
MSIL in Specification meeting. (Refer Annexure – 1, clause 5.3)
7.1.3 Samples shall be produced on the fully tooled up line and samples shall be submitted as given
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in 7.3. 100% readiness of Tools, Jigs, equipment or as per the tooling condition / level agreed
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in the specification meeting for each stage of development, should be confirmed by the vendor
at the time of sample submission.
In case samples are not produced on the mass production line i.e Off Tool/ Off Process sample
submission (refer 7.3), then the reports related to mass production line shall be submitted at
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Mass production stage or Pilot production stage with a prior approval of MSIL’s QAPQ.
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7.2 Inspection of Samples

7.2.1 Before/Along with the sample inspection report, vendor shall prepare the validation report for
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jigs, fixtures and tools used for production of samples.

7.2.2 The raw material used for preparation of samples must either be tested by the vendor or shall
be got tested from a recognised laboratory as provided by MSIL in specification meeting.
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Samples for all Quality characteristics; appearance, dimensions, material (i.e. chemistry,
hardness, microstructure etc.) and performance should be inspected. The decisions taken in
the Specification Meeting regarding the number of samples to be manufactured and inspected
should be followed. The inspection shall be done on the basis of the MSIL approved drawing
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(inspection of 100% parameters as per drawing), related standards and items decided during the
Specification Meeting. Inspection report of samples shall be prepared giving the actual values
of characteristics for individual pieces. When using multiple dies or multi-cavity dies, die/cavity
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numbers on each piece shall be marked and also this shall be mentioned in the inspection report
against the inspection result of the piece. In case of proprietary parts, detailed evaluation of
each and every child part going into the main component shall be carried out.

7.3 Submission of samples to MSIL

7.3.1 The no. of samples shall be submitted as per specification meeting. Followings are the guidelines
for minimum number parts, inspected by MSIL:-
ITEMS TO BE INSPECTED NUMBERS
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(a) Dimensional inspection/appearance inspection 3
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(At least 1 no. for each cavity)
(b) Plating thickness, welding penetration, heat treatment 1
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(c) Rubber, plastics, glasses, metal (specimen) 1
(d) Mechanical properties 1
(e) Salt spray, Ozone resistance, Weatherometer 1
(f) Each Function / Performance check 1
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7.3.2 Kindly submit the following documents along with the samples to MSIL:
(a) Parts drawing (trial/final) approved by MSIL 1 Copy
(b)
(c)
Draft process control standard
Material certificate test reports
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1 Copy each
(d) Dimensional inspection report of samples 1 Copy
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(Min. 5 samples)
(e) Process FMEA and Design FMEA Reports 1 Copy
for parameters requested during specification meeting.
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(f) Appearance inspection reports 1 Copy

(g) Process capability report as per the discussion done during 1 Copy
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Spec. meeting
(h) Measurement system analysis report 1 Copy
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(i) Contingency plan 1 Copy

(j) Indigenisation report 1 Copy
(k) List of sub vendors supplying raw material & parts 1 Copy
(Approved bill of material, child part & raw material)
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(I) Any other document as asked by MSIL

These documents shall be signed/approved by vendor side by and to be submitted.
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7.3.2.1 The number of parts for first run to submit samples shall be 300, if production in MSIL is more
than 100 per day. However if MSIL’s production is less than 100 per day than an alternate
number, as decided by MSIL’s QAPQ in the specification meeting, shall be followed.
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7.3.2.2 If process capability reports/MSA reports cannot be submitted along with the samples, a plan
should be provided for carrying out process capability study/MSA study at a date not later than
Pilot lot submission date. Process capability study should include minimum 100 parts (refer
AIAG Manual for SPC).

Note: The requirement of Process capability index Ppk > 1.67 shall be applicable to all newly
selected vendors and new processes/new machine setup at the existing vendors. For others
the requirement of Ppk > 1 minimum along with the contingency plan will be accepted.
7.3.2.3 Measurement system analysis study shall be carried out (refer AIAG Manual for MSA) for
parameters listed in the process control standards or as decided in Specification meeting.
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MSA shall also be carried out for Attribute type parameters (Visual defects or Appearance) as
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decided in Specification meeting.
7.3.2.4 Contingency / Risk Plan is required when process capability (Ppk) or measurement system’s
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repeatability and reproducibility (R&R) are not satisfactory. Also, a contingency / risk plan should
be available in case of bottleneck or critical machines / tools i.e. the machines / tools, which will
affect the MSIL production line in case of breakdown.
7.3.2.5 In case the sample is not for a new part but for process/design change in a part which is already
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under supply, the reference of the corresponding change document (i.e. ‘Engineering change
notice’ of MSIL or the ‘Change approval request’ made by the vendor) should be mentioned in the
sample inspection report. A copy of change document should be attached to the inspection report.
7.3.3 Samples and Others
7.3.3.1
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Other than above reports (refer 7.3.2) the following should be submitted:
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(a) Number of Samples: 5 set minimum or as decided by MSIL’s QAPQ.
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(b) Master Sample: One number (on which measurements have been made) to be
identified as master sample.
(c) Raw Material Sample: One number or as decided by MSIL’s QAPQ.
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(d) Test Slabs: If required by MSIL’s QAPQ.

(e) Checking Fixtures: If required by MSIL’s QAPQ.
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(f) In case of assemblies: Samples of inner parts / Child Parts shall be submitted to MSIL’s
QAPQ
7.3.3.2 The sample parts, test specimens and documents should be submitted to the MSIL’s QAPQ.
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7.4 Process Audit

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7.4.1 After submission of samples and related documents to MSIL’s QAPQ shall visit the vendor’s
plant and conduct the process audit (refer chapter 19) as per the process control standards and
process flow chart, for all and functional parts. For other parts, it will be at the discretion of
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Departmental Manager MSIL’s QAPQ.

7.4.2 If process audit could not be conducted after sample submission then it will be done at the time
of Pilot production (if required).
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7.4.3 While performing the process audit MSIL’s QAPQ shall also verify the jigs and fixtures used in
production.
7.4.4 For the issues / Problem found during Process audit, Vendor has to provide the action plan to
MSIL’s QAPQ along with timeline. In principle, all points shall be closed by Vendor before Start
of Mass production.

7.5 Evaluation of Samples by MSIL

7.5.1 The MSIL’s QAPQ will evaluate samples for material, dimensions, appearance and performance
characteristics. If necessary, Parts Quality members will visit the vendor’s premises to witness
performance tests and/or to check tooling and inspection fixtures.
7.5.1.1
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In parts where functional / performance evaluation is necessary, samples will also be required
to be submitted to Engg department of MSIL for performance evaluation. This requirement may
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be concurrent to the evaluation of samples by MSIL’s QAPQ and will normally be explained in
the initial Spec. meeting. However, extra samples may be requested from vendor later on by
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Engg during course of development.
7.5.2 MSIL’s QAPQ will check the reports submitted by the vendor (refer 7.3.2) in relation with sample
submitted and inspection done by MSIL’s QAPQ to ensure that inspection at vendor’s end is
correct.
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If Ppk is <1.67 then a contingency plan /improvement plan needs to be submitted by the
vendor to bring the process in desired Ppk limits. These plans will be reviewed / verified during
specification review meeting or when MSIL’s QAPQ person visits the vendor’s premises.
7.5.3
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If MSIL’s QAPQ judges that the samples or reports are not satisfactory, the vendor will be given
a Copy of the “Sample Evaluation Report” indicating the improvement items and it will be asked
to re-submit samples. Necessary improvements in tooling etc. should be made and samples
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resubmitted with inspection reports at the earliest keeping the development schedule (refer
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Chapter 3) in mind.
7.5.4 If samples are accepted and reports are satisfactory, vendor shall prepare a draft Maruti
Inspection Standard for Part (MIS-P) and a Specification Review Meeting will be held with the
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Q.A. incharge of the vendor. The primary purpose of this meeting will be to finalise inspection
standard of part (i.e. MIS-P). The details regarding MIS-P and other items to be discussed in
the specification review Meeting are given in Chapter 9.
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7.5.5 Meanwhile, MSIL’s QAPQ will hand over the samples to Engineering department for endurance
testing (if it is necessary) along with necessary documents. MSIL shall carry out endurance testing
on vehicles/engines and evaluate performance of the part under actual use. If performance is
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not satisfactory, the vendor shall be asked to make improvements in the samples. In such cases,
samples are to be re-submitted by the vendor to MSIL’s QAPQ after necessary improvement.
7.5.6 If the Evaluation of samples is found satisfactory, the vendor shall be given a Copy of “Sample
Evaluation Report”. Then vendor shall be asked by MSIL to:
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(a) Submit drawings for final approval, if required (details have been explained in Chapter of 4) and
(b) Proceed for ‘ Peak Production Verification Trial’(PPVT) evaluation.
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VERIFICATION TRIAL
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PEAK PRODUCTION VERIFICATION TRIAL
8 PEAK PRODUCTION VERIFICATION TRIAL (PPVT)

8.0 The purpose of “PEAK PRODUCTION VERIFICATION TRIAL” or PPVT is to capture Quality,
Production or Process related problem, which may arise during ramp up of production at SOP
or major volume increase, so that these problems can be identified and countermeasures are
taken well in advance.
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In principle, PPVT shall be carried out after approval of mass production samples by MSIL or
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line readiness within MPP ± 1 month subjected to Off Tool Off process readiness.
MSIL’s QAPQ & SC members can choose to participate & observe PPVT at vendor’s premises
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at their discretion.
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8.1 SCOPE
PPVT needs to be conducted for :
i) All parts of new model
ii)
iii)
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New plant established or location shifting
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iv) Mass production parts where volume has increased more than 20 % of peak volume.
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8.2 This trial shall be an exact replica of Mass production conditions i.e. the conditions in which this
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trial is done, must be same under which the Mass Production of parts will be carried out.
Few examples of these conditions (which needs to be same as those during Mass Production)
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are as follows-
o All the Tooling / Equipment and Facilities used
o Man Power or Operators (It should cover operators for all the shifts)
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o Process Flow & Sequence / Production Method

o Operation Standards & Quality & Productivity Targets
o Product Quality Assurance System
o Raw Material
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o Gauges etc.
8.2.1 Also, the rate at which the parts are to be produced (i.e. parts / hour) shall also be calculated.
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This rate indicates the maximum no. of parts that can be produced under given condition by the
vendor. This production rate (ok parts only) must match MSIL’s maximum production requirement.
In principle, the rate of production for PPVT shall be calculated as follows-
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o PPVT Rate = MSIL’s peak daily requirement /

[Net operating time available per day for the part (in hours)]
o MSIL Peak Daily Requirement = Monthly Peak Volume shared by MSIL
o Net Operating Time = Total production time available for the part in a day–[Time for

PEAK PRODUCTION VERIFICATION TRIAL
breaks (lunch, tea, rest etc) + Time for planned maintenance

activities + Time for Quality Checks]
8.3 MSIL shall decide that for how many hours (in principle for 2 hour/200 parts whichever is
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minimum), this run has to be carried out.
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If the rate is not achievable or at the PPVT rate it is not possible to match MSIL’s requirement for
Quantity specifications as set in drawings/ MIS- P/ Process control standards etc., then the vendor
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along with MSIL shall review the conditions and shall take the necessary countermeasures.
After taking the countermeasures, parts have to be produced again and PPVT rate has to be
re-validated.
8.3.1 Judgement criteria for PPVT
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OK if ----- [OK parts hourly production achieved*] X 0.80 ≥ PPVT Target rate
NG if ----- [OK parts hourly production achieved*] X 0.80 < PPVT Target rate
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80% Operational efficiency to take care of Change over time, setup approval, breakdown etc)
* repair OK parts will not be considered in calculation of aforementioned formula
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PPVT report will be prepared in “PPVT observation Sheet” (refer Format 8.1)
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If PPVT is judged as NG, then countermeasure will be taken by vendor and submitted to MSIL
for verification.
8.3.2 Once the desired rate has been achieved, in principle, an additional trial should be conducted
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for at least 4 hours, to ensure the consistency of the process conditions and effectiveness of
countermeasures and prevention controls.
8.3.3 Process Capability studies should be carried out during Peak Production Verification Trial for
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important parameters as decided in Specification meeting or listed in Process control standards.

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8.4 The vendor shall submit the PPVT reports along with the countermeasures taken (if any) and
the process capability study results to MSIL’s QAPQ.
Note: 1. All the OK parts produced during PPVT trials may be shipped to MSIL.
2. All the NG parts produced during PPVT shall be scrapped with proper Identification.
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8.5 Requirement of PPVT shall be extended to new Line/ Plant/ Location shifting/ Addition of model
supply.
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QAGREEMENT OF
QUALITY
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PREPARATION
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AGREEMENT OF QUALITY SPECIFICATIONS & PREPARATION OF MIS-P
9 AGREEMENT OF QUALITY SPECIFICATIONS &

PREPARATION OF MIS-P
9.0 Before start of supply of parts to MSIL, it is important that a clear understanding is reached
between the vendor & MSIL regarding the Quality of parts and the methods of measuring and
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judging various Quality characteristics and also regarding the method of assuring Quality during
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trial and mass production. This is necessary not only to ensure supply of good Quality parts but
also to avoid unnecessary confusion and disagreements later on. Such an agreement regarding
Quality of parts is made by establishing “Maruti Inspection Standard for Parts” (MIS-P) and for
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such Quality characteristics, judgement for which is subjective, by establishing limit samples.
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9.1 MSIL Inspection Standards for Parts (MIS-P)
As explained in Chapter 7, the vendor shall prepare MIS-P immediately after the evaluation of
samples and this shall be finalised during the Specification Review Meeting. Here, the procedure
9.1.1 Scope
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of preparation, approval and revision of MIS-P is explained in detail. The other items to be
discussed in the Specification Review Meeting are explained in 9.3 of this Chapter.
MIS-P shall be made for all indigenised parts delivered to MSIL & must be submitted to MSIL.
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9.1.2 Enactment & Revision

The route and persons responsible within the vendor’s company for formulation, approval,
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enactment, control and revision of MIS-P standard should be clearly specified in a documented
procedure.
9.1.3 Approval of MIS-P
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MSIL’s QAPQ will call vendor’s representatives to discuss and finalize the draft MIS-P, before
clearance is given for supply of the First Production Parts lot. In principle, the Principal QA
Incharge of the vendor must approve the MIS-P on behalf of the vendor. However, the Deputy
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QA Incharge of the vendor can approve in the absence of the former. From MSIL’s side, the
Department Manager of QAPQ will approve the original copy of MIS-P & it will be given to the
vendor. MIS P shall be produced whenever asked by MSIL.
9.1.4 Revision of MIS-P
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All MIS-P should be reviewed and revised, whenever there is a change in part due to design
modification, Quality problems reported, process changes etc.
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In all such cases, the revised MIS-P should be submitted by the vendor to MSIL’s QAPQ clearly
indicating appropriate issue number, reason for revision & revision number marked. MSIL’s
QAPQ shall scrutinize the revised MIS-P and return to vendor after approval.
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Alternatively, if there is a need for revision in MIS-P felt by MSIL, MSIL’s QAPQ shall make a
revision and send a copy of the revised MIS-P to the vendor. Vendor shall sign the MIS-P and
share with MSIL’s QAPQ.
9.1.5 Contents of MIS-P and how to use it
9.1.5.1 MIS-P shall be made in the format - 9.1 (a,b,c)

9.1.5.2 MIS-P shall contain the following information:

1) Vendor Name and Vendor Code
Fill the name of the company and the vendor code assigned by MSIL.
2) Part Name and Part Number
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As given in MSIL drawing or drawings approved by MSIL, if the part is part, stamp
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is to be affixed at the end of the part number.
3) Batch code
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This space should be utilised to indicate whether batch code requirements are there for the
part or not (as decided in specification meeting with MSIL). It can be indicated by mentioning
“Yes” if batch code is required & “No” of it is not required.
Further, in case batch code is required, an annexure shall be provided to MIS-P indicating
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the drawing & exact location of the batch code on the part.
4) Serial Number and Inspection Items
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Quality characteristics of the part are classified in the following major categories and are
listed serial number wise.
a) Appearance
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b) Dimensions
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c) Functional or Performance characteristics

d) Durability tests
e) Material
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f) Others.
For dimensions a simple sketch is drawn and dimensions are marked on it, giving
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corresponding serial numbers on the sketch.

5) Judgement Criteria
The specification values of Quality characteristics giving tolerance limits or clear criteria
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for judgement of acceptance/rejection are to be mentioned.

6) Inspection method
The method to be followed for inspection of a characteristic is specified briefly giving the
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reference of applicable standards (e.g. IS, JIS, JASO etc), if available, or by specifying
inspection, reference points, surfaces, location etc.
7) Inspection tool
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The inspection instrument, equipment, jigs, fixture etc. used for inspection are specified.
8) Sampling Plan
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The sampling plan to be followed by the vendor is to be written (e.g. n=5, c=O, per lot).
9) Inspection Stage
The stage at which inspection is carried out at vendor’s end e.g. receipt of raw material, in
process inspection, final inspection, pre-dispatch inspection etc. should be mentioned.
10) Requirement of BOM
Bill of Material containing Child Part and Tier-2 Sources shall be attached.

11) Remarks
(i) For items of parts, “ ” will be marked in the remarks column.
(ii) Similarly, for functional items F will be written.
(iii) For traceability items, of which recording is to be done by vendor will be written.
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(iv) For Poka-Yoke items, where poka-yoke is installed, will be written.
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9.2 Limit Samples
9.2.1 For those important Quality characteristics, which are subjective and their judgement criteria
cannot be described precisely in inspection standards for example, texture of surface, colour,
profile, etching pattern etc; limit samples will be established, as decided in Specification meeting,
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to facilitate uniformity in judgement by the vendor as well as in MSIL.
9.2.2 When it is necessary to establish limit samples, MSIL’s QAPQ shall ask the vendor to prepare
limit sample(s) and submit them to MSIL. Limit samples will be approved by MSIL’s QAPQ by
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fixing “Limit Sample Tag” to each of the sets. The tag will have part name, part number, vendor
name, vendor code, and Quality characteristics to be judged, validity period of the limit sample
and approval signature and date & will be given back to the vendor. (refer Format-9.2).
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9.2.3
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Particulars of the limit sample shall be recorded by the vendor in a register and the sample
should be displayed at the final inspection area or at a place where actual judgement of the
characteristic is done. The inspection area shall have proper lighting. The person carrying out
this inspection shall be trained properly.
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9.2.4 Proper control of the limit sample is very necessary. The limit sample should be protected from
dust, heat and any other kind of damaging condition. Periodic inspection at the end of the indicated
validity period must be carried out and it should be re-approved by the Principal or Deputy QA
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Incharge of the company. In case the limit sample has deteriorated or is damaged it must be
abolished and a new limit sample must be established after getting the required approval from
MSIL’s QAPQ. In such cases, new entry should be made in the control register.
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9.3 Specification Review Meeting

9.3.1
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All items discussed during the Specification Meeting (refer Chapter 3) shall be reviewed in the
Specification Review Meeting. In principle, Specification review meeting should be conducted
one month before the Mass production trials / SOP.
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Following points will be discussed in detail by the MSIL’s QAPQ with the Q.A. Incharge of the
vendor:
o Contents of the draft Process Control Standard submitted by the vendor with samples (in
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case they have been submitted)

o Inspection and test equipment to be used for all Quality characteristics of the part and their
readiness.
o Size of the First Production Parts lot to be manufactured and submitted, inspection to be
carried out for FPP lot (In case of mass production change).
o Items for which process capability and MSA need to be carried out

o Initial Flow Control (refer Chapter 11).

o Traceability requirements and lot control along with TIS-P document (Traceability Information
Sheet-Part).
o Marking of Batch code and Vendor Code on the part (method, location etc.).
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o Inspection reports and data to be submitted by the vendor to MSIL at various stages (i.e.
FPP lot, Initial Flow Control period and periodically during Mass Production).
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o Review of problems faced by the vendor and MSIL in similar parts during sample production
and preventive measures (such as fool proofing devices)
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o Review of schedule
9.3.2 In principle, in the same meeting, members of the Supply Chain Department and OPC Department
will discuss with the vendor about the requirements related to packaging and handling. The
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following point will be clarified during the discussions:
I. Type of packing, whether reusable bins/returnable trolleys or cartons will be used
I. Type of packing, whether reusable bins/returnable trolleys or cartons will be used
II. No. of parts per packing unit
III. No. of parts in a supply lot (usually)
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IV. Points of caution in handling.
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V. Storage condition requirements (e.g. dust protection, protection from heat etc)
VI. Problems faced in the past regarding similar parts.
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VII. Labelling to be done on packages. (refer Chapter 15).

VIII. Preventive maintenance checksheet for trolley / bin, to be used by vendor after SOP.
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ESTABLISHMENT OF OPERATIONS STANDARDS
10 ESTABLISHMENT OF OPERATION STANDARDS

10.0 The primary objective of making operation standards is:-
• Provide correct work instruction to operators
• Prevent Defects due to ignorance
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• Maintain Quality level in case of operator change
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• Facilitate training of operators easily
• Establish Control
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10.1 Scope
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In principle, operation standards must be made for all process stations for such operations
where their absence would adversely affect product Quality .However, in the interest of good
management, operation standards can be made on various aspects e.g. control of machines,
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good workmanship practices, safety precautions during work, control procedures, administrative
procedures, in process inspection, material handling etc.
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10.2 Enactment and Revision of Operation Standards

The vendor shall make a clear documented procedure for enactment/revision of operation
standards so as to avoid any oversight in their enactment/revision. In principle, the head of the
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concerned department should formally approve operation standards and their revisions.
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10.3 How to make Operation Standards?

While making operation standards, it should always be ensured that all the requirements (like
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drawing requirements (latest approved drawings), process sequence, measurable parameters,

etc.) mentioned in process control standard are addressed properly.
10.3.1 Format
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Vendor can choose any suitable format for making Operation standards which gives detailed
information of performing operation and pictorial references. However, should be indicated
in the title column, if the operation has a bearing on item of Part. An Operation standard
format shall have, among other things, the columns for enactment date, revision records, and
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control number, place of usage and copy distribution. If a poka-yoke is installed on station then
details of poka-yoke shall also be captured. A control register should be made for Operation
standards and Original operation standards should be kept in safe custody. A suggested format
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of Operation standard / Work instruction sheet is Format-10.1 (a,b), 10.2 (a,b) for reference.
10.3.2 Contents
 Operation Method:
Write the operation condition, operation procedures and describe the correct way of performing
an operation in a simple manner preferably through sketches.

 Caution Points :
Explain in an easily understandable way using pictures, sketches etc. the caution points and
“don’ts” regarding the operation.
Operation standards should be made in English and Hindi or language easily understandable
by operators.
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It is always better to use pictorial description, sketches or photographs liberally to make operations
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standards more effective. An example is shown in Format-10.1 b.
The operation standards are made in such a way which is easy to follow by operator and should
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take care of their convenience and ergonomics aspects also.
 Process/Machine parameters:
Write the control parameters of the process/machine and their control specifications for that
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station. The control parameters given in the standard shall conform to MIS-P/ Process Control
Standard.
 Quality Check Points :
 Abnormality Handling :
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Write the Quality check items, judgement criteria and check frequency etc. for that station.
Write instructions for the operator, as to what he should do in case of abnormalities (e.g.Stop:
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Call: Wait).
 Defect History:
Write details and causes of occurrence of critical Quality problems, which have occurred at the
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station or at similar stations, so as to prevent recurrence of these problems.

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10.4 Points to be noted while making Operation Standards

10.4.1 The basic objective of making an Operation standard is to produce good products and not just
to check products already made. Therefore, past experience of defect investigation & prevention
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must be used to prepare operation standard.

10.4.2 All the critical operations defined in the operation standard, should be identified by suitable means
and details of fool proofing used at these operations should be listed in operation standard.
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10.4.3 Whenever an operation standard is revised or newly made it should be ensured that it is in line
with the latest drawing.
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10.5 Implementation of Operation Standards

The work method defined in operation standard should be followed by operators performing the
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task. The supervisory officers of the vendor should continually check if the standards are followed
by the workers or not. In case workers don’t follow the operation standards, the supervisors
must educate them. Also, abnormality handling procedure to be initiated for suspected parts
where operation standard was not followed. They must also review the standards and revise
them to eliminate any short comings. Workers should be encouraged to give their suggestions
for upgrading these standards.

10.6 Review of Operation Standards

Whenever there is a Quality abnormality or a feedback about Quality problem, it shall be
thoroughly investigated and during this time all related operation standards must be critically
reviewed. Based on investigation results, not only the directly relevant operation standards,
but also the ones related to similar operations must be revised and upgraded. The dictum “if a
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standard is not upgraded periodically, it gradually becomes useless” should never be forgotten.
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10.7 Job Set Up Instructions
The instructions (set up and verification of set up) for all major job changes (die change, major
tool change, model change), affecting critical Quality characteristics etc. shall be made and
record for the same should be maintained.
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10.8 Work instruction Sheet
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A Work instruction sheet could be used for describing various aspects of the operation done
at a station. The work instruction should contain step by step details of the operation being
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done at the station, characteristics of the part achieved at the station, criticality of the part ( ,
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Functional, General); safety & Quality details and a list of anticipated problems apart from station
name, model name and part name. Use of photographs is highly advisable. An example of Work
Instruction sheet is given on in Format-10.2 b.
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10.9 Operators / Inspectors

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10.9.1 Operator / inspector is a person, who performs an operation which affects Quality level of
item. However, if all stations in a process affect Quality levels of items, then the last operator,
who, assures Quality will be called operator. In case, the operations affecting item are
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carried out by fully automatic machines, then the person, who controls the operating conditions
(i.e. settings) of the machines will be called operator / inspector.
10.9.2 Vendor must nominate only the senior most and the ablest workers as operators / inspectors.
Their names should be entered in a register with date of nomination as operator / inspector.
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Whenever operator / inspector is absent, his work should be carried out by another
operator / inspector only. Multiple persons should be trained to handle station, in case of any
requirement. operators / inspectors must be distinguished by making them wear special cap
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or badge or arm band etc. Also the photographs of all operator / inspector should be
displayed at the work stations.
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10.10 Expression in the work place:

10.10.1 In principle, the following expressions must be used in the work stations:
(1) Put up display boards with the following expressions written on them, at the processing
station of parts (Including casting, forging, heat treatment etc. here after indicated as
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‘Process’) and at the assembly process.
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Parts Colour : Red letters on White background
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Part No. Part Name Size : in principle 250 x 1000 mm
(2) Put up display boards with the following expressions written on them at the process
stations and assembly process of items.
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Item Processing Station Colour: Red letters on White background.
Size : in principle 250 x 1000 mm
(3)
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Put up display boards with the following expressions at the dispatch inspection stage:
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Part Dispatch inspection area Colour: Red letters on White background
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Size : in principle 200 x 600 mm

(4) Put up display boards with the following expression written on them, on parts storage
racks or boxes:
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Parts Colour: Red letters on White background

Part No. Part Name Size : in principle 250 x 1000 mm
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Q INITIAL
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FLOW CONTROL &

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INITIAL FLOW CONTROL & PART SENDAI
11 Initial Flow Control & Part Sendai

11.0 This chapter covers the details of special / extra control which should be exercised during the
initial phase of mass production when the following occurs:-
1. New Product / Engineering Change
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o A new part is manufactured
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o Modification in parts,
2. 4M Condition Change
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o Installation or change in machineries / equipment
o Major change in process,
o Start of manufacturing after a long lay-off (12 months)
o Raw Material Change
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o Sub Vendor Change
o Operator Change (refer 11.5)
11.1 Objective
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Special control needs to be exercised during the initial phase of mass production when one of
the above items occurs, with the purpose of collecting sufficient data in order to judge whether
the mass production can be continued using the existing process or not.
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11.2 Establishment of Initial Flow Control

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11.2.1 Vendor must clearly determine the parameters to be controlled during the initial stage and the
duration of such control. In this, vendor should formulate clear documented guidelines by enacting
procedures and necessary standards to establish all the requirements of Initial Flow Control
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as entailed in this chapter. Some of the requirements for Initial flow control are as mentioned
below:
The following activities related to the part (for which Initial Flow Control is being observed) shall
be carried out during this period:
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 Special inspection / Process Controls that is higher than normal controls. These could be
either added inspection points or inspections at higher frequencies.
 Establishing Lot Control & Traceability (refer Chapter 16)
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 Sub vendor audits (if the change happens to be from sub vendor)
 Process Capability check (important points to be specified: check items, check method,
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check frequency should be decided along with MSIL’s QAPQ and implemented).
 Systematic observation and recording of problem and taking counter measures and
improvement actions quickly without undue delay.
 Systematic confirmation of effects of countermeasures for the problems which were observed
during the trial stages prior to Mass production & during the production of mass production lot.
 Establishment and confirmation of proper inspection methods during the initial flow period.

11.2.2 The initial flow period must be fixed:

 In principle, the initial flow period should be 3 months or Quantity of parts as decided
mutually with stakeholder (whichever is later) for new parts.
 Termination condition shall be decided before start of Initial flow control.
 The Initial Flow Control can be terminated, if at the end of the initial flow period, the following
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conditions are satisfied:
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 If it is confirmed that the capability of the process can fully satisfy the specified tolerance
accuracy requirements.
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 If it is confirmed that the countermeasures taken for the problems occurred during the
production of production of mass production lot are effective.
 If the countermeasures taken against problems observed during initial flow period itself are
found to be effective.
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 If it is confirmed that no repeated defect has been reported at customer end for 3 consecutive
days during initial flow period.
 If all criteria listed above are met, vendor shall take approval for initial flow control termination
from MSIL’s QAPQ.
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If any of the criteria listed above are not met, Initial Flow Control period shall be extended till
the time all criteria are met.
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11.3 It is essential that the person who shall declare & authorise the start & termination of Initial Flow
Control period is clearly defined in the organisation. In principle, it shall be QA Incharge of the
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organisation.
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11.4 Also, there should be clear identification & display on the process in the shop floor that Initial
Flow Control is being observed for the part in question along with the name of the customer,
part name, duration of initial flow control etc. This shall help the people on the shop floor to
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exercise the added controls on the part as required during Initial flow control.
11.5 Out of the 4 type of 4M changes (Man, Machine, Material, Method), Man (operator) related
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changes are the one which is often taken most lightly leading to serious consequences later on.
Initial flow control must be observed for even this type of change. This becomes all the more
important for operator related changes occurring in stations & processes
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The added or extra controls for such type of changes could be :

o Thorough training of the operator about the job, its Quality and safety aspects.
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o Educating operator about the criticality of his job and impact of its failure.
o Skill assessment of the operator before putting him on the job.
o Special extra check of operation carried out by new operator at some defined frequency in
a day by his supervisor.
However, the period for which initial flow control is observed (especially the last control), in
operator related changes, could be of shorter duration, say, a few days.
NOTE : Any man (operator) related change shall be recorded in 4M control register (refer Format-16.1)
11.6 All records of Initial Flow Control shall be retained by the vendor as agreed or conveyed by MSIL.
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11.7 Reports to MSIL on Process Capability
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Process capability studies shall be carried out (refer latest “AIAG Manual” for SPC) for all
items & Functional items of part and for those characteristics as decided by Parts Quality
department and these should be submitted to MSIL along with “Summary of Monthly inspection
report” (SMIR). At any stage if the process show sign of instability or show less capability
(Cp<1.67 and / or Cpk<1.33), corrective actions shall be taken and the plan shall be submitted
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to MSIL. Till the corrective action is implemented effectively, the inspection process should be
strengthened in order to ensure right Quality of the products. 100% check shall be ensured by
the vendor for all such items till the corrective action is implemented.
The report shall have the following also:

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Analysis of Quality characteristic data/parameters
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 Sampling plan (size and interval)
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 Duration & lot size of the study.

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11.8 Deputation of Vendor Quality Representative at MSIL

For and Functional parts, during the start of Mass Production at MSIL and till the time Initial
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Flow Control is exercised by MSIL, it is required to have a “Quality Representative” from vendor’s
Production department or QC department, at MSIL.
The “Quality Representative” shall be
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o Well aware of the process

o Capable of taking immediate actions
o Implementation of Countermeasures at the vendor’s end
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The purpose of having a “Quality Representative” is to have a faster resolution of problem faced
during initial stage after SOP at MSIL.
Note: Vendors, whose ‘Quality representative’ is required, shall be decided & informed by MSIL
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Timeline for IFC can be understood from below defined process:

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11.9 Part Sendai

The objective of this process is:
• To introduce a system of extra checks / inspection done on the first 1000 parts produced
by the vendors at the start of mass production and supplied to MSIL.
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• To prompt initiation of countermeasure for the defects observed during evaluation of first
1000 mass production parts.
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This process is applicable to:
• New part, Part change
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• Other causes - Based on the discretion of MSIL’s QAPQ (Department Head).
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11.10 Vendor shall prepare a “Sendai Check Implementation Plan”. While preparing implementation
plan, following points shall be defined:
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i) Evaluation criteria
ii) Evaluation method
iii) Sequence of Evaluation
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iv) Manpower
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v) Checking area etc.

Sendai Check Implementation Plan shall be approved by Head of Production and QA, and
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submitted to MSIL’s QAPQ.

If any feedback is provided by MSIL’s QAPQ, then the feedback shall be incorporated in plan
and then Sendai check shall be started for parts.
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11.10.1 Defective parts identified during Sendai check shall be separated from OK parts and proper
marking shall be done for identification.
All the defect data shall be consolidated and responsibility shall be defined for performing the
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corrective actions.
11.10.2 In principle, a meeting shall be conducted on daily basis with all concerned departments like
production, QA maintenance etc.
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11.11 Countermeasures initiated against defects shall be verified by Sendai inspector by performing
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relevant checks. Effectiveness of countermeasure/s shall be monitored, and if, countermeasure/s

are not effective then corrective actions taken should be reconsidered till countermeasure are
effective.
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11.11.1 Once the countermeasures are effective, prepare the “Sendai Check Completion Report”.
Approved report from Head of QA and Production shall be submitted to MSIL’s QAPQ.
11.11.2 Once the approval is granted by MSIL for releasing Sendai check on basis of completion report,
information shall be given to all concerned departments.

11.12 IFC & Sendai records for export shall be retained for 11 years and 3 years for domestic.
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Q INSPECTION
REPORTS & DATA
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TO BE SUBMITTED
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TO MSIL DURING
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MASS PRODUCTION
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INSPECTION REPORTS & DATA TO BE SUBMITTED TO MSIL DURING MASS PRODUCTION
12 INSPECTION REPORTS & DATA TO BE SUBMITTED TO MSIL

DURING MASS PRODUCTION
12.0 After SOP of new model at MSIL, MSIL shall issue schedule for regular supply to the vendor. As
a part of assurance by the vendor to MSIL regarding the Quality of parts supplied during mass
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production, vendor will be required to submit inspection reports and test data monthly to MSIL.
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In this chapter, the manner of submission and contents of such reports have been explained.
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12.1 Submission of Inspection Reports
12.1.1 For & Functional and Regulatory Parts, consolidated Summary of Monthly Inspection Report
(SMIR), shall have to be submitted to MSIL, for all the lots supplied during the previous month
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for those Quality characteristics of the parts, which have been mentioned in MIS-P. However,
if the periodicity of check for a characteristic is more than a month, submit the report in that
month in which that characteristic is checked.
12.1.2
12.1.3
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Submit Inspection reports to MSIL’s QAPQ by the 7th day of the following month.
For General parts, SMIR shall be submitted for parts as decided by MSIL’s QAPQ.
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12.1.4 It shall be ensured that the data submitted in form of Inspection Report / SMIR is authentic and
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no alteration has been done in inspection results. While inspection it shall be ensured that all
the dimensions have been inspected as per drawing specifications.
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12.2 Contents of Inspection Report

12.2.1 Format of the inspection report can be decided by the vendor in consultation with MSIL’s QAPQ.
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12.2.2 The inspection report should include the following information:

(i) Name of the vendor’s company.
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(ii) Part Name and Part Number: as given in MSIL drawing/MSIL approved drawing.
(iii) Part Classification i.e. , Functional or General.
(iv) Judgement criteria: as given in MIS-P
(v) Inspection Sampling Plan: as given in MIS-P (i.e. 100% or sampling)
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(vi) Inspection results: Give total rejection %. In case of 100% check items, give number of
defective products found during the month and total numbers inspected. In case of sampling
inspection of variables, give actual data as decided in the Specification Review Meeting.
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(vii) Judgement: Write judgement for each of the lots.

(viii) Signature of person who prepared the report and signature of Principal or Deputy QA
Incharge.
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(ix) Batch Number or batch Code: If the inspection data pertains to more than one batches,
write batch codes of all of them.
(x) Space should be provided for vendor’s remarks and the remarks by MSIL’s QAPQ and
their signatures.
(xi) The month for which the report is pertinent.

INSPECTION REPORTS & DATA TO BE SUBMITTED TO MSIL DURING MASS PRODUCTION
12.3 Preservation of Inspection records

12.3.1 Inspection records have to be preserved for the purpose of facilitating:
(a) Evidence of Quality Assurance activities performed.
(b) Investigation in case of Quality abnormalities or market complaints for taking corrective
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actions.
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12.3.2 For parts, functional and Regulatory parts, inspection reports must be preserved for minimum
11 years and in case of general parts for minimum 3 years or as specified by MSIL.
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12.4 Submission of 4M Report
12.4.1 Vendor shall submit the 4M report to MSIL’s QAPQ, for all the 4M changes carried out at
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vendor’s end during the previous month. In case there is no 4M change in previous month at
vendor’s end then also he has to submit this report by mentioning –No 4M change.
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12.4.2 Any 4M change at vendor’s end should be tracked properly; Plant head level/ Manger shall
approve the 4M report
12.4.3 Vendor shall submit 4M Report every month to MSIL’s QAPQ by the 7th day of the month.
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12.4.4 In case Vendors fail to submit the 4M Report /SMIR as per the schedule then there vendor rating
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will be impacted according to detail given in next section.

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12.5 Linkage of Document Submission with Vendor Rating

12.5.1 Submission of SMIR & 4M report is linked to Vendor rating marks. In vendor rating 50 marks
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are allocated for Submission of documents with respect to timeline, details are given in table
below:
12.5.2 In case vendors fail to submit the 4M Report /SMIR as per the schedule, then their vendor rating
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shall be impacted.
Conditions 4M Change SMIR

(Report Submission Date) (25 Marks) (25 Marks)
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By 7th of each month 25 25

Between 8th ~ 15th 12.5 12.5
After 15th Zero Zero
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12.6 SMIR of Pass through Part Vendor

Vendor shall submit a monthly Quality performance report to MSIL along with report of pass
through part vendor. Report must include total number of parts received, the total number of
non-conforming parts and a description of non-conformances / defects.

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QSYSTEMS TO BE
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SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION
13 SYSTEMS TO BE IMPLEMENTED AFTER STARTING

MASS PRODUCTION
13.0 MSIL expects its vendors to be certified to ISO 9001:2015/ IATF 16949:2016, as a minimum
demonstration of a model for Quality Management System. Apart from this, the vendor shall
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also ensure the implementation of the following systems.
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13.1 System For Development of Sub Vendors
A documented system should be established for ensuring proper Quality Management System
at sub-vendor’s (Tier-2 vendor’s end). Vendors shall clearly define its requirements to the
sub-vendors in line with MSIL’s requirements and establish mechanism to ensure their
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compliance. A list of sub-vendors should be established, whose selection shall be done on basis
of clear guidelines laid out by the vendor. An evaluation mechanism should also be established
for sub-vendors to ensure their eligibility for supplying parts. Whenever required by MSIL,
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arrangement shall be done by the vendor for audit to be conducted by MSIL at sub-vendor’s
end to verify that sub vendor is in conformance to the specified requirements provided by MSIL
(For more details refer Chapter 29).
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13.2 System for Maintaining Quality History of parts and its Analysis
13.2.1 There shall be an established documented system for maintaining Quality History of each part
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by means of a control register or in soft form. The Quality History shall contain information about
the problems encountered in the part right from development stage till the part is active, in a
chronological order. The Quality history shall be analysed at regular interval & used as a tool
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for providing inputs for subsequent development & monitoring the effectiveness of previous
countermeasures.
Quality History of each part shall have the following information:
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o Part Name & Part No.

o Description of defect / abnormality -Batch code
o Stage of part (i.e. Development / Sample / Mass Production)
o Date of Occurrence
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o Acceptance / Rejection trend

o Type of rejection {in-house / MSIL (Line/SRV) / Market }
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o No. of parts returned/rejected.

o Cause of failure / Root Cause Analysis (e.g. Why-Why, Fish Bone Etc.)
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o Details of the immediate countermeasures taken.

o Details of permanent countermeasures taken
o Date of countermeasure implementation
o Effectiveness status of the problem
13.2.2 For each part, trends shall be maintained month wise for each type of rejection. On a monthly
basis analysis of all the rejections shall be carried out, to see whether there is any increasing

trend, abrupt increase, also understanding improvement status after countermeasure and
taking suitable countermeasure based on the analysis. Records of monthly analysis and the
countermeasure taken shall be maintained. Whenever asked by MSIL the same shall be
submitted. A monitoring sheet should be made to monitor and effectively handle the reoccurring
defects.
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13.3 Monitoring Delivery Performance
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Vendor delivery schedule will be communicated electronically on a daily basis by MSIL through
extranet (e-Nagare). Vendor shall monitor the delivery performance of their company against
the schedule of supply lots given by MSIL.In case of any default (Both time and quantity default)
in the schedule, Supply Chain of MSIL will raise DPCR (Delivery Problem Countermeasure
Report) / NDCR (Nagare Default Countermeasure Report) as per the devised criteria. Vendor
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should reply within a week of receiving the DPCR / NDCR with proper investigation and
countermeasure. Format-13.1, 13.2, shall be used for replying DPCR / NDCR.
13.4 Ongoing Process Capability Studies

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During mass production for items of part and/or for those characteristics as decided by
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MSIL Parts Quality department, on-going process capability study shall be carried out, which
includes control charts to be maintained for these characteristics. For these characteristics
control limits shall be calculated and be used for their control charts. In case any non-control
of the process is observed, corrective action shall be taken.
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For calculating the control limits, data should be taken for sufficient period so that all possible
variations are included (e.g. variation of man, m/c, method, measurement environment, material
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etc.), refer latest “AIAG SPC manual”.

The control limit calculated shall be verified on a regular basis and shall be changed in case
of process change.
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13.4.1 Process Capability (Cp) & Process Capability Index (Cpk) for all the & F characteristics
shall be calculated every six months. Capability Index (Cpk) for all the characteristics shall be
more than 1.33. In case it is less than 1.33 improvement in the process shall be taken up. The
reports of the capability studies, if asked by MSIL, shall be submitted to MSIL.
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13.5 Observance of Operation Standards

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13.5.1 There shall be periodic (preferably monthly) check carried out to ascertain if the operations on
the shop floor are being performed by the operators exactly as per various set standards of
Quality & Safety. This is to ensure that products are manufactured with consistent Quality &
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adequate Safety.
13.5.2 The “Observance of Operation Standard” check is quite different from a process audit in the
sense that it specially focuses on observing carefully how an operator is working on line &
whether he is adhering to all the set standards.

13.5.3 This check shall be used not only for determining the compliance level of the operation standards
but also as a tool to continually & proactively identify Kaizens & Poka Yokes on the shop floor
& amend the standards accordingly.
13.5.4 This check usually is carried out by the Supervisor but shall preferably be carried out by a
CFT involving people from non-manufacturing related areas also. This is particularly important
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as “out of the box” ideas for improvements may often be received from personnel from non-
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manufacturing related areas.
13.5.5 It should always be ensured that the operation standards cover all the requirements as per
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drawing and are formulated on basis of latest version of drawings.
13.5.6 Each vendor shall develop their own checklist for the items to be checked during this process.
The checklist may include but not be limited to the items given in the Format-13.4.
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13.6 Role of Managers & Supervisors and Job Mapping
13.6.1
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Daily roles & responsibilities of Managers & Supervisors on the shop floor shall be clearly
defined by means of a checklist.
13.6.2
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These roles & responsibilities checklist shall give consideration to the activities to be performed
& supervised on the shop floor during the time of new model trial production, initial flow control,
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change management, normal production, crisis situations like customer complaints, discovery
of Quality abnormalities, accidents etc.
13.6.3 These job responsibility check sheets shall be regularly filled up by the Supervisors & Managers.
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13.6.4 The check sheets serve the purpose of keeping a self check, that none of the important activities
on the shop floor are missed. Also they can be used for re-allocation & distribution of workload
amongst Supervisors & Managers in the case of special events like new model launch etc.,
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when additional responsibilities have to be taken up.

An example of such a checklist is shown in Format-13.3
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13.7 Periodic Coherence Check of Various Related Standards

13.7.1 It has been observed that often with the passage of time, related chain of standards (Drawings,
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FMEA, PFD, Control Plan, PCS, Work Instruction Sheets, Checksheet etc.) start losing harmony.
That is to say, whenever standards are updated as a consequence of any design change,
process change, Quality problem etc. updation of related standards are missed out. This can
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be quite a serious issue & vendors should ensure that there is a proper system in place (by
means of suitable checksheet/ formats/ IT system etc) to control updation of all linked/related
standards in the case of any event necessitating updation of standards.
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13.7.2 Additionally, vendors shall have a system of periodically checking all related standards of a
part picked randomly, by means of an audit to ensure that the chain of standards are coherent.

13.8 Tool Management

Vendor shall have the proper facilities for maintenance, repair of tools & their storage. A system
shall be implemented:
- To record the details of tool, change of tool, repair of tools and tool life.
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- To change the tools as per the specified frequency.
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13.9 Part Level Conformity of Production
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Vendor shall ensure the Conformity of Production [COP] for Safety Critical Components as per
AIS-037 Standard.
13.9.1 Type Approval or Homologation Approval (TA)
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Homologation approval (Type Approval) is done by Government agency whenever a new part
is introduced in a model. Obtaining part level homologation is the responsibility of Vendor.
13.9.2
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During vehicle homologation, along with vehicle testing reports, Part level homologation
certificates / COP certificates are submitted to test agency.
Vendor shall carry out the Conformity of Production (COP) for Safety Critical Component,
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subsequent to part homologation approval.
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13.9.3 Vendor shall define a system or set up a control mechanism to ensure continuous monitoring
of COP certificates.
13.9.4 MSIL has introduced online System for monitoring COP certificate Validity.
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Vendor shall upload the latest valid copy of COP certificate in MSIL portal before expiry of the
previous certificate.
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13.9.5 Supply of any Safety Critical Component, without a valid COP compliance certificate is a
regulatory non-compliance on part of the vendor.
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13.10 Spare Parts Quality: The vendor is required to maintain the same process controls used during
mass production for spares parts production.
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13.11 Revalidation of Parts & Raw Material : Refer chapter 14

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13.12 Lot Control & Traceability: Refer chapter 16

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13.13 Maintenance of Inspection & Production Equipment: Refer chapter 17

13.14 Quality System Audit: Refer chapter 18
13.15 Process Audit: Refer chapter 19
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13.16 Education & Training: Refer chapter 20
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13.17 Skill Development: Refer Chapter 21
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13.18 Quality Abnormality Measures: Refer Chapter 22
13.19
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Horizontal Deployment and Re-occurrence Prevention: Refer Chapter 23
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13.20 Continual Improvement: Refer Chapter 25

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13.21 Change Approval: Refer Chapter 26

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13.22 Sub Vendor (Tier-2) Control: Refer Chapter 29

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13.23 Risk Assessment: Refer Chapter 30

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QREVALIDATION
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OF PARTS &
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RAW MATERIAL
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CHAPTER 14
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$ MARUTI SUZUKI
Revalidation of Parts and Raw Material
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Establish documented procedures for Revalidation
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( Parts, Raw Material and Process)
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Prepare yearly / monthly revalidation plan
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Carry out Revalidation activity as per plan
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Make internal review mechanism to ensure
adherence to Revalidation plan
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Inform Non-conformity observed during

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revalidation to MSIL's QAPQ
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Share Revalidation report with

MSIL's QAPQ
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{Flow Chart - 14.1)

NOTE:• This flow chart is only a brief' Activity Flow' description of the chapter.
Please go through the complete chapter for detailed requirements of MSIL

REVALIDATION OF PARTS AND RAW MATERIAL
14 REVALIDATION OF PARTS AND RAW MATERIAL

14.0 Revalidation is a detailed verification of dimension, metallurgy, appearance, performance,
endurance items as mentioned in drawing or including the MIS-P items which comprise items
for regular check. All vendor shall carry out revalidation of parts and revalidation of raw material
(in case of parts affecting item).
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In case of proprietary items, revalidation of inner parts shall be carried out.
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Vendors shall carry out revalidation of sub vendor’s parts.
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Revalidation of Part and raw material shall be done as per drawing requirement.
14.1 Establishment of revalidation system
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a) Vendor shall have a documented procedure for carrying out Revalidation of Parts and raw
material.
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b) Vendor shall have a trained person/identified person for doing Revalidation activity
c) Vendor shall prepare Yearly / Monthly Revalidation Plan for all parts and raw material that
are supplied to MSIL through various channels like OE, KDO & Spares, at least once in a
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year. If required, revalidation at a higher frequency may also be carried out.
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d) Vendor shall carry out Revalidation of Process also.
e) All the parts have to be checked 100% as per drawing parameters, covering MSIL controlled
drawings as well as internal detailed drawings, covering all child parts and additional
dimensions if any.
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The sample size for checking is as per table below:

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f) Make a robust internal review mechanism to ensure adherence to Revalidation plan and
effective actions for non-conformities.
g) Information of Non-conformity observed during Revalidation should be promptly shared
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with MSIL’s QAPQ along with corrective actions.

h) The Revalidation reports have to be submitted to MSIL’s QAPQ on monthly basis in the
format given in end of the chapter.
All the revalidation reports shall be approved by vendor Quality head and Plant head before
submitting to MSIL.

REVALIDATION OF PARTS AND RAW MATERIAL
14.2 Report of revalidation shall be submitted to MSIL through extranet in online revalidation reports
portal before the 10th of every month.
• Refer Format-14.1 for Revalidation Report.
• Refer Format-14.2 for Revalidation NG-Information Report.
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14.3 All the material and performance test reports should be submitted by vendor through extranet
on revalidation portal along with dimensional reports and balloon drawing.
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CHAPTER 15
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PACKAGING Lim
REQUIREMENTS ite
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PACKAGING REQUIRMENTS
15. PACKAGING REQUIREMENTS

15.0 Packaging of parts is very important in order to preserve Quality of parts during transit from the
vendor’s premises to MSIL and during storage. This chapter gives guidelines for establishing a
system for Development of New packaging, maintaining the existing packaging and Modifications
in existing packaging based on requirement. Before deciding the packaging of part, it is advised
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that vendor’s personnel meet the MSIL’s OPC department (Operation Process Control) personnel
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for specific guidance.
Packaging of parts shall be done in reusable packaging (bins/trolleys) unless specified by MSIL.
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Parts of irregular sizes and weight shall be identified and special purpose packaging shall be
devised for them.
Definitions:
Packaging- Any Material employed for transport of Parts from its manufacturing location to
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MSIL in a defect free condition till a required stage as defined by MSIL.
Example- Trollies, Bins, Separators and any protection sheets etc.
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Parts- Semi finished or finished parts supplied by vendors which are to be used after further
processing or direct assembly in any vehicle manufactured by MSIL.
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15.1 Understanding MSIL Requirement related to Packaging:

For new packaging development or Modification of existing packaging: - MSIL guidelines to be
understood in coordination with department responsible for packaging (OPC Department).
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15.2 Preparation of samples

Sample of packaging to be prepared as per defined timelines and approval from MSIL.
15.2.1 General Guidelines for designing of packaging:
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While designing packaging for a part following factors should be considered:

i) Environment protection (Reuse, Recycle, returnable)
ii) Potential damage to parts during transportation & handling (Scratch, tear, deform, stain
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etc.) and required protection

iii) Impact of packaging on part during the required timeline till part will be in packaging
conditions
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iv) Interference (between parts, parts and container, etc.)

v) Workability ( Easiness in taking out, easiness in holding, mix-up prevention)
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vi) Vibration / Shocks to be undergone during transport- potential effects on parts and required
cushioning.
vii) Total load to be carried on packaging considering Maximum stacking requirements.
viii) Strength analysis for stacking
ix) Packaging ergonomics like part picking, trolley movement etc.

x) Kind of protection required against weather conditions such as water, heat, air, light, dust,
foreign particles, etc.), during storage and transportation.
xi) Maintainability of packaging in terms of cleanliness etc.
xii) Life expected from wear parts like wheels, paint & Velcro’s etc.
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xiii) Prevention of past problems from recurring.
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xiv) Efficiency of loading and transportation of parts.
xv) Regulations and policies with respect to containers of parts and products.
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xvi) It should be safe while handling and during transportation.
15.2.2 Colour of Packaging
a. For Bins- Blue
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b. For Trolleys- Off White
15.2.3 Packaging Identification
Unique Trolley no/ Bin no to be mentioned on Trolley’s or Bin’s.
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15.3 Submission of New Packaging Samples to MSIL & Getting approval
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In case of new packaging/ improvement in existing packaging, Packaging samples along with
filled Packaging Approval Form to be submitted to MSIL as per required timeline in coordination
with OPC department. The sample shall be checked by MSIL. If packing is not found satisfactory,
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vendor shall re-submit the sample after incorporating changes / improvements as proposed by
MSIL. Vendor is expected to carry out the necessary changes in the supply of next lot which
shall again be subjected to evaluation.
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Also Vendor shall submit the Preventive Maintenance system proposal i.e. Schedule of inspection
/ checks of packaging and applicable Check- Sheets for Trolley / Bin etc. to MSIL.
In principal all development related activities to be completed by one month before the cut-off
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date of Pilot Production start date. After approval, parts shall be supplied in approved packaging
only.
Vendor shall submit the sample lot in the approved packing with each container’s identification
tag marked “PP/MPT/Pilot Trial Material”. The MSIL’s OPC along with MSIL’s QAPQ department
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and Shop shall check the trial lot packing (Packaging chekkai) as per the approved specification,
drawings and photographs.
In case the packaging is found unsatisfactory, the same shall be intimated to the vendor with
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required changes/ improvements. Vendor is expected to carry out the necessary changes in
the supply of next lot which shall again be subjected to evaluation.
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15.4 Day wise colour coding of labels:

• Monday – White
• Tuesday – Magenta
• Wednesday – Golden Brown

• Thursday – Vivid Green

• Friday – Orange
• Saturday – Process Blue
• Sunday – Purple
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In case of parts, shall be printed on the label.
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15.5 Necessary Information to be printed on Packaging Labels
Following information shall be printed on labels which should be pasted / put on Carton / Bin /
Trolley
i. Part Name
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ii. Part Number (of MSIL)
iii. Box Number (Box number/Total no. of boxes in the supply)
iv.
v.
Model
Batch Code
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vi. Vendor Code
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vii. Vendor Name

viii. Date of Despatch Date of Supply
ix. Quantity (Pack quantity and Lot Quantity)
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x. Challan No.
xi. PSL (Plant Shop Line)
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xii. Packing Code

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15.6 Routine Supply of parts

During routine packaging of parts, following activities to be followed and implemented
1. Colour coding to be followed as per day-wise schedule described in point 15.4
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2. Tag printing and attaching as per items described in point number 15.5
3. Inspection and maintenance of packaging as per approved system from MSIL
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(Note-applicable records to be stored at vendor end as evidence of maintenance activities)

4. Rectification of any problems / abnormalities informed by MSIL on priority
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15.7 Maintenance of Existing Packaging: Routine checking and audit of Packaging at

MSIL
MSIL shall be doing random verifications / checks of packaging at parts receipt stage. Problematic
packaging shall be identified and a VPPCR (Vendor Packaging Problem countermeasure report)
shall be issued to vendor (refer Format-15.1). Vendor shall take appropriate Countermeasures
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and submit the VPPCR to MSIL as per the timeline informed by MSIL.
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Vendor shall check if any modification required in Preventive maintenance system i.e. Schedule
of inspection and check-sheet as a countermeasure for Packaging problem and shall discuss
with MSIL.
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Modified Preventive maintenance checksheet shall be approved by MSIL.
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LOT CONTROL AND

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TRACEABILITY
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CHAPTER 16
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LOT CONTROL AND TRACEABILITY
16. LOT CONTROL AND TRACEABILITY

16.0 The concept of traceability and the manner of controlling lots in mass production, in order to
meet traceability requirements, shall be explained in this chapter.
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16.1 Definition of Traceability
Traceability can be defined in the following two manners:
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(a) Forward or Down Stream Traceability:
• This means the ability to locate defective or suspected defective products in all stages of
product life cycle subsequent to the stage in which defect was discovered, with the aim to
repair or replace such products.
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(b) Backward or Upstream Traceability:
• This means the ability to find out the history of a defective product in various stages of
product life cycle previous to the stage of discovery of defect, with the aim to investigate
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the causes of occurrence and to take countermeasures to improve processes/systems.
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16.2 Traceability Requirements
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16.2.1 The following table gives the guidelines for the periods for which traceability must be established
for different types of parts
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Traceability Forward Backward

Part Type (Down Stream) (Up Stream)
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Maru - 11 Years 11 Years

Functional 5 Years 11 Years
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General - 3 Years
16.2.2 The above period of traceability shall be as per the requirement of that market, where MSIL
sells its automobiles, regulatory requirements and anticipated usage of automobiles in the field
by customers.
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16.2.3 The exact traceability requirement should be discussed with MSIL during Specification Meeting.
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16.3 Steps to meet Traceability Requirements

16.3.1 Traceability requirements cannot be met without establishing lot control system and meticulously
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following it.
16.3.2 Definition of Lot or Batch Code
A lot means the collection of parts, which have been produced with one setting of process
condition. In other words, parts produced during one setting of process belong to a different lot
from the parts produced during another setting of process.

In case of continual production, one day/one week’s production can be considered as a lot
depending upon production volume.
16.3.3 Lot Code (or Batch Code) marking on parts
In principle, Batch code marking shall be done for all Parts, Functional Parts and General
Items at a location where it is easily visible and where it does not affect function of the part.
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Vendor shall obtain approval of MSIL’s QAPQ regarding the method of marking vendor code
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and batch code, its constitution and the location (on the part). Batch code status should also
be mentioned in MIS-P as explained in chapter 9.
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16.3.4 Traceability of manufacturing history
The batch coding system and the system of keeping records at vendors end shall be such that
it should be possible to know the following from a batch code:
• Size of the lot (Quantity produced in the lot)
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• Operating conditions (Process parameters, setting conditions)
• Inspection results
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Dates on which the lot was supplied to MSIL.
Lot of child parts used.
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For such parts, on which it is not possible to mark batch code, vendor must control lots in such a
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way that it would be possible to trace manufacturing history and date of supply to MSIL through
the records.
In case of raw material of part affecting item, vendor shall record details of heat code,
date & shift of production.
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16.3.5 ‘First-In First-Out (FIFO)’ Practice

In order to be able to locate and recall defective/suspected parts from subsequent stages in
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case of discovery of critical defects, it is must to follow the First in First out (or FIFO) practice.
For implementing FIFO vendor must do the following:
(a) In case of and Functional parts, make sure that lots are not supplied in mixed up condition
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i.e. all parts delivered to MSIL against an SRV must have the same batch code. However
it is OK to supply parts belonging to one batch code against more than one SRVs as long
as parts belonging to two or more different batch codes are not mixed up in one supply.
(b) In case of shifting in-process parts from one station to the next station make sure that all
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operations to be done up to that station have been completed and that the parts are not
shifted to a wrong station.
(c) Rework parts, must be repaired immediately without delay, so that they do not lag behind
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the lot and do not get mixed up in the subsequent lots.

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16.4 Traceability Information Sheet-Parts (TIS-P)

16.4.1 The exact traceability requirement shall be discussed with MSIL during Specification Meetings.
Based on Specification meeting inputs, vendor shall prepare and capture the Traceability
information in Traceability Information Sheet- Parts (TIS-P).

16.4.2 “TIS-P” document shall prescribe minimum backend traceability which shall be available at
Vendors end. It shall specify the process parameters and child part for which traceability is
must and shall be maintained and retained by the vendor.
Vendor shall prepare the Traceability document (TIS-P) on Format “Traceability Information
Sheet – Part” (refer Format-16.2).
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16.4.3 For other processes and child parts, vendors shall maintain traceability requirement as per their
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internal guidelines after assessing severity/occurrence/ detection in their process /End of Line.
In case parts are going for complete machining process (or where traceability of parts is lost on
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the part), the traceability code and processing details are to be noted at the machining process
/ manufacturing process & to be stored by vendor.
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16.5 Identification System
Vendor shall have a proper documented system of identifying parts and also their inspection
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status (i.e. accepted, rejected, under inspection, under rework etc.) in all stages right from raw
material receipt up to finished parts despatch.
(a) Rejected/Rework parts identification
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Rejected parts and rework parts shall be identified by putting proper identification mark or
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tag. It can be achieved by putting red and yellow magic ink mark or paint respectively or
by putting rejection / rework tag respectively.
(b) Identification of inspection status
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There shall be a clearly defined method of identifying under inspection lots, accepted lots,
rejected lots and rework lots to prevent mix-up.
(c) Identification of parts
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Part name, part number, production date and supply date etc. must be marked on containers/
cartons, so as to prevent mixing up of similar materials and parts.
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16.6 Traceability during delivery of part to MSIL

16.6.1 Batch code information shall be input by vendor in BIN card during transportation to MSIL
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16.7 Traceability of Changes

16.7.1 Vendor shall keep the records in case of following changes:
(1) Design change (including Child Parts)
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(2) 4M condition change (refer Format-16.1)

• Change in Layout
• Change In Process / Operation Sequence
• Change in Manufacturing unit Location / Machines
• Induction of New Machine / Dies / cavity etc.

• Sub-vendor (Tier-2) Change / Addition.

• Deviation / Special use.
• Inner part indigenisation.
• Change / repair in Tools / Dies / Cavity etc.
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• Operator change
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(3) All Process parameters of Maru and Functional items mentioned in MIS P.
(4) Critical characteristics mentioned in Process Control Standards / Control Plan.
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16.7.2 Records shall include the following details, at least:
(a) Lot No.
(b) Reason for change
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(c) Date of change.
(d) Production shift/operator.
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(e) Any other record to trace back the history of changes.
A control register should be maintained having the above points of 16.7.1 & 16.7.2 as different
columns. Any changes listed above in 16.7.1, shall be done with prior consent (refer Chapter
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26) of MSIL.
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16.8 Common Requirements for Identification & Traceability

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16.8.1 There shall be a proper documented system in place to address identification & traceability
requirements.
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16.8.2 Identification & Traceability methods employed shall be clearly defined in the Inspection &
Process Control Standards.
16.8.3 Even if not specified by MSIL, it is recommended that Identification & Traceability methods be
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developed & informed to MSIL.

16.8.4 Absence of or inadequate identification & traceability method shall be addressed as a failure
mode in FMEA.
16.8.5 It shall be ensured that all the requirements for identification & traceability as laid out in this
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chapter are extended & applied to Tier-2 vendors (MSIL’s sub vendors) as well.
16.8.6 Vendor shall have a sound identification system for Trial Parts & Production Parts like ( Tag /
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Colour marking / Bar Code ). Identification method for trial parts should be discussed in spec.
meeting.
16.8.7 The vendor shall ensure that any requirement specified in part drawing or Inspection standard
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for traceability are satisfactorily complied with.

16.8.8 In case of rubber and polymer base products, the vendor is required to keep master batch sample
for each lot (duration may be discussed and decided with MSIL’s QAPQ) and the corresponding
records of composition and parameters.

16.8.9 While deciding the size of batch, the part criticality with respect to regulation & safety point of
view must be considered. If any regulation or / and safety issue occur in market, which may
lead to product recall, in such a case small batch size will help in identifying the exact number
of affected vehicle. Risk analysis should be used to minimize the size of batch compared to risk
of product recall.
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NOTE: Wherever records are asked to be kept in this manual, the record retention period is 11
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years for parts of model exported by MSIL & 3 years for parts of domestic models.
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Additional Information:
For additional inputs or further information on Traceability implementation and TIS-P preparation
refer “MSIL Traceability Manual”

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MAINTENANCE OF
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INSPECTION &
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PRODUCTION
EQUIPMENT
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CHAPTER 17
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MAINTENANCE OF INSPECTION AND PRODUCTION EQUIPMENT
17 MAINTENANCE OF INSPECTION AND PRODUCTION EQUIPMENT

17.0 This chapter explains the requirements of MSIL related to the preventive maintenance of
instruments and equipment used for inspection and machines, dies, jigs, moulds, fixtures, tools
etc used for production.
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17.1 Maintenance of Inspection Equipment
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A documented system shall be implemented for proper control and maintenance of inspection
equipment. System shall include the following:
17.1.1 Periodical Accuracy Inspection and Calibration
17.1.1.1 Periodical accuracy inspection is different from Calibration. Calibration is a less frequent, scientific
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method employed to ascertain & correct the accuracy of a measuring device, whereas periodical
accuracy inspection methods could be very simple like comparing the results with a standard
or a reference on a daily basis (e.g. weighing a standard weight before start of each shift with
17.1.2
a weighing balance etc.).
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Simple daily or weekly periodical accuracy checks at defined frequencies shall be carried out
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to find out if any error in the measuring device has crept in during routine handling.
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17.1.3 Apart from periodical accuracy checks, methods should be adopted to carry out daily maintenance
of measuring equipment & devices. These could be-
a) Daily cleaning & visual inspection of measuring surfaces of such equipment to determine
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wear & tear

b) Proper storage of measuring equipment & gauges at designated places on & off the line
while in use & not in use respectively to prevent handling damages.
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17.1.4 Implement a system of maintenance & periodical accuracy inspection using a check sheet and
calibration of the following types of inspection equipment.
(1) Measuring instruments:
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Such as dial gauges, micrometers, vernier callipers, bore gauges, torque wrenches etc.
(2) Gauges:

Metrological gauges such as snap gauges, plug gauges, width gauges, ring gauges, special
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gauges (e.g. Jigs made to check the profile) etc.

(3) Inspection Machines:

Such as hardness tester, UTM, spring tester etc.
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During the accuracy check/calibration actual reading before correction and after correction
(if applicable) shall be noted down in the check sheet.
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Inspection Classification of In Case used by In Case used by

Instrument Items Manufacturing Dept. Inspection Dept.
Measuring /Functional item Once/300 Nos. Once/600 Nos.
Instrument General Items Once/600 Nos. Once/1200 Nos.
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Gauge / Functional Item Once/500 Nos. Once/1000 Nos.
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General Item Once/1000 Nos. Once/2000 Nos.
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Machine / / Functional Item Once/1000 Nos. Once/1500 Nos.
Equipment General Items Once/1500 Nos. Once/3000 Nos.
17.1.5 In principle, calibration frequencies shall be decided based on the type of application & the
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frequency of usage e.g. Calibration frequency of gauges & instruments used for inspection of
& Functional items ideally should be higher than those used for General items.
Similarly, calibration frequencies for measuring devices that are used more frequently (e.g. due
17.1.6
to higher production rates) should be more.
Preparation of inspection standards
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Inspection standards should be prepared specifying the inspection items, judgement criteria,
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daily maintenance & periodic accuracy methods, inspection frequency etc. for each type of
measuring instrument and also for gauges and inspection machines.
17.1.7 Display of validity period
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Validity period for which an instrument or equipment can be used after calibration, must be
indicated by using colour codes or labels on the instrument/equipment or as per 17.1.10
17.1.8 Calibration of calibration equipment
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As a principle, calibration of the master equipment, which is used for calibrating other instruments,
should be done once/year. In principle, calibration of the masters must be traceable to the
national or international standards.
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17.1.9 Control of Inspection Instrument

All the inspection instruments including master instruments shall be identified by a unique
control no. A sticker/information shall be put on all inspection instruments regarding
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- Control no.
- Next calibration date (showing validity period, in dd/mm/yy format).
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17.1.10 Registration of Inspection Equipment

A control register shall be maintained for inspection instrument with the following details.
 Name of equipment
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 Model
 Manufacturer
 Date of procurement
 Date and place of installation
 Control Number

 Persons/groups that use it

 Frequency of Calibration
In case any inspection instrument is discontinued for use, then its control no. shall not be used
again for the new inspection instruments and also same needs to be captured in control register
by writing “OBSOLETE” .
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17.1.11 Annual Plan of Calibration
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In order to properly control the calibration work and to ensure that no inspection equipment
remains un-calibrated, it is better to make each year an annual plan of calibration.
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17.1.12 Preservation of calibration records
The retention period for calibration records shall be minimum 3 years. Calibration record should
be available and preserved for the specified period even if calibration is done by an outside
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agency.
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Maintenance of Production equipment (Dies/ Tools / Moulds / Jigs / Fixtures /
Machines) :
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17.2.1 A documented system shall be implemented for proper control and maintenance of production
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equipment. System shall include the following:
(a) Work start up checks: These are simple checks of machines which can be done by their
users daily while starting their work, with the help of a checksheet.
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(b) Periodic checks: These are carried out for the purpose of preventive maintenance of
machines, dies etc. (Refer Annexure-II, Working Procedure for Inspection of Parts).
Main functions of various subsystems and parts of machine should be checked. An annual
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Preventive Maintenance Plan for the same should also be made and periodic checks shall
be conducted according to this plan and records shall be maintained.
(c) Periodic accuracy checks: These are checks of important dimensions of machine tools,
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dies, mould etc. to know the extent of wear and also for calibration of measuring devices
fixed on machines.
(d) Break down maintenance: In case of break downs, it is important to recheck machines,
dies etc. after repair. Also, analysis of Breakdowns shall be done by the vendor.
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(e) Predictive maintenance: While carrying out maintenance, following Predictive Maintenance
method/points should be considered-
1. Tool wear
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2. M/c downtime
3. Process Capability & Control Chart Data
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4. Oil/coolant analysis
5. Bearing noise analysis
17.2.2 It is important to have proper standards and system of recording (checklist) regarding the above
checks. For 17.2.1 (a), (b), (c), a checklist shall be prepared for recording the same.
Note 1: Whenever any die / tool is repeated / duplicated or any major corrections are done in a die due
to breakdown, such events shall be reported to MSIL by vendors
Note 2: 1st piece inspection shall be done after every maintenance activity and records shall be kept
for the same. Inspection shall be carried out for 100% parameters as per drawing.
Note 3: Whenever any corrections / countermeasures are being carried out in die / tool, drawing / CAD
data of the die shall also be updated, without fail.
Note 4: For more details on working procedure for inspection of parts, after die / mould maintenance or
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die duplication, refer Annexure -II
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Note 5:- Part produced Post repair must be treated as a newly developed part and inspection of 100%
parameters shall be carried out as per approved drawing.
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17.2.3 Gauges, checking fixtures and test equipment shall be identified with the part number, certification
date etc.
17.2.4 Checking fixture, gauges and test equipment are to be made available to evaluate the first off
tool sample parts.
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17.2.5 Vendor shall ensure that necessary training is given to all operators for proper usage of checking
fixtures, gauges and test equipment.
17.2.6
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The vendor shall ensure that handling, preservation, storage and use of all checking fixtures,
gauges are done in such a way that accuracy and fitness for use are maintained.
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17.3 History Cards

Measuring equipment & Production equipment history cards shall be maintained, recording
the events of calibration & maintenance activities respectively in a chronological fashion. Such
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history cards should also contain repairs or corrections done & countermeasures taken in the
equipment from time to time.
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17.4 Action to be taken in case a measuring device is found out of calibration shall be established
through a documented system. These shall include but not be limited to-
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a) Intimation to MSIL
b) The retroactive action to be taken on the products on which judgement has been made by
usage of such equipment since last calibration.
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c) Maintenance of records of actions taken in such an event.

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17.5 Similarly, documented system shall be established to define the set of actions needed in case
a failure occurs in production equipment. These shall include but not be limited to-
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a) Intimation to MSIL (in case of major breakdowns or failures).

b) The retroactive action to be taken on the products which were under the state of being
processed in the production equipment when the failure occurred.
c) Maintenance of records of actions taken in such an event.

17.6 Vendor shall implement system to monitor the Spare parts / machines available at his end. This
is helpful in case of emergency or sudden breakdown of a machine.
17.7 Summary of Monthly Maintenance shall be prepared by vendor every month. Records of the
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same shall be kept by vendor.
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17.8 Whether the maintenance done is effective or not, the breakdown analysis shall be regularly
carried out by the vendor. Also the checksheet used for any maintenance activity shall be
continuously updated based on the feedback of breakdown.
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17.9 Record of Summary of Monthly Maintenance sheet or maintenance related documents shall be
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kept by vendor for 3 years.
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17.10 Tool Life Management
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• While using a machinery that has components designed for sharpening, cutting, slicing
or chopping, it is required that these components maintain their sharpness. If no routine
maintenance is performed on specific parts that need to sustain a particular sharpness,
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production quality can be put at a very high risk. The sharpness of a machine part is important
because it needs to be assured that cut materials are shaped correctly and accurately.
This could include checking the sharpness of tools like end bills, drill bits, lathe tools and
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precision cutters.
• Vendor shall define a defined frequency for re-sharpening and replacement of consumable
tools.
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• Monitoring of re-sharpening and replacement of tools as per the decided frequency should
be ensured by the sub-vendor.
• Vendor shall have the proper facilities for maintenance, repair of tools & their storage. A
documented system shall be implemented:
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- To record the details of tool, change of tool, repair of tools and tool life.
- To change the tools as per the specified frequency.
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17.11 Machine Lubrication

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• For machine tools that are frequently used, it’s extremely important to inspect the machine’s
lubrication levels on a weekly basis. By ensuring that the moving parts are properly
lubricated, the motor can remain protected over an extended period of time.
• This includes greasing of moving parts, oiling or internal moving components and visual
inspection of all part movement in action. Without the right amount of oil, grease or other
lubricant, any machine tool could face unnecessary wear and tear.

• Vendor shall ensure to inspect the Lubrication Level of machines on a daily basis. While
checking, areas of leakage must be observed and repaired on urgent basis. Proper records
shall be maintained.
• Any loose wiring, temporary connections of machines/Equipment must be immediately
repaired.
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Flow chart for Breakdown Maintenance
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For additional inputs on Maintenance refer following manuals of MSIL:
a) “Sheet Metal Die Maintenance Manual”
b) “Mould Maintenance Guidance Manual”
c) “Weld Jig & Equipment Maintenance Guidelines”

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AUDIT
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CHAPTER 18
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QUALITY SYSTEM
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QUALITY SYSTEM AUDIT
18 QUALITY SYSTEM AUDIT

18.0 This chapter explains details regarding the audit of Quality system, which is to be conducted by
MSIL on its vendors as well as audit which can be conducted by the vendor voluntarily within its
company. The objective of both the audits is to maintain and improve Quality of product through
effective implementation and improvement of Quality system.
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18.1 Audit conducted by MSIL on its vendors
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18.1.1 Types of audits
A. Periodic Audit
- Audit conducted by QA on the basis of an annual plan.
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B. Unscheduled Audit:
- Audit Conducted for New Vendors.

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Audit conducted for development of new parts which are critical and have new type of
Audit conducted when the Department Manager of MSIL’s QAPQ feel that an audit is
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necessary in such cases as:
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Assurance departments of MSIL feel that an audit is necessary in cases of:

(a) Occurrence of market claims or serious abnormalities.
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(b) Major change in manufacturing process.

(c) Production of FPP lot of critical parts.
18.1.2 Submission of improvement action plan
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After an audit by MSIL, vendor will be asked to submit an improvement action plan giving specific
dates for implementation of improvement actions against each point mentioned during audit.
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Effectiveness of the countermeasures submitted by the vendor shall be verified by MSIL. If the
countermeasures are effective, MSIL shall close the audit report. In case they are ineffective,
vendor shall be asked to resubmit fresh countermeasures.
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18.2 Audit conducted by vendor

18.2.1 Types
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(1) Top Management Audit: It is an audit conducted by the President or Managing Director and/
or other Directors of the vendor’s company. It could be once or twice in a year.
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(2) Quality Assurance Chief’s Audit: It is an audit conducted by the Principal QA Incharge of
the vendor’s company. It could be quarterly or half yearly.
(3) Internal Audit: It is an audit conducted by the persons independent of the responsibilities
in which department/area, he is carrying out the audit e.g. QA carrying out the audit of
marketing department etc. These internal audits shall be carried out by the qualified/
trained auditors only on basis of QMS / MSIL VQM requirements / ISO 9001:2015 /
IATF 16949:2016 or any other national / international standard the vendor company is
certified with. These audits should be conducted bi-annually.

(4) Vendor Audit: It is an audit conducted by the vendor on its vendors (Tier-2 of MSIL).
18.2.2 Standardization of audits:
Audit should be conducted periodically by standardizing -
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• the number of processes/departments
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• audit frequency (monthly/quarterly/bi-annually etc.)
• audit duration (3-4 hours)
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• audit method (through some standardized audit checklist)
• audit reporting (Audit Report Format to be standardized).
18.2.3 Content of audit
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An audit shall have check of the following aspects:
- Compliance to the requirements of this manual.
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- Checking of Compliance of any additional requirement of MSIL as agreed by the vendor.
- Compliance of Environmental & Safety Aspects : SOC requirement (Refer Annexure-VI,
Guidelines for Environment Regulations)
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- Effective implementation of Defect Prevention measures.
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Following are typical broad areas to be covered during the audit

(a) Documented Quality system.
(b) Drawing Control.
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(c) Incoming Inspection of Parts/Raw Material.

(d) Process Control.
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(e) In process & Final Inspection.

(f) Inspection Gauges & Instrument Control.
(g) Preventive / Predictive / Breakdown Maintenance of Production Equipment/ jigs / fixtures
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/ die / mould.
(h) Calibration of Gauges and Inspection Instruments and their Accuracy.
(i) Quality Abnormality Dealing.
(j) Rejects/Rework Control.
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(k) Traceability/Recording of Changes.

(I) Training of Employees
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(m) Preventive maintenance of Trolley / Bin.

(n) Risk Management
Note: Auditor shall check the compliance of requirements mentioned in the drawings and op-
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eration Standards also.

18.2.4 Preparation for the audit
It is useful to prepare the checklist to carry out the audit. Checklist should include all the areas
to be audited. Areas given in 18.2.3 can be referred to prepare checklist.
Auditor competency should be identified for conducting audit.

18.2.5 Annual Audit Plan

An annual audit plan should be prepared for each type of audit mentioned in 18.2.1 in the
beginning of every year.
18.2.6 Audit records
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“Audit results and improvement action plans must be recorded systematically and follow ups
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must be done to see that problems pointed out during audit are improved upon. Records of in
house audit shall be a part of management review (refer Chapter 2). These shall be presented
to MSIL on request.
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18.2.7 Countermeasure
Against the audit result findings, the vendor shall give the “Countermeasures” and shall keep
following up with the concerned department in its company, till the Countermeasure is / are per-
manently implemented. Effectiveness of the countermeasures implemented should be verified
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before the closure of the report. Vendor shall also keep the records for the same.
Note: MSIL Vendor Quality System Audit Checksheet is provided for reference (Checksheet-18.1)
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CHAPTER 19
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PROCESS AUDIT Lim
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PROCESS AUDIT
19 PROCESS AUDIT
19.0 This chapter explains in detail regarding the process audit, which is conducted by MSIL on the
vendor and which can be conducted by the vendor within its own company. These audits are
undertaken as a preventive measure to get the confidence that the processes being followed
by the vendor shall continue to produce defect free parts.
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These are the detailed audits of the vendor’s processes. These audits are conducted as per the
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documented Process Control Standards (PCS)/MIS-P/inspection & other standards referenced
in the drawing/MIS-P/PCS. The purpose of the process audit is:
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(a) To identify areas where improvements are required for correcting specific Quality problem
faced.
(b) To highlight areas where improvements can be made in the process for making improve-
ments in the Quality and productivity of parts produced.
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19.1
19.1.1
Audit conducted by MSIL on the vendor
Type of audits
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A. Periodic Audit
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- Audit conducted by MSIL on the basis of an annual plan
B. Unscheduled audit
Audit is conducted when MSIL’s QA Department or Quality Assurance feel that an audit is
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necessary in cases such as:

(a) Serious Quality abnormality.
(b) Sudden increase of warranty claims / line rejection / SRV rejection.
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(c) Major changes in manufacturing process.

(d) After submission of sample parts.
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(e) Production of FPP lot.

(f) If required by QA.
19.1.2 Submission of improvement action plan
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After an audit by MSIL, vendor will be asked to submit an improvement action plan giving specific
dates for implementation of improvement actions against each point mentioned during audit. If
the improvement actions suggested are not effective, vendor shall be asked to resubmit action
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plans.
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19.2 Audit conducted by the vendor

Types of audit
(a) Vendor Audit: It is an audit conducted by the vendor on its sub-vendors.
(b) Quality Assurance Chief’s audit: It is conducted by the Principal QA incharge of the vendor’s
company itself.

PROCESS AUDIT
19.3 Preparation for Process Audit

1. Establish the purpose of the audit clearly i.e. preventive measure or to solve a specific
Quality problem.
2. All approved and latest relevant standards / documents should be collected.
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3. Investigate the previous Quality performance of the part and collect the relevant data (rejec-
tion %, problems from the market or from the customer, line problems previously reported).
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4. Collect the previous audit & countermeasure report.
5. Prepare a checklist of the critical areas that have to be checked to ensure that all the critical
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areas are covered.
Checklist may include the following areas:
1. Documented work instructions/process control parameters
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2. Check for job/machine setup before regular production
3. Machine jigs/fixture control
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5.
Die/mould/tool control
Process Control
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6. Incoming/In process/Final Inspection
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7. Storage/Handling
8. Traceability (including backup and TIS-P)
9. Identification
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10. Calibration of inspection/measuring instruments

11. Corrective & preventive actions
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12. Control & monitoring of special processes

13. Plant layout for smooth material flow & 5S
14. Statistical Process control
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15. Process Effectiveness

16. Inventory Control
17. Poka Yoke Working (Prevent error / Defect generation)
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18. Part Mix-Up Prevention

19. Rejection/Rework/Breakdown Control
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20. 4 M change control

21. Defining of time frame for closing actions of Process audit points
22. Skill level of operators involved in for performing the task.
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23. Effectiveness of Quality checks.

PROCESS AUDIT
19.4 Performing the Audit

Following are the guidelines for conducting the audit:
- Conduct audit step by step
- Go into details and see yourself
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- Don’t assume things & look for objective evidence for both compliance & non-compliance
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- Follow checklist
Process/Product Audits – While conducting the process/product audits, it is recommended to
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verify all the parameters defined in the control plan and record in the audit checksheet. Process
audits should be planned to cover all the working shifts.
When conducting Product audit, it needs to be ensured that all parameters mentioned in the
MIS-P are verified and updated in the audit checksheet.
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19.5 Reporting & Countermeasure
For audits conducted by the vendors on its sub-vendors, the findings should be reported by the
vendor to its sub-vendor and the countermeasures should be received from the sub vendor.
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Information of Non-conformity observed during audit should be promptly shared with MSIL’s
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QAPQ along with corrective actions.
Countermeasures should be followed up till they get implemented. Effectiveness of the counter-
measures implemented should be verified before the closure of the report. Records of the audit
done within the vendor’s company shall be a part of the management review (refer Chapter 2).
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CHAPTER 20
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TRAINING
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EDUCATION AND
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EDUCATION AND TRAINING
20 EDUCATION AND TRAINING

20.0 This chapter explains the requirement of MSIL related to the implementation of Education &
Training on Quality. The purpose of such education is maintenance and improvement of product
Quality by promoting Quality Assurance activities and concepts.
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20.1 Types of Education programmes on Quality
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20.1.1 Fundamentally, Education and Training can be differentiated from one another according to the
following definitions.
(a) Education means giving inputs to employees at conceptual level to improve their
understanding and thinking.
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(b) Training means to provide inputs to employees in order to improve their skills, which are
required to perform their respective jobs and thus to meet the customer requirements.
20.1.2 Keeping the above in mind, the vendor should devise and implement the following types of
education and training programmes on Quality:
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- Orientation programmes for new employees and employees who are transferred from one
function to another.
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- Training and education programmes for Managers.

- Training and education for Supervisors.
- Training and education programmes for Operators.
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Further, the vendor should devise special training and education programmes for the following:
• Personnel designated as operators.
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• Personnel deployed at critical operations, which on later stages may lead to serious issues.
• Personnel designated as inspectors.
• Person carrying out Quality Control and Quality Assurance activities.
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• 4M change management.

20.2 Vendor shall employ suitable means & techniques to capture training needs of individuals at all
levels.
20.3 Prior to SOP, training shall be provided to each operator based upon actual operation instructions.
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20.4 A Training plan for all the Manpower across all levels i.e workers (including contract manpower),
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engineers, supervisors and managers, shall be made by the vendor. In principle MSIL may audit
this plan from time to time.
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20.5 On Job trainings (OJT) should be provided to people who are engaged in Production & Quality
activities.
20.5.1
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MSIL recommends vendors to implement the concept of DOJO center.
DOJO is a place for providing offline training to the associates before sending them to actually
work on the shop floor.
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Training Facility should comprise of –
• Classroom Training (Theoretical Training)
• Offline Center (Practical Training)
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20.5.2 Refer “Education & Training Guidance Manual” available on MSIL extranet, for guidance on
setting up the Dojo center.
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20.6 Contents of Education and Training programmes:

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Following are some examples of the topics which may be included in the education and training
programmes.
• Product safety (i.e. Maru-A items)
• Relevant operation & inspection standards
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• Legal regulations related to products

• Product knowledge (including part’s function in the vehicle and its significance). Dealing
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with Quality abnormalities and defective parts

• Construction, functioning and handling of inspection equipment
• Safety in work place and safe practices
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• Work practice training

• 5S (Orderliness, Neatness, Cleaning, discipline, good manners).
• 3G (Go to the actual place, See the actual thing and Take appropriate action)
• Various tools & technique for Quality Improvement & Cost reduction (SPC / MSA / FMEA
/ 7QC Tools / Value Engineering / Benchmarking etc)

• Customer/Market feedback
• Quality system implemented in the vendor’s organisation
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20.7 Some guidelines for effective implementation of education and training programme:
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(a) Establish a section for promotion of education on Quality in the company
(b) Make annual plans for education programmes and implement them as per the plan. Track
Plan Vs actual attendees and make recovery plan for absentees
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(c) Standardize training contents and training methods.
(d) Maintain records of training.
(e) After the training evaluation to be carried out for checking the effectiveness of the training.
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Evaluation passing criteria to be define.
20.8
Maru
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Vendor shall keep a list of trained operators for Maru stations; in case, any operator of
station is not available then replacement operator can be selected from the list. One
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for Many and many for one.
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20.9 The contents of this manual must be used to devise Education & Training programmes by the
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vendors as it is imperative that the requirements of MSIL as laid out in this manual is understood
by one and all in the vendor’s organisation.
Vendors are urged to contact MSIL, should they need any assistance. MSIL shall be glad to
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help the vendor in its endeavour to the extent possible.

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For inputs on setting up the Dojo Center refer:
MSIL “Education & Training Guidance Manual”

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SKILL
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CHAPTER 21
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DEVELOPMENT ite
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SKILL DEVELOPMENT
21 SKILL DEVELOPMENT
21.0 Operators & workmen are the most important asset of any organisation. It is very essential to
nurture, develop & hone the skills of the workmen.
A skill map shows ‘who can perform which job & at which level’. It serves as an important tool
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to allocate & distribute work in case of absenteeism. It also helps in identifying & managing the
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development & training programmes of the operators to enhance their ability.
In this chapter, the methods to be adopted for identifying, evaluating & developing the skill sets
of the operators are explained.
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21.1 Skill Identification
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21.1.1 The activities in the organisation which require special skills of operators should be clearly
identified.
In principle, skill sets may broadly fall in one of the following categories:-
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Skill which help in delivering a job (within the targeted cycle time, if any) that meets the
specifications & requirements of the customer e.g. machining, fitting, painting, welding,
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assembling, etc. This also includes maintenance, testing, inspection, calibration, auditing
and repair & rework activities.
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o Skill which is required to ensure a safe working environment involving safety of the personnel,
products & equipments in the job area. e.g. Crane operation, Forklift operation, handling
of hazardous chemicals & wastes etc. Minimum skill level requirement for each operation
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to be defined.
o Minimum skill level requirement for each operation to should be defined
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21.1.2 It is advisable to adopt a CFT approach involving personnel from production, maintenance,
product & process engineering to determine the current skill level and identify the important
operator skill requirements in the processes of the organisation.
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21.1.3 Whenever a new product or part is under development with MSIL, a review of the skill
requirements should be carried out to identify if any extra skill needs to be developed amongst
its operators.
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21.2 Skill Level Evaluation & Mapping

21.2.1
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Once the skill sets are identified, they should be subdivided into various levels based on the
skill status an operator has attained with respect to that particular skill. One such example of
classification has been explained in Format-21.1
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However, other methods may also be defined. It is important is to have a objective assessment
criteria, to decide the level of an operator in a particular skill.
21.2.2 An objective evaluation & assessment system should be devised to decide the current level of
Skill of an operator. The assessment should be done by Supervisor of the operator.
The skill Evaluation technique may include judgement by the Supervisor based on:-

SKILL DEVELOPMENT
a) Observation of the skill activity performed by the operator / work output evaluation.
Awareness of abnormal situations & 4M change management to be checked.
b) Written tests and / or interviews
c) Results of performance indicators like rejection & rework rate, customer feedback &
response, no. of accidents & near miss etc.
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21.2.3 There shall be a periodic skill evaluation system in the organisation in which operators &
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workmen shall be evaluated at planned intervals.
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21.3 Skill Development & Upgradation
21.3.1 Vendor shall implement the concept of one operator for many stations and many operators for
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one station, so that no untrained operator works on station under any condition.
21.3.2 It is not only essential to identify and map the skill levels of the operators but also to upgrade
them to higher levels & develop them for newer skills.
21.3.3
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The need for developing an operator for a new skill should be assessed by his Supervisor at
the time of periodic evaluations.
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21.3.4 Once such a requirement is felt, the supervisor should make a time bound action plan to get
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the operator developed for the new skill.
21.3.5 Whether or not a need is felt for developing an operator for a new skill, the Supervisor must have
a time bound action plan to raise or upgrade the level of all the operators in the current skills they
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possess. That is to say, that if an operator is at level 2 for a particular skill, (refer Format-21.1)
the supervisor must have a plan to upgrade him to level 3 & then 4.
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Q QUALITY
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ABNORMALITY
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MEASURES
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CHAPTER 22
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$ MARUTI SUZUKI
QUALITY ABNORMALITY MEASURES
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Quality Abnormality Measures
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Quality Abnormality observed Quality abnormality observed
in MSIL or in Market at Vendor's end
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Issue of QPCR by MSIL
Inform MSIL immediately in
Receipt of QPCR case a defective lot has
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already been dispatched
Take action on parts in stock
and in process parts
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Till the time permanent counter
Record the details of abnormality,
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measures are in place, send ev
ery shipment to MSIL with some circumstance s, investigation results
identification (as agreed with MSIL) and countermeasures and submit
to MSIL (QAPQ)
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Investigate the root cause of occurrence
Decide on countermeasures and In case of heat treated parts,

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implement for prevention of recurrence if retreatment of lot is

undertaken as a counter
Upgrade necessary control sys measure, submit samples to
tems & review / revise standards MSIL with records of heat
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treatment along with special

Carry out Horizontal use request in the form of
deployment of countermeasures CARV format for approval.
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Check effectiveness of countermeasures
Sign & approval QPCR reply

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Submission of QPCR to MSIL
Receipt and confirmation to

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vendor by MSIL
(Flow Chart - 22.1)

NOTE:-This flow chart is only a brief 'Activity Flow' description of the chapter.

22 QUALITY ABNORMALITY MEASURES

22.0 This chapter explains the manner of handling cases of Quality abnormalities in parts, which are
detected either in the market, within MSIL or within the vendor’s organisation.
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22.1 Quality Abnormality discovered in MSIL
22.1.1 Quality abnormalities discovered are classified in 3 categories designated as Maru , Functional
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and General. Their definitions are given below:
: Such problems which most likely will cause accidents or fire resulting in injury to
the vehicle’s occupants and/or other road users.
Functional : Such problem which may seriously affect sales or which seriously affect function
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of vehicles.
General : Such problems which may cause warranty claims and complaints from customers
or which shall hamper productivity in MSIL’s production process and such problems
22.1.2
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for which improvements are required.
Depending upon the category of a Quality problem, “Quality Problem Countermeasure Report”
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(QPCR), (refer Format-22.1) shall be raised by MSIL on the vendor.
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QPCR shall be raised on Vendor for Quality problem observed during new model development
or during mass production as per the MSIL internal rule.
22.1.3 When a QPCR is received, the following actions must be taken as given in the flow chart and
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explained below:
(1) Action on parts in stock and in-process parts:
Immediately separate and quarantine those lots where there is a doubt that defective parts
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are mixed up and segregate bad parts from good ones or rework them. Follow the instructions
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of MSIL’s QAPQ, in case there is a defective lot already supplied to MSIL, which might be
in MSIL’s component store, spare parts store and / or which might have been already fitted
in the assembled vehicles/engines.
Also immediate information should be provided to the production lines by the vendor
within its organisation to take care that no defective parts are further manufactured, while
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countermeasures are being taken against defective parts at various places. Also, the
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suspected material available at vendor’s end/local storage areas should be quarantined.
(2) Investigations for root causes of occurrence
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Find out the causes of defect occurrence by investigating the following:

 Investigation of actual defective pieces

 Investigation on the line

 Investigation of operation and inspection standards (for outflow cases)
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 Investigation of 4M (MAN, MACHINE, MATERIAL, METHOD)

 Records of defective parts and defective lot

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 Estimate from the records the number of defective parts, which might have reached
market (refer chapter 16 for traceability requirements)
 Defect Simulation / Re-appearance check
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 5 Why Analysis / Application of QC tools / DOE etc.
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(3) Permanent countermeasures for prevention of recurrence of defect:

Based on the results of investigation, countermeasures are to be implemented by the
vendor, so that the same type of defects do not occur and do not leave their organisation
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undetected. In case countermeasure requires any changes in process/part/material it shall

be done in consultation with QA/Supply chain deptt. of MSIL.
(4) Checking the effectiveness of countermeasure
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The effectiveness of countermeasure should be monitored for 3 consecutive weeks as

required by MSIL and also internal system of Vendor.
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This monitoring should be done by doing defect reappearance tests and/or normal inspection/
testing, regular audits.
If a problem is not observed, then countermeasure may be considered as OK. But, if problem
comes again during the monitoring period then countermeasure is not effective and further
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analysis should be done to find out root cause and implementing effective countermeasure.
If the problem was reported by MSIL then information about non-effectiveness of
countermeasure should be given to MSIL.
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(5) Submission of Q.P.C.R.

Q.P.C.R. is to be submitted after entering the necessary details with the signature of the
principal QA Incharge of the vendor to MSIL by the recommended reply date as mentioned
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in QPCR. In case it is not possible to submit the QPCR by the recommended reply date
due to countermeasure taking longer time etc., an interim reply (countermeasure planned)
must be sent to MSIL by the expected reply date.
In case the information filled in QPCR is incomplete or the countermeasure taken is not
effective, then QPCR shall be reissued by MSIL.

22.2 Quality abnormality discovered within the vendor’s premises

22.2.1 If the vendor suspects non-conforming parts have been shipped to MSIL or finds the non-
conforming parts within their finished goods inventory, the vendor is required to undertake the
following:
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1) Immediate communication to MSIL’s QAPQ.
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2) Vendor must give the following information:
a) Part description and part number
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b) Description of non-conformance
c) Suspected parts identification method
d) Suspected root cause
e) Details of temp. Countermeasure
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f) Temp. Countermeasure part identification method
22.2.2 The following shall be implemented by the vendors to deal with Quality abnormality observed
within their plant:
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(1) A Standardised and documented procedure shall be put in place for dealing with Quality
abnormality.
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(2) Check if defect qualify the requirement for putting a Quality hold for “Stopping dispatch of
Parts” (Refer Annexure-III, Dispatch Suspension System).
(3) Rework instructions shall be made and located near the work area. Any part reworked shall
be inspected thoroughly as per inspection standard. Records of rework shall be maintained.
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(refer Chapter 24)

Also, required countermeasures should be taken to rectify the abnormality and till the
implementation of permanent corrective action, each and every shipment (which is being
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shipped to MSIL during temporary corrective action) should be identified by providing tags/
special marks etc. (as agreed with MSIL) and checked. Generally the tag should contain
information like; Batch Code, Date & brief of Non-conformance (abnormality).
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22.2.3 In case a Quality abnormality is discovered in the manufacturing line or inspection stations at
the vendor’s premises, action should be taken immediately as explained above in 22.1.3. The
following must be implemented:
(1) In case a suspected lot has already been supplied to MSIL, MSIL’s Supply Chain & QAPQ
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shall be informed immediately.

(2) As far as possible, the details of abnormality, circumstances of its occurrence, investigation
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results and countermeasures should be recorded in a one sheet format and the
effectiveness of countermeasure shall be recorded in one sheet format and effectiveness
of countermeasure shall be checked and submitted to MSIL’s QAPQ.
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(3) In case of heat treatment parts, if re-heat treatment of a lot (or lots) has to be undertaken
as a countermeasure, samples must be submitted with records of heat treatment to MSIL’s
QAPQ and special use approval for supply of such parts should be obtained by submitting
a “Change Approval Request from Vendors” (refer Chapter 26).
Note: Vendor shall ensure the implementation of same system for handling abnormality
found at Tier-2 vendor or during receipt inspection.

22.3 Quality abnormalities discovered in market (field):

In case, critical or recurrent Quality problems are reported from market by MSIL’s dealers,
Market Quality department of MSIL shall attribute the Field Problem Countermeasure Report
(FPCR) to MSIL’s QAPQ.
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MSIL’s QAPQ then raise QPCR on the vendor based on the FPCR. For this, actions must be
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taken as per 22.1.3.
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Q HORIZONTAL
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DEPLOYMENT AND
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RE-OCCURRENCE
PREVENTION
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CHAPTER 23
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$ MARUTI SUZUKI
Horizontal Deployment and

Re-occurrence Prevention
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Carry out Red Bin Analysis
)
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1
Identify the countermeasure/learning for

Quality problem.
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Identify similar processes (same plant or
plants at other locations)
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1,
Horizontally implement the same

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countermeasures on all identified processes

for Re-occurrence prevention
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Maintain records
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(Flow Chart - 23.1)

NOTE:-This flow chart is only a brief' Activity Flow' description of the chapter.

Horizontal Deployment and Re-occurence Prevention
23. Horizontal Deployment and Re-occurence Prevention of

Defect
23.0 Many times it has been observed that countermeasures taken for a particular problem are not
horizontally deployed, which lead to occurrence of same defect in other similar process.
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The objective of this chapter is to define guidelines for horizontal deployment of countermeasure
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of Quality issues reported in MSIL or Quality issues coming with in Tier-1 plant across all line/
model and hence preventing re-occurrence of defects.
Once the effectiveness of countermeasure is verified, supplier should horizontally deploy
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countermeasure in their processes, line as well as in other plants.
Improvement actions identified for one process shall be implemented in all similar processes
or operations after performing a detailed study.
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This act of studying all the similar processes for implementing learnings earned from one
process may be defined as Horizontal Deployment.
23.1 Horizontal Deployment of Corrective Action

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23.1.1 Corrective actions may be initiated on basis of any defect or problem identified in process of
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manufacturing a product or Quality issue faced by MSIL or its customer/s.
23.1.2 When a corrective action is implemented, it should be ensured that a detailed study has been
conducted to identify other similar processes (in-house or plants at other locations) where same
problem may occur.
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23.1.3 Corrective actions should be implemented in all such processes (in-house or plants at other
locations), which are similar in nature.
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23.1.4 Record should be maintained for horizontal deployment of corrective actions.

Horizontal deployment of corrective actions helps in reducing the chances of re-occurrence of
same defect by standardizing all the similar processes.
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23.2 Re-occurrence Prevention

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23.2.1 To stop the re-occurrence of same defect in same / other parts, the following are to be kept in
the mind:
• Use why-why methodology to identify technical root cause and managerial root cause.
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• The countermeasures should not simply end with verbal instructions, guidance, education
to workers etc. but should result in development or up-gradation of control system and
review/revision of standards and procedures.
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• Carefully consider if it is possible to install fool proofing devices in the process to prevent
mistakes.
• Investigate if there is a danger of occurrence of a similar defect in similar parts or similar
processes and based on the investigation, horizontally deploy the countermeasures.
Note In case countermeasure requires any changes in process/part/material it shall be done in
consultation with MSIL’s QAPQ or Supply Chain.

Horizontal Deployment and Re-occurence Prevention
23.2.2 Red Bin Analysis

Red bin analysis is the process of segregating and reviewing the defects occurring on production
lines on a daily basis to understand their nature to further investigate root cause and take
countermeasure as early as possible. This is very important to prevent the recurrence of defects
and control problems at their initial stage.
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CHAPTER 24
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REWORK CONTROL
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REWORK CONTROL
24 REWORK CONTROL
24.0 Reworked parts are responsible for the majority of Quality defects that are passed to MSIL or
ultimately the end customer.
To prevent these defects, vendor shall have a process for control, verification and proper
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identification of reworked product.
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In principle, rework shall not be allowed in Maru processes of Maru parts. In case rework
is required, it shall be carried out in completely controlled conditions. Inspection of reworked
parts shall be done on the normal production line. Re-worked parts shall be clearly identified.
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Complete record of part-wise rework details and dispatch details shall be kept by vendor for
ensuring traceability.
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24.1 Rework Requirements
24.1.1 Rework parts, must be repaired immediately without delay, so that they do not lag behind the
24.1.2
lot and do not mixed up in subsequent lots.
Reworked parts identification:
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Reworked parts shall be identified properly by putting identification mark or tag e.g.
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R mark(R- Rework). The important requirement of rework is identification of reworked parts so
that it should not get mixed up in the subsequent Lot.
24.1.3 Vendor should have proper rework process defined at his end that must include:
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1. Method of recording: which product received what rework?

2. A system for determining whether rework will occur online or offline
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3. A criteria for selecting rework operators

4. Proper Skill plan of rework operator
5. Written procedure for how to do rework
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6. Approval of written procedure of Repair/ Rework by Parts Quality incharge.

7. A process for re-verification of product after rework is completed (using line-standard
inspection equipment whenever possible)
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8. An approval procedure for the completeness of rework

9. Method for identifying reworked product after it has been dispatched from his (vendors)
end to MSIL.
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24.1.4 Offline rework must be conducted on an area separate from the production line. Components/
Parts that are replaced during rework must not be returned to the production flow. /Safety
Characteristics may not be reworked.
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24.2 Approval
24.2.1 Special rework processes may require MSIL approval prior to the start of rework. MSIL has the
right to reject any rework item or process. Ongoing or high volume rework activities that change
the manufacturing process require approval. In the event of ongoing or high volume rework,

REWORK CONTROL
MSIL will need to review and approve:

1. Rework procedure
2. Boundary samples
3. Rework identification method
4. Re-inspection method
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24.2.2 After rework, reworked product must be reviewed and approved by a person other than the one
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who has performed the rework. Unless absolutely impossible, this person should be a supervisor
or manager.
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24.2.3 Reworked product must be re-verified before it is returned to the production flow or inventory.
All characteristics must be reconfirmed, not only those related to the rework. Unless absolutely
impossible, the same inspection equipment used for inspection of standard product must
be used for the inspection of reworked product. Records for rework inspection activity shall
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be maintained, mentioning the name of person who performed rework and person who has
performed inspection of rework and approved.
24.2.4 Rework of Maru components should be avoided till possible, however if it is not possible
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then special approval has to be taken from MSIL for rework of Maru components/items.
Inspection of these reworked components should be done on basis of special inspection
checksheet to ensure the desired Quality level and record for same shall be maintained.
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CHAPTER 25
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CONTINUAL Lim
IMPROVEMENT ite
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CONTINUAL IMPROVEMENT
25 CONTINUAL IMPROVEMENT
25.0 This chapter explains the method/tools that can be adopted for continual improvement in all
areas of the organisation.
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25.1 Kaizen
25.1.1 To provide value for money to the customer to remain competitive and to maintain growth of the
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organisation, path of Kaizen or continual improvement shall be followed. Kaizen signifies small
improvements as a result of continual efforts involving employees at all levels and at all areas.
25.1.2 For implementing Kaizen, employees in the organisation should be motivated to give suggestions
(e.g. by giving token reward, recognition etc.) and an environment should be created which gives
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confidence to the employees that their suggestions will be considered and will be implemented
(if appropriate).
25.1.3 Resources should be provided to implement the suggestions.
25.1.4
- Make it smaller
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To focus the thinking process, the concept of Kaizen should be promoted using the following:
- Make it fewer
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- Make it lesser
- Make it lighter
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- Make it beautiful
25.1.5 All the improvements done may be quantified in terms of
- Man hour saved
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- Cost saved
- Space saved
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- Energy saved
- Material saved
- Productivity improvement
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- Quality improved
This will help the organisation in analysing the Quality and effectiveness of suggestions.
Through this, it is possible to check the benefits the organisation is getting from this activity and
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helps in setting the targets.

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25.2 Quality / Productivity / Cost / Customer Satisfaction Performance Measurement

and Improvement
25.2.1 Sincere efforts should be made to improve the Quality and productivity levels continually.
Performance indicators shall be identified to improve Quality & productivity and the progress
in these areas shall be monitored by the management at regular interval (e.g. management
review). Following are some of the typical examples of the performance indicators.
25.2.2 Improving Productivity

Performance indicators
- Machine downtime
- Machine set-up, tool die change and machine change over time
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- Cycle time for each product
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Some of suggested techniques used for improving the productivity
- M/c breakdown analysis
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- Time & motion study of each process
- MTTR (Mean Time to Repair)
- MTBF (Mean Time between Failures)
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- Yield %age
- OEE (Overall Equipment Efficiency)
25.2.3 Improving the Quality of the product
Performance Indicators
-
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Capability indices (Cp & Cpk) / % of processes having Cpk more than 1.33
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- Measurement system accuracy (% R&R)
- % of rework & rejection in-house
- SRV Rejection/line rejection at MSIL end
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- % Warranty
Some of techniques used for Quality Improvements are
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- Statistical process control

- FMEA
- Cause & effect diagram
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- Histogram
- Measurement system analysis
- Pareto analysis
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- Design of experiments
- Fault tree analysis
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- PPM Levels
- Lean manufacturing
- 6 Sigma process
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25.2.4 Cost reduction

Some of the performance indicators are:
- Value added per employee.
- Cost of Quality
- Product produced per employee

- Reduction in material movement inside the company

- Man hour saved
- Indigenisation level (inner part)
- Saving of floor space
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- Cost of carrying inventory
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Some of techniques used for cost reduction are:
- Benchmarking
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- Standardisation
- Measure of cost of Quality-value analysis
- Energy Consumption (Kwh / Ton)
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25.2.5 Any changes done in the process, material, method, design, sub-vendor, location to improve
the Quality and Productivity shall be done in consultation with MSIL and with the prior approval
of MSIL (refer Chapter 26).
25.2.6 Improvement in Customer Satisfaction
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25.2.6.1 Vendor shall work to continually improve the customer satisfaction. Customers should include
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all the different departments of MSIL, with whom dealings are done (Supply Chain /QAPQ/OPC/
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Engg. etc).
25.2.6.2 Performance Indicators
The following can be considered and used as performance indicators to monitor customer
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satisfaction:
- Quality system audit rating/process audit rating/vendor rating
- No. of complaints (QPCR, VPPCR cards, verbal complains, other feedback)
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- No. of warranty claims / %age of warranty claim / warranty cost

- Delivery Performance (% on time delivery, delivery, delivery frequency)
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- Cost control
- Quick response to MSIL needs
- % of components supplied in reusable packing
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- Rejection %, PPM level of MSIL

25.2.6.3 The performance of the company on the customer satisfaction shall be included as a part of the
management review (refer Chapter 2).
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25.3 5S
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5S are five pillars supporting a system for improvement in the company. The five pillars are
defined as:
- Sort (Seiri)
- Set in order (Seiton)
- Shine (Seiso)

- Standardize (Seiketsu)
- Sustain (Shitsuke)
As these words begin with “S”, they are referred to as “5S”. The intent of 5S activity is to improve
the organization cleanliness and orderliness for achieving excellence in operations management.
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5S activity can be followed in production shop floor, stores, maintenance, utilities, laboratory,
standard room, offices and in facilities like reception, canteen etc.
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25.4 Energy Management
It is the practice of using energy more efficiently by eliminating energy wastage in an organization’s
operation.
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The intent of energy management is to:
→ Save the organization’s energy
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→ Reduce environmental impact
→ Optimize usage of current energy resources
Energy management shall be done in all areas of plant and should apply to power consumption
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by machines, lighting, HVAC, water, fuel consumption etc.
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25.5 Proactive capturing of customer voice

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Customer’s voice shall be proactively captured and used for betterment of the system and
supplied product. Further, the same would help in:
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→ Root cause analysis

→ Countermeasure review
→ Continual improvement
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→ Risk mitigation
There may be two modes by which customer’s voice can be captured:
→ Improvement survey format
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→ Monthly review meetings

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25.6 Error Proofing/ Poka- Yokes/ Mistake Proofing

25.6.1 Error proofing is a process improvement system that reduces the likelihood of any error to happen
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at a manufacturing process station. There are many other terminologies which are used having
the same meaning, such as - “Fool Proof”, “Mistake Proof”, “Fail Safe”.
25.6.2 Mistake Proofing –
- Make wrong actions more difficult to carry out.
- Makes it harder to reverse any action.

- Makes it easier to identify the errors that have been generated.

25.6.3 Vendor shall identify the areas for error proofing and maintain a schedule for implementation
at the start of development of part.
(It shall be discussed during the Specification Meeting with MSIL)
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25.6.4 Poka-yoke details shall be entered in the Operation Standards / WIS wherever the Poka-yokes
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are installed on the stations.
25.6.5 Vendor shall maintain a documented list of all the Poka-Yokes installed on manufacturing lines
and all Poka-Yokes should have a unique identification number.
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25.6.6 Vendor shall ensure a daily check of all the installed Poka-Yokes at the starting of each shift
and shall be recorded in the Poka-Yoke Control Register.
25.6.7 Vendor shall ensure that whenever there is a long lay-off of any manufacturing line(s), all the
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poka-yokes installed on those lines should be thoroughly checked and recorded before start of
the production.
25.6.8 Wherever possible, vendor shall try to explore the areas of installing error proofing mechanisms,
especially at the process stations of Maru
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/ Functional Parts.
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CHAPTER 26
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CHANGE
APPROVAL
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CHANGE APPROVAL
26 CHANGE APPROVAL
26.0 This chapter explains the manner of requesting to MSIL about changes proposed by the vendor
in the parts which have already been approved for mass production use.
Category of changes are:
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a) Design change
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b) Inner Part Localisation
c) VAVE
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d) New Sub-vendor
e) Process Change (Die/Mould/New equipment/ New process/process sequence)
f) Manufacturing location change.
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g) Material change
h) Deviation/ Special Use
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Line Restart after 6 month
Liquidation of Buffer Stock i In
k) Any standard like MIS –P, PCS etc. which have been submitted to MSIL or approved by
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MSIL.
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l) others
MSIL’s experience tells that many problems have occurred because of implementation of
changes without prior information to MSIL. It is thus very important for the vendors to keep
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MSIL informed in timely manner about such changes done in any part ( , Functional or
General), prior to implementation, by vendors.
Note: Whenever a process is shifted from one location to another, comparison of process shall
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be done with previous location to ensure the product Quality. Aspect of change of existing plant
layout should be recorded.
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26.1 Vendor shall inform MSIL, without fail for Parts, minimum one month prior to Implementation
of any changes, e.g. -
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o Partial or whole of any process is outsourced to Tier-2 Vendor.

o Change of Tier-2 Vendor.
o Change of RAW material Vendor.
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o Change of location of own plant or Tier-2 plant.

For Parts, such requests for changes from vendor shall be first concurred by the department
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head of the concerned department in MSIL’s supply chain and then forwarded to MSIL’s QAPQ/
Engg for evaluation.
Note: - If there is any change in Set Part (related to above change point) then it should be routed
through MSIL and Tier-1 will be the Part of Evaluation Process.

CHANGE APPROVAL
26.2 Manner of informing changes

26.2.1 Vendor shall initiate the change approval request from extranet (online CARV system).
26.2.2 Details of 4M (Man, Machine, Material & Method) validation appears automatically in the Online
system, which shall be filled by the vendor.
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26.2.3 Each Change request will come to MSIL with unique control No.
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26.2.4 The request shall be moved internally to concern SC, Engineering & QA-PQ department along
with the unique request number for internal tracking and approval.
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26.2.5 How to fill up “Change Approval Request from Vendors”.
(a) CARV needs to be initiated by vendor by filling all the details on screen.
(b) Fill name of the company and vendor code given by MSIL in the respective columns.
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(c) Write the no. of samples in the Sample Quantity column, if samples have to be submitted
with the Change Approval Request. If samples are not being submitted, select “NA” in this
column.
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(d) Write the name and number of the attached part.
(e) Tick the appropriate box in the nature of change column to indicate the reason for change.
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(f) Give the details of change proposed explaining the reasons in details and also the tentative
schedule. Also indicate the batch code or identification of change parts.
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(g) Give details of inspection and testing done on change parts and attach the reports.
(h) Change Approval Request must be approved by the Principle or Deputy QA Incharge.
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(i) In case of request for special use approval, indicate quantity/duration for which deviation
is being sought.
(j) In case CARV is raised based on ECR / ECN (by MSIL then ECR / ECN no. to be filled in
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the column provided.

(k) In case of inner part localization, mention details of buffer stock to be kept, if asked by
MSIL.
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26.3 List Of Documents to be submitted

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26.3.1 All documents to be submitted as per the Nature of Change

• Material certificate test reports or Material Inspection Report.
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• Dimensional inspection report

• Updated Process FMEA and Design FMEA Reports.
• Appearance inspection reports.
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• Modified Process capability report.

• Records of Raw Material and Test Results.
• Modified Process Flow Diagram/ Process control Standard (PCS).
• Machine/Die/Tool/ Maintenance report.
• Modified Drawing SPC details.

CHANGE APPROVAL
• Updated MIS-P
• Updated TIS-P
• POKA YOKE Details
• Changed inner parts and assemblies (as desired by QA-PQ /Engg)
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• Function / performance / Endurance test report
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• Laboratory Test Reports/Metallurgy Report
• System generated 4M Report from Online System
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• Traceability requirements
26.3.2 For all the changes related to ELV (Cr6+, Cd, Pb, Hg) & Asbestos:
26.3.2.1 Vendor shall raise request & documents as per additional requirements given in Table.1 to
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supply chain Dept.
26.3.2.2 For all the components where ELV requirements are to be complied, vendor shall submit the
material data sheet via online website (www.mdsystem.com) and enter the generated IMDS
such cases. i In
node ID in the CARV format. Vendor shall ensure the IMDS Node ID in the CARV format for
(For more details on Environment Regulation refer Annexure-VI)

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26.4 Evaluation of Parts & Judgement by MSIL

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Evaluation means Dimensional inspection, Material testing, Homologation Testing, Performance

testing and Endurance testing on Engines / Vehicles / Test rigs.
Supply Chain will forward the Change Approval Request to MSIL’s QAPQ or Engineering
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department as per the approval route defined by MSIL.

MSIL’s QAPQ / Engineering department will give their comments and make decision as Approved
or Not Approved on the request after considering the change and carrying out evaluations as
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deemed necessary. They will also indicate if an FPP should be submitted or the supply of the
parts can be continued without any special evaluation by MSIL.
In case of design or material change, an Engineering Change Notice may be issued if the change
is accepted.
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The initial lot supplied by vendor shall be identified with the FPP tag and submitted to MSIL
along with the inspection data.
If there are more than one delivery locations, FPP tag shall be attached to each initial lot
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released for each of the locations. In case where an FPP lot is divided and delivered in multiple
containers, attach a supplemental FPP tag to each container. Handling of supplemental FPP
tag should be consulted in advance with MSIL.
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26.4.1 For changes in & Functional items of parts, evaluation of parts submitted through “Change
Approval Request” may be done in following two stages:
1. Initial Sample Evaluation
2. Peak Production Trial Evaluation
MSIL’s PQ department shall indicate whether the change evaluation shall be done in MSIL in

CHANGE APPROVAL
one stage or both the stages by selecting option 1 or 2 in online Change Approval request.
26.4.2 The First stage or “Initial Sample Evaluation” shall be normal evaluation of the parts as given
in Chapter 7 –“Submission of Samples & Evaluation by Maruti”.
26.4.3 For the second stage, changed parts shall be produced through systems followed by the vendor
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in similar manner as entered in the chapter 8- “ Peak Production Verification Trial”. Parts from
the second stage may also need to be submitted to MSIL by the vendor for evaluation at the
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discretion of MSIL’s QAPQ (If option 2 is ticked by MSIL’s QAPQ).
26.4.4 MSIL Parts Quality department can choose to go for direct 2nd stage (PPVT) evaluation for
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& Functional Parts at MSIL. The same shall be indicated in the Change Approval Request.
26.4.5 Irrespective of whether option 2 is ticked or not by MSIL, Vendor shall, without fail, perform stage
2 (Peak Production Verification Trial Evaluation) at its own end & Keep all relevant records as
given in the chapter on PPVT.
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26.4.6 Vendor may proceed to the next approval stage with prior approval from MSIL’s QAPQ. But,
for and Functional Parts,in all the cases, vendor has to keep all the evaluation records with
them and same shall be provided to MSIL on request.
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After evaluation of proposed change, on the Change Approval Request, MSIL’s QAPQ/
Engineering department will share the Change Approval Request in online system to Supply
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Chain department. Then, if the request is accepted, action can be taken by the vendor as advised
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by MSIL.
NOTE 1: For CARV related to New Sub-vendor (Tier-2), following to be considered:
a. Vendor shall ensure that New Sub-vendor is selected from the Approved List of MSIL.
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b. After CARV approval, vendor shall give the controlled copy of TIER-II Quality Manual to
Tier-2 vendor and shall take a receiving for the same. TIER-II Quality Manual copy can be
obtained from Extranet. For Sub-Assembly/process shifting to Tier-2 (Refer Annexure-V,
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26.5 Online Tracking of Change Approval Request

Vendor may track the status of Change request submitted by him to MSIL with the help of Unique
CARV control No through Extranet.
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NOTE:- In Case of design change, material change or Critical processes like die duplication,
process change .design change Pre meeting or Spec meeting has to be done. However spec.
meeting can be done for other category as desired by MSIL.
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26.6 Liquidation of Buffer Stock

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For keeping and consumption of KD Buffer stock at vendor end, approval needs to be taken
from MSIL.
NOTE: For liquidation, pre-meeting needs to be done with all concerned agencies (SC/Engg./
PQ)

CHANGE APPROVAL
26.7 Special Use Request

26.7.1 Special use request can be made by the vendor when it is found out during inspection at any
stage at vendor’s end that some Quality characteristic does not conform to the standards and
it cannot be rectified. Such request shall only be made when vendor feels that there would not
be any Quality, Functional, Service, Legal or Sales related problem due to this aspect during
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usage of this part.
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26.7.2 Special use request must be submitted to MSIL well before despatch of the parts for which
special use request is made to MSIL, so that judgement regarding special use could be made
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and MSIL approval is given by the time parts reach MSIL (Production or spares).
26.7.3 For making request for special use following information should be filled clearly:
(i) Description of Quality Problem: Write details regarding the characteristics which are deviating
from standards i.e. what is wrong with the parts. Give details of inspection & testing done
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and indicate the reports enclosed.
(ii) Reason for Special Use: Explain in detail why the deviation has occurred and also the
circumstances due to which deviation parts need to be used. Tick the special use in the
column of “Nature of Change”.
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(iii) Identification of special use parts: Describe the method of identifying special use parts e.g.
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batch code, any other special indication like paint mark etc.
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(vi) Time Period for Deviation: Mention the time period for which deviation is required.
NOTE: -
1) MSIL SHALL RESERVE THE RIGHT TO REJECT OR APPROVE THE DEVIATION
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REQUEST.
2) UNDER NO CIRCUMSTANCES DEVIATED PRODUCTS SHALL BE DELIVERED
WITHOUT PRIOR APPROVAL OF MSIL.
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3) DEVIATIONS SHALL BE GIVEN BY MSIL ONLY IN SPECIAL CIRCUMSTANCES AND

IT SHOULD NOT BE CONSTRUED AS A GENERAL PRACTICE / POLICY ADVOCATED
BY MSIL.
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Table.1
S. No Documents required to be enclosed by Vendor
1 Declaration Letter stating Part Name, Part Number, Quantity, Plater name & Chemical
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vendor name
2 Test reports ( SST & Pb/Cd/Hg/Cr6+/ Asbestos free report) from third party
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3 Appearance & Plating thickness check report.

4 Modified MIS P with ELV / Asbestos check points
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5 Modified PCS with ELV / Asbestos check points.

6 PCS of Plater
7 Modified Samples ( 3 Nos.)

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Q APPROVAL
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OF FIRST
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PRODUCTION PART
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CHAPTER 27
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APPROVAL OF FIRST PRODUCTION PART
27 APPROVAL OF FIRST PRODUCTION PART

27.0 Whenever a changed part is made for the first time using mass production process and conditions
e.g. production tooling, equipment, environment (operation, operating conditions etc.), facilities,
cycle time or when a new process is used for the first time to manufacture a part, there could
be many unexpected troubles, commonly called as teething troubles. During such times,
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both the vendor and MSIL need to be very careful and should thoroughly evaluate such first
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time manufactured changed parts in a methodical way, lest they become cause of customer
complaints. In the following sections, method of handling first time manufactured changed part
supplied to MSIL has been explained.
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FPP approval shall be the Part of Change approval process (CARV) or Sample approval process
(SERV). Vendor shall prepare the FPP lot as per the MSIL requirement.
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27.1 Definition of First Production Parts (FPP) lot:
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27.1.1 A lot of parts, which is produced for the first time just after the implementation of one or more
of the following changes-
(a) A Design or Engineering Change
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(b) Material change
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(c) Process layout or process control parameters change

(d) Die, Jig and/or machinery change
(e) Sub-vendor change
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(f) Plant location Change

(g) Inner part localisation
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(h) Second sourcing

(i) VAVE
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(j) Liquidation of Buffer Stock

(k) Or as asked by MSIL’s QAPQ or Engineering during CARV approval process.
Such a first lot when produced is called a FPP lot.
27.1.2
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In principle, a minimum of 300 parts shall be produced as FPP lot for submitting it to MSIL.
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27.2 Dealing with FPP at vendor’s end:

27.2.1 It is essential that operators & supervisors on the shop floor are able to differentiate such FPP
lot from normal production lots so as to be able to:-
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a) Carry out Special checks/inspection different from general lots (should be defined in process
control standard/ control plan)
b) Prevent it from getting mixed with normal production parts.
27.2.2 Thus it is important that some tagging or identification mechanism is adopted for the FPP lot
from the point of change in the process till dispatch stage. One such Format-27.2 of tag is given

for reference. The tag moves from the station where the change originates in the process along
with the product/batch/lot & moves till the dispatch stage. At dispatch point, this internal tag
should be removed before dispatching the lot to MSIL.
Please note that the internal tag used should be noticeable (preferably of a different colour from
the normal lot) so as to enable the operators & supervisors to identify the lot easily on the shop
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floor. In the event when the change occurs from the sub vendor’s end, the internal tag should
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start right from receipt of such changed material from the sub vendor.
27.2.3 Inspection Items
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For the Parts, which have been produced for the first time after design or process change,
inspection shall be done for the affected Quality characteristics as per drawing.
27.2.4 Number of pieces to be Inspected
In principle, more than 5 pieces should be inspected in an FPP lot. However, for destructive
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test, minimum one part should be checked. In case of multiple dies or multi cavity dies minimum
one part per die/cavity shall be considered for 100% dimensions check (inspection of 100%
parameters as per drawing).
27.2.5 Inspection Reports
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27.2.5.1 Vendor can decide about the format of the inspection report of FPP lot, however the following
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information must be included in it:
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 Model
 Part Name
 Part Number
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 Reason for FPP Lot

(e.g. design change, process change, die change, sub vendor change, new part etc.).
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 Reference of change document

(e.g. Engineering Change, Notice Number, Date of Change, Approval Request etc.)
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 Date of inspection
 Inspection Items
 Judgement Criteria
 Observations
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 Judgement
 Batch code of the lot.
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27.3 Submission of FPP lot to MSIL

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27.3.1 After producing FPP lot, QA Incharge of the vendor shall submit the FPP lot along with the
following reports:
(a) One master sample (duly identified) on which measurements have been made and included
in FPP inspection report
(b) Dimensional inspection report

(c) Material inspection report

(d) Checking aids (if requested by MSIL’s QAPQ or not submitted during sample submission)
(e) Performance test report
27.3.2 All boxes/bins/trolleys/documents/reports shall be marked with letter “FPP”. The batch code
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shall also be marked on the boxes/bins/trolleys.
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27.3.3 All the inspection listed in 27.3.1 other than process capability study/ MSA study / FMEA shall
include the measurement of at least 5 parts. If any measurement is destructive in nature, then
minimum 1 part should be checked. In case of multiple dies or multiple cavity dies, minimum 1
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part per die/cavity measurements shall be included.
27.3.4 Important Points:
(1) If the final or revised Process Control Standard and Process Flow Chart have not yet been
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submitted to MSIL’s QAPQ these shall be submitted before the despatch of FPP Lot.
(2) If the copy of (approved/revised) MIS-P has not yet been received, MSIL’s QAPQ should
be contacted.
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(3) Over and above these points, whether the approval of any other control document that
needs modification/approval has been received or not should be confirmed.
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27.4 Evaluation of FPP Lot by MSIL

27.4.1 FPP lot will be inspected by MSIL’s QAPQ for relevant Quality characteristics given in drawing
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and MIS-P.
27.4.2 MSIL’s QAPQ will scrutinise all the reports submitted by the vendor to ensure that they are
meeting the requirements.
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27.4.3 If the lot along with reports and plan are found satisfactory, then lot will be fed to production shop
in MSIL along with the FPP Tag. (refer Format-27.1) The chassis numbers/engine numbers to
which the FPPs are assembled, will be recorded for maintaining traceability. At every stage in
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MSIL, up to the final vehicle inspection stage, performance of the parts will be carefully checked
and results shall be recorded on the tag. Finally the FPP tag gets returned to MSIL’s QAPQ
which shall make the final judgement. After that MSIL’s QAPQ will make the “Parts Inspection
Report”. A copy of this report will be given to the vendor.
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27.4.4 In case FPP lot or reports are not satisfactory, FPP lot is rejected by MSIL’s QAPQ Fresh lot
with improvements/ corrections suggested shall be submitted to MSIL at the earliest keeping in
view the Change implementation Plan. As MSIL considers subsequently supplied parts as First
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Production Parts until they are cleared by MSIL’s QAPQ the vendor shall supply subsequent
lots as FPP lot.
27.4.5 Separate FPP Sample for each Die/Cavity/Mould shall be submitted by vendor as per the
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discussion done with MSIL’s QAPQ.

27.5 Future Road Map For Robust Change Management:

With the upcoming dynamic and demanding market it is very important that we keep on upgrading
ourselves at regular intervals and be upto the mark.
It is very important, from Quality point of view, that whenever a change is taking place in
established process (mass production), it is properly addressed & recorded and is traceable.
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To address the above mentioned requirement, MSIL has already released complete online CARV
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system, however FPP activity performed during CARV approval is still a manual activity. MSIL is
working on making FPP also online through PCCS System (Part Change Control Sheet). Also,
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with the implementation of this system, whenever first mass production lot of changed parts is
supplied, an alert shall be generated in online system and a tag shall have to come with such
initial Lot.
This will help in linking the ECN implementation and VIN cut off and will also help in avoiding
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implementation of unapproved changes.
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CHAPTER 28
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VENDOR RATING Lim
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VENDOR RATING
28 VENDOR RATING
28.0 This chapter briefly explains the method / criteria of evaluation for calculating vendor rating by
MSIL.
Vendor rating shall be calculated once in a year by MSIL for all the Indian vendor, who are
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supplying parts, semi-finished parts and/or direct consumables to MSIL. The purpose of this is
to make the overall comparison of the Vendors.
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Vendor Rating may be used for -
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a) Vendor Awards
b) Defining Future Business Dealing
c) Deciding Vendors for Improvements
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28.1 Evaluation Parameters
Evaluation parameters are as follows:-
• Quality
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• Cost Reduction
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• Delivery
• Response & Service
• Design & Development
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• Sustainability
• MSIL focused initiative
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28.2 Each parameter is further divided in to several Sub-parameters. Brief details of these parameters
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is as follows -
28.2.1 Quality Rating
Quality rating shall have the following sub-categories-
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a) Warranty Rating
b) Incoming Quality rating
c) Vendor Audit Rating
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28.2.2 Cost Reduction Rating

Cost reduction rating shall be calculated based on following factors-
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a) Periodic Cost Reduction

b) Cost Saving Through VA-VE
c) Price reduction in Focus Models
d) Inner Part Localization
e) Overall Achievement of cost Reduction Target
f) Financial Performance
VENDOR RATING
28.2.3 Delivery Rating

Delivery rating shall be calculated on the basis Delivery Performance, which includes -
o E-nagare Quantity default
o Spare Defaults
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o E-nagare Time defaults
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o Condition of Bins / Trolleys which are being used to deliver Parts to MSIL.
28.2.4 Response & Service Rating
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The response rating shall consider, typically
o Vendor’s support in case of other Vendor’s failure
o Investment in capacity expansion
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o Service Provided
o Tier 2 vendor development
28.2.5 Development Rating
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Development rating shall be calculated on the basis of parameters like design capability, testing
/ evaluation capability and tooling development capability etc.
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28.3 Quality Negative Marking

Penalty /deduction of marks shall be done on Quality rating for
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1. Recall / Service Campaigns

2. Dispatch Suspension
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3. Unapproved Changes
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28.4 Vendor Penalty

28.4.1 Continual problems flowing from vendors to MSIL cause a major & unrecoverable monetary &
non-monetary loss to MSIL along with disruption in the supply chain.
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This clause details with the method of penalizing vendors due to whom considerable loss
occurred to MSIL (Financial, Man-hour wastage and repair/rework cost and brand image).
28.4.2 Reasons for Loss
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Loss may occur due to the following few reasons:

o Loss due to Un-informed/Un-approved changes.
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o Serious Quality Problems leading to vehicle dispatch stop, hold up and repair.
o Serious Quality problems due to which a market action has to be taken.
o Line stopped/ Line Run Without parts (LRWC) due to non-supply of parts.
o Line stopped/ Line Run Without parts (LRWC) due to non-supply of OK parts.
o Loss causing ‘Air-freight’ of components.

VENDOR RATING
28.4.3 Vendor Penalty / Recovery of Losses from Vendor

MSIL shall extend all possible help & support to the vendors to meet MSIL quality requirements.
However in the event of serious Quality problems, repeated defects, or continuous nonperformance
reported from the vendor. MSIL shall impose the penalty on vendor.
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Penalty will be imposed in the form affecting vendors ratings, commitment letters from vendors
top management, financial recovery (as per internal policy), impacting the share of business,
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skipping RFQ’s for new models and foremost in case of no improvement, MSIL shall think about
dropping of vendor.
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SUB VENDOR
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(TIER-2) CONTROL
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CHAPTER 29
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SUB VENDOR (TIER-2) CONTROL
29 SUB VENDOR (TIER-2) CONTROL

29.0 This chapter details with the guidelines for Tier-1 vendors, in controlling the Quality of MSIL’s
sub vendor (Tier-2).
The Tier-1 vendor has to guide & coordinate with Tier-2 in all Quality related activities. Tier-1
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has to ensure that the systems at Tier-2 are as per his Quality requirements and also all the
requirements of MSIL as laid down in this manual are being met.
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Note : Child part source (for all parts) shall be informed to MSIL by Tier-1 vendors.
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29.1 Responsibilities of TIER-1 Vendors for TIER-2 vendors
Tier-1 Vendor
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1. Shall have a documented system in place for selection and evaluation of Tier-2 vendors.
2. Shall have a documented system in place to ensure the identification & traceability of parts
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supplied by Tier-2 vendors.
3. Shall ensure that all MSIL’s requirements, as per this Vendor Quality Assurance Manual,
& other product & process related requirements of MSIL as detailed in various drawings
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& standards have been communicated correctly to Tier-2 vendors. Tier-1 vendor should
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have a system in place to conduct communication meetings with Tier-2 vendors.
4. Shall ensure that, any design or process changes, are not implemented at Tier-2 vendors
without the prior knowledge & appropriate approval of Tier-1 vendor and same shall be
communicated to MSIL.
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5. Shall have a system to assess the Quality Systems/ Production / Process controls and
Capability of Tier-2 vendors.
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6. Shall ensure that process validation is performed at regular intervals.

7. Shall have defined checksheet for selecting a Tier-2 vendor.
8. Shall ensure that for all the items given in MIS-P, required facilities are available with Tier-2
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to inspect / check those items.

9. Shall involve their Tier-2 vendors in planning / problem solving activities etc. and to make
sure that Quality levels of Tier-2 vendors are of acceptable level.
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10. Shall ensure that countermeasures for Quality problems encountered at Tier-2 vendors
during development & Post SOP are effective, sustainable & such problems are non
recurring.
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11. Tier-1 vendor shall keep track of the following-

o Rejection & defect levels of all Tier-2 vendors
o Delivery Performance of all Tier-2 vendors
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o Process Capability of all Tier-2 vendors

12. Shall be responsible for training & development of Tier-2 vendors.
13. Shall have a system in place to rank the Tier-2 vendors based on parameters like Quality,
Delivery etc.

14. Shall have a documented system of taking suitable action against Tier-2 vendors in the
event of repeated Quality problems being received from Tier-2 vendors or Tier-2 vendors
consistently not showing any improvement.
15. Shall ensure that a system is in place to record the above mentioned information. These
records should be produced whenever asked by MSIL.
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16. Shall be completely responsible for Tier-2’s sub vendors (e.g Tier-3, Tier-4 etc).
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17. Shall ensure that all operators performing MARU operations have received special
training for performing the operations.
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18. Shall ensure that a documented system is in place at Tier-2 for proper control and
Maintenance of inspection equipment and production equipment. System shall include the
following:
a) Periodical Accuracy Inspection and Calibration
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b) Display of Validity Period
c) Annual Plan of Calibration
d) Periodic Check Plan
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e) Part produced Post repair must be treated as a newly developed part and its
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100% inspection (inspection of 100% parameters as per drawing) should be carried out as
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per the approved drawing.
19. Shall ensure that operation standards for performing different operations are formulated
and implemented at place of use at Tier-2’ s.
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20. Shall ensure that a controlled copy of TIER-II Quality Manual is provided to newly selected
Tier-2 vendor and receiving has been taken for the same.
21. Shall ensure that a proper system is implemented to stop dispatch of part incase any serious
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Quality Problem is observed during inspection / Production, so that necessary repairs can
be done in the Part.
22. To ensure traceability, the Tier-1 vendor shall assure that sub vendors shall employ the
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same degree of control for manufacturing history.

23. Approval system shall be established for cases of duplication of tool / die.
24. Tier 1 shall ensure basic/ mini DOJO setup at their Tier-2 vendor end.
25. Tier-1 hall ensure implementation of Revalidation system at Tier-2 vendor
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29.2 If any or functional part / item is outsourced to Tier-2 vendors then Tier-1 shall ensure the
following-
1. Tier-1 vendor has the necessary concurrence / approval of MSIL.
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2. Tier-2 shall be explained about and Functional part / item & their impact in
case of failures.
3. Tier-1 shall communicate all the and Functional part / item to Tier-2 by marking the same
in drawing & inspection standards and these should also be reflected in Tier-2’s drawing.
4. In case of location change of Tier-2, Tier-1 shall inform MSIL minimum one month in advance.
(refer Chapter 26)

5. Ensure the prior concurrence / approval of MSIL is there for any design / process / 4M
changes at Tier-2.
6. Tier-1 shall specify all the controls/inspections to be exercised on such Maru /F parts/
items as per the guidelines provided by MSIL in it drawings/ specification meeting’s etc.
7. All parts / child parts outsourced shall also be clearly marked by Tier-1 in MIS-P.
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29.3 Audit Conducted by Tier-1 suppliers on Tier-2 Suppliers
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 Tier-1 vendors shall make annual plans to conduct audits of their Tier-2 vendors.
 Tier-1 vendors have to keep the records of these audits and Root cause analysis with
countermeasures has to be taken from Tier-2 vendors for non conformities observed.
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 Tier-1 vendors have to ensure that the required countermeasures have been implemented
by Tier-2 vendors.
 Tier-1 vendor shall have to ensure the effectiveness of countermeasures taken by Tier-2
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vendors.
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For ‘Contents of Audit’ and ”Preparation of Audit” refer 18.2.3 and 18.2.4 respectively.
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 In addition to other audits, Tier-1 vendors shall perform special process audits on Tier-2
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vendors who are performing the processes like plating, heat treatment etc.
The Audit findings shall be communicated to MSIL, if asked but if any abnormality is suspected
in product then immediate communication shall be provided to MSIL’s QAPQ.
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Also, if necessary, MSIL’s QA department, SC and Engg, can conduct Process Audit of Tier-2
vendors.
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For additional inputs or further information on Tier-2 Quality System
refer MSIL “TIER-II Quality Manual”

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CHAPTER 30
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RISK ASSESSMENT
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RISK ASSESSMENT
30 Risk Assessment
30.0 The vendor must have a process for the identification and management of potential risks to
ensure proper supply of parts and materials to MSIL. The intent of this process is to proactively
address risk.
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30.1 Steps for Risk Management
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1. Identify possible risks: recognize what can go wrong.
2. Analyse each risk to estimate the probability that it will occur and the impact (i.e. damage)
that it will do if it does occur.
3. Rank the risks by probability and impact (maintain a control register) – Impact may be
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negligible, marginal, critical and catastrophic.
4. Develop a contingency plan to manage those risks having high probability and high impact.
30.2
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The assessment process at vendors end shall include (but not be limited to) a periodic assessment
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and review of all possible risks. The process shall analyse risks associated with both facilities
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and personnel, considering issues such as:
o Product, facility or individual skill uniqueness.
o Labour unrest and resulting in production disruptions.
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o Critical process element susceptibility to disruptive damage / breakdown.

o Susceptibility to natural phenomena (i.e. flood and earthquake).
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o Sub vendor related issues.

o Hazardous Material Reporting (i.e. End of Vehicle Life requirements, Cadmium, Mercury,
Hexavalent Chromium etc.)
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The output of this assessment shall be used to identify where action is required, if economically
feasible, to remove or reduce the likelihood of these problems occurring. The assessment
shall also include an estimation of potential occurrence of down time in the event of a major
catastrophe.
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ANNEXURES Lim
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ANNEXURE-I
Policy Guidelines for Vendors

(Supplying Parts to MSIL)
1. OBJECTIVE
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1.1 The Objective of this Policy is to lay down Guidelines for Vendors who are supplying Parts
to MSIL so that no defect is reported at MSIL or in market.
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2. Scope of Application
2.1 This Policy shall be applicable to all Indian Vendors who are supplying parts to MSIL directly.
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3. Controlling Division At MSIL
3.1 MSIL’s QAPQ shall be controlling agency for document approvals.
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4. Definition of Part, Parameter & Process :
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4.1 parts are those parts and components which are essential for the safe operation of vehicles
under normal use, and if defective, could result in incidents of injury or fatality by causing loss
of vehicle control or fire.
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4.2 Parameter or items are those Quality characteristic of part, which if defective, could
result in incidents of personal injury or fatality by causing loss of vehicles control or fire.
4.3 process is such, which controls the parameters of part.
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4.4 Definition of Part, Parameter & Process shall be agreed to the Vendor during the
Specification meeting / Technical review meeting.
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5. Guidelines
5.1 Process Controls
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5.1.1 All Processes / Operations shall be performed In-house by Vendor. Specific concurrence
shall be obtained from MSIL’s QAPQ in advance if any Processes are to be outsourced or
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as agreed during specification meeting / Technical review meeting.

5.1.2 All Processes / Operations shall be performed by trained / permanent technicians only (As
per the details given in Chapter 10).
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5.1.3 For Processes / Operations such as Welding, Heat Treatment, Forging etc, special controls
to be exercised for ensuring that Process parameters are adhered to & not changed without
adequate approval.
5.1.4 Poka Yoke shall be implemented for Processes / Operations to eliminate human error as
far as possible.
5.1.5 Incase of Weld Nuts used in applications, re-tapping shall not be permitted.

ANNEXURE-I
5.2 Inspection
5.2.1 Vendors shall have the facilities for checking all parameters Inhouse or through a NABL
accredited lab, and shall check the same at agreed frequency (As discussed with MSIL’s
QAPQ & approved in MIS-P).
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5.2.2 Fail-Proof detection mechanisms shall be employed for checking Parameters at Incoming,
Inprocess & Final Inspection Stage. Auto detection mechanisms shall be used wherever
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practical.
5.2.3 On Components to avoid mix-up,there shall be Auto marking after checking (wherever
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applicable).
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5.3 Raw Material, Child Parts, Sub vendor Control
5.3.1 Raw Material & Child parts for all Parts shall be procured from the sources as agreed with
MSIL. Details of the same shall be provided in MIS-P and PCS by respective Vendors.
5.3.2
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High Tensile strength fasteners (>7T) and spring steel clips, clamps, washers which have an
parts must be procured as per the joint agreement with MSIL.
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5.3.3 Vendors shall have a proper system for Process Audits for exercising Quality controls at Tier-2
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Vendors including raw material suppliers (As per details given in Chapter 19 ad 29).
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5.4 Change Control

All changes with regards to Process, Location, Design, Sub Vendor etc in relation to
parameters shall be approved by MSIL’s QAPQ before implementation. (As per details given
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in Chapter 26).
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5.5 Traceability
5.5.1 TIS-P shall be prepared for part by vendor (refer Chapter 16).
5.5.2 Batch Code shall be provided on all parts to establish traceability for all Processes /
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Operations. The Batch Codes shall be provided in such a way that these are easily visible after
fitment of part in the vehicle. The same should be discussed and agreed with MSIL’s QAPQ.
5.5.3 Incase of Sub Assemblies, Child parts & raw material used and their linkage with Sub
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Assembly & Assembly Batch Code shall be maintained at Vendor end.

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5.6 Others
5.6.1 MIS-P & PCS shall be approved by MSIL’s QAPQ. Vendor shall preserve these documents
(Approved originals) & follow them in right earnest (As per details given in Chapters 6 & 9).

ANNEXURE-I
Vendors shall implement proper system to record, analyse & take countermeasures for all in-house
rejections related to In-house problems should be given special focus at all levels in the Vendor
Organisation.
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ANNEXURE-II
WORKING PROCEDURE FOR INSPECTION OF PARTS

(After Machine / Die / Mould maintenance or Die Duplication)
A) Purpose:
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The purpose of this procedure is to indicate the methodology for cutting and evaluation of samples
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/ parts by the vendors before start of regular production to detect abnormal cross-section.
This procedure is made based on failures happened / experienced by MSIL, when proper sections
were not cut after change in core / insert of already running part.
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Normally the work flow is as follows-
PLAN Production - Identifies certain Repair areas based on process rejection.
PLAN + DO Tool Maintenance - Areas identified by Production + Additional areas &
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do the die / insert maintenance / replacement - Keep maintenance record.
CHECK Production + Inspection - Takes trial run and to confirm change in the area
repaired / replaced - Keep inspection record.
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Tool Maintenance + Production + Inspection - Check the repair and reconfirm
till OK - Inspections records are kept.
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Production + Inspection - Give go ahead for production - Keep record.
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B) Applicable Conditions: (Die casting, core sand moulds etc)

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This procedure is applicable to samples produced by the vendors for :

a) New part development with new tooling/ or die duplication after completion of useful die life.
b) Samples produced with full / partially new tooling such as change in core / mould / insert / die
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/ cavity , etc for already approved production parts.

c) Samples made due to die repair and maintenance (periodical / breakdown)
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d) In case of routine production parts, periodically (say once in a quarter) carry out the cutting of each
part to seek out any abnormality in the parts even when no changes have been carried out.
For the first part produced in all the above conditions (a,b,c) 100% inspection (inspection of 100%
parameters as per drawing) should be carried out as per the approved drawing.
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C) Responsible Persons:
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The responsible persons for checking and confirming the new samples shall be Vendor’s Production,
Tool Maintenance , Inspection & QA dept.
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D) Method of Checking the samples and its approval

1) Whenever the applicable condition occurs, parts should be cut without fail.
2) Cut-sectioning shall be carried out as per the sections given in MSIL approved drawing and
each of 3-Dimensional plane.

ANNEXURE-II
3) In addition, Cut-sectioning and checking of the parts to be carried out at places where wall
thickness is critical for performance, leakage of fluid or gas. Reference values from CAD can
be used for evaluation.
4) The inspection records should be prepared clearly mentioning the purpose of inspection and
information about core / mould / cavity / die number, batch code and other details pertaining
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to traceability of part.
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E) Guidelines/Judgement after Inspection
1. The checking of cut-sections is to be carried out to detect / search out for any abnormal condition.
For reference, the OK cut-sections must be available first and displayed at the production /
inspection area.
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2. A blue print / photo of cut-section must be taken for records
3. In case sample is not ok, corrective actions should be carried out on the spot & confirm that
the part is OK.
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In case of die duplication after completion of tool life, samples/ inspection results must be
submitted to MSIL when new die/ tool is made before mass production, along with “Change
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Approval Request (CAR)”.
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5. In case of routine / breakdown maintenance, detail inspection report/ CAR need not be sent to
MSIL. However, summary of such repairs and inspection as per mutually decided die revalidation
frequency must be given.
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F) RECORDS
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The cut-sectioned sample and its inspection record should be preserved at vendor end. Actual
section blue prints / photographs of cut sections with dimensions to be preserved for 11 years.
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G) TRAINING
The necessity of making this Procedure & Procedure itself, should be part of the awareness and
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education to the concerned persons on the shopfloor . It is expected that the Incharges of Production,
Maintenance, Inspection and QA will provide this training to their subordinates, to avoid production
of defective parts.
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NOTE:
1. While cutting such sections, be careful to judge profiles/bosses/cavities. Change cutting angle
to 45º, 60º etc. based on the part contours.
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2. The cut section analysis & its judgement can be a part of control plan / process control standard
for each part. This can then be incorporated as an additional sheet to MIS-P.

ANNEXURE-III
DISPATCH SUSPENSION SYSTEM
1. Objective:
The objective of this Annexure is to indicate the methodology of introducing the dispatch suspension
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system at vendor’s end.
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This system is to be introduced at vendor end to stop dispatch of part in case of any Quality Problem
observed at vendor’s end by the vendor during inspection/ Production, so that necessary action can
be taken in the Part before dispatching it to MSIL.
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2. Dispatch Suspension
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i. The suspension of dispatch means to stop dispatch of parts in the event of any Quality
abnormality/ doubt observed in the Part during inspection/production, in order to take some
remedial steps e.g. repairing, reworking, replacement of child components etc.
ii.
iii.
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Vendor shall define proper dispatch suspension system / Q-Hold system (Quality –Hold) at his
When any defect is observed, vendor shall hold such parts and check if parts with same defect
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has passed to next station or to MSIL.
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iv. In case of any doubt of outflow of defected parts, vendor shall inform MSIL about the range of
components which may have probability of defect.
v. Vendor shall take corrective action / carry out repair of such part as per the requirement laid
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down in Rework chapter.

Vendor shall properly identify the reworked Part while supplying to MSIL.
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Note: Concept of Dispatch Suspension / Q-Hold System is given below

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ANNEXURE-IV
Guidelines for Documentation requirements and its Control
1. Implementation of Quality Systems

Senior Management of vendor i.e. QA Head, Production Head, Quality In charge and other department
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heads should read and understand this Quality Manual and make own internal Rules / Procedures
and follow them.
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2. Control of Documents
The Quality Management System documentation of vendor shall include-
- Documented statement of Quality Policy and objectives.
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- Documents needed by the vendor for effective planning, operation and control of its processes.
- Records as laid down in this Manual.
in this Quality Manual. ki In

- Documented procedures as required by vendors’ customers or as per the requirements laid down
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3. Documentation Requirements
It is management’s responsibility to ensure that documentation requirements are fulfilled in all stages,
while performing the daily activities.
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Documentation requirements cover following activities:-

i) Preparing records for all activities.
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ii) Storing the records in a safe place.

iii) Maintaining the traceability of documents.
iv) Adhering the retention system of records as per the defined timeline.
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v) Ensuring the safe keeping of stored records.

vi) Ensuring the disposition of obsolete records in such a manner that no one can use them. etc.
For the chapters where retention time for records is not mentioned. In such cases it should be
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considered as given below:

i) For Domestic – 3 Years
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ii) For Export – 11 Years

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ANNEXURE-IV
4. Confidentiality
All the vendor partners shall adhere to the confidentiality obligations applicable to them at
all times.
Requirements:
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Notwithstanding anything contained in any other document or agreement executed between
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MSIL and Vendor, Vendor shall ensure:
i. confidentiality of all information received in any form whatsoever while performing any
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activity with MSIL.
ii. that the information shall be securely controlled and disposed of, with prior written
consent of MSIL, in a proper manner when it becomes obsolete.
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iii. to develop a system to maintain confidentiality that starts at sourcing decision and
continue till the life of part.
iv. to immediately report to MSIL any breach of confidentiality or unauthorized disclosure
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ANNEXURE-V
Guidelines for Sub-Assembly/Process Shifting
1. Sub-Assembly/Process Shifting
There have been many cases where the process was originally started with Tier-1 vendor during
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mass production, however on later stages due to production ramp up or other factors, it is decided
by vendor to shift some operation / sub-assembly to Tier-2.
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Many a times after shifting sub-assemblies at Tier-2, it has been observed that MSIL has faced
some Quality issues. So, it is recommended that proper care shall be taken while shifting any
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operation / sub-assembly to Tier-2. A shifting may be done in following two ways:
i) Any operation / sub-assembly is shifted from Tier-1 vendor to Tier-2.
ii) Tier-2 vendor has been changed i.e. shifting of operation / sub-assembly process from one
Tie-2 to another.
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2.
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Method of Shifting and Setting up of Line at Tier-2
The following process shall be followed for shifting and setting up of line at Tier-2:
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i) Handing over process sequence approved by MSIL.
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ii) Sharing of MSIL approved BOM.
iii) Training Tier-2 for operation / sub-assembly process.
iv) Shifting of measuring and production equipment like jigs, machines etc(as applicable).
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v) Tier-2 submits samples of sub-assembly and packing to Tier-1 for inspection.

vi) Tier-2 gets the go ahead for sub-assembly if the sample passes the inspection by Tier-1 &
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MSIL.
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3. Specification Meeting
3.1 Tier-1 shall have a meeting with Tier-2, in which Tier-1 shall explain it’s requirements to Tier-2.
3.2 There shall be a clear understanding between Tier-1 and Tier-2 for requirements regarding Quality,
Production Quantity etc.
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3.3 In this meeting Tier-1 shall handover the documents required for performing operation / sub-
assembly process to be shifted like drawing, operation standards, work instruction sheet (WIS),
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past Quality feedback and countermeasure for problem reported by MSIL or Quality issue observed
in this plant etc.
3.4 Proper system should be established for submission and approval of Tier-2 drawings / specifications
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(as applicable).
4. Education & Training

4.1 Tier-2 shall study the documents given by tier-1 for operation / sub-assembly processing and shall
clear all the queries (if any) before moving ahead.

ANNEXURE-V
4.2 Tier-1 shall give hands-on training at his end to Tier-2 persons before shifting the process at their
end.
4.3 In case operation / sub-assembly is shifted from one Tier-2 to another, then Tier-1 shall provide
the training and other documents to new Tier-2 selected for the process.
4.4
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Tier-1 shall ensure that the Tier-2 is capable enough to perform the shifted operation / sub-assembly
task as per requirements, after the training is complete.
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5. Sample Evaluation
5.1 While the samples are prepared at Tier-2, concerned person from Tier-1 shall be available at the
place and check the process being followed, standards being used etc.
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5.2 The sample shall be submitted to MSIL for necessary evaluation and approval through online
CARV system (refer chapter 26).
6. Change Point Communication

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Tier-1 shall develop a system for proper communication in case of any change point (part no.
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change, spec. change, part addition / deletion etc.) with respect to the operation / Sub-assembly.
6.1 Tier-1 shall take approval of New Sub-Vendor from MSIL through CARV system (refer Chapter
26).
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Note: All the requirements mention in Chapter 29 (Sub Vendor Control) shall be followed by Tier-1
Vendor for Sub-Vendor Control.
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7. Records
Tier-1 shall keep the records of sample evaluation, training, operation standards etc. for 11 years.
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ANNEXURE-VI
Guidelines for Environment Regulations

1. Introduction
An ideological model shift to protect the environment at large has sprung up very stringent
Global Environment Regulatory norms specific to the Automotive Industry. MSIL is working on
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proactively implementing norms by formulating Eco-friendly policies, audits, monitoring usage
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of hazardous substances etc.
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2. Scope of Work
The responsibility lies to explain the importance of the activities being done at MSIL and their
contextual applicability for everyone at Maruti Suzuki and its Vendor partners. Through Green
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Procurement Guidelines MSIL mandates its suppliers to follow SOC (Substance of Concern)
compliance and develop SOC management system.
3. Environment regulation control at MSIL

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As per the request of MSIL Material Analysis department, vendor is advised to submit SOC
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related reports & declarations for validation/approval in order to comply with global regulations.
The following regulation data must be submitted to MSIL’s Material Analysis department through
the Supply Chain department:
a. SOC (Substances of concern) Control rule
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b. ELV: End of Life Vehicles regulation through IMDS tool

c. GHS : Globally Harmonised System regulation
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3.1 SOC (Substances of concern) Control Rule

3.1.1 OBJECTIVE
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Substances of concern (SOCs) are substances which have an inherent capacity to cause an
adverse effect, immediately or in the more distant future on humans or the environment. At
MSIL, there are certain special categories of substances for which documents are collected
from MSIL vendor partners apart from IMDS data collection. Such categories are Asbestos,
POPs & Phthalates and other hazardous substances.
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3.1.2 SOC Control Process:

i) By Japanese Industrial Safety & Health Law, 0.1% is the max threshold limit for Asbestos.
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It is banned by MSIL in all our products and raw materials

ii) MSIL mandates collection of Asbestos Free Declaration Letters and Test Reports from
concerned suppliers during all Stages of Model Development
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iii) POPs (Persistent Organic Pollutants) are a global concern due to their perseverance
in the environment, ability to bio-magnify and bio-accumulate in ecosystems. Vendors
are requested to declare non usage of 11 categories of POPs.
iv) Phthalates (DEHP, DBP, BBP, DIBP) are used as plasticizers, i.e., substances added to
Plastics to increase their flexibility & transparency. Their exposure can cause reproductive
toxicity. REACH & RoHS Regulation restricts usage to 0.1% by wt.

ANNEXURE-VI
3.1.3 SOC Control Supplier Audit:

i) Suppliers will undergo SOC audit conducted by respective Supply Chain (SOC self-check
sheet) and QA (vendor system audit) teams of MSIL.
ii) Suppliers must establish SOC management system and satisfy all the SOC audit
requirements as listed below;
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iii) Ranking of vendor shall be done based upon fulfilment of above SOC audit requirements.
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Rank A: Meeting all the Check Points.
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Sl No. SOC audit elements
Developing companywide SOC Awareness
Strict adherence to Green Procurement Agreement
1
Asbestos Control at parts and raw material
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IMDS Data submission
Establishing SOC Management Rules
2 Mix Up Prevention

3

Abnormality Handling
Keeping a complete Tier -2 List
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Collection of SOC declaration reports from Tier-2
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4 Green Procurement Agreement / PO / Order Sheet with Tier-2
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Conduct periodic SOC test of Tier 2 and investigate for any discrepancy with the
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previous reports.
Rank B: Partially meeting with future action plan.

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Rank C: Not meeting and no future plan

3.2 ELV: End of Life Vehicles regulation through IMDS tool
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3.2.1 OBJECTIVE
EU ELV Directive 2000/53/EC & 2005/64/EC specify heavy metal restriction and control of
SOCs in automotive parts. It also states calculation of RRR (Recyclability & Recoverability) of
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a model. The above mentioned objectives are compliant through the IMDS tool.
3.2.2 IMDS
IMDS (International Material Data System) is a public website created by DXC in collaboration
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with major OEMs globally. It is used to fulfill the need of various environmental compliances,
enforced by national and international regulatory bodies on the OEMs. Compliance is achieved
by analysing substance level data as shown below
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3.2.3 Process Flow for Suppliers

a) MSIL will request the supplier to upload IMDS data of their corresponding part into MSIL
IMDS portal.
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b) Supplier must check the drawing during the creation of IMDS data for knowing the correct
structure and weight of the part.

ANNEXURE-VI
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c) The composition mentioned in the IMDS data of the part must be as per the MTC (Material
Test Certificate).
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d) Supplier must have a validation checklist before sending the data to MSIL IMDS portal
in order to avoid rejections.
e) An active IMDS window must be established at every supplier end to address queries
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or share updates on IMDS data submission.

f) MSIL mandates collection of IMDS data from its suppliers within the stipulated deadline.
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g) Suppliers must be aware of periodic changes in IMDS tool and study Suzuki IMDS
operational manual(refer 3.2.4) after every new revision.
3.2.4 Supplier IMDS Validation Checklist
Please follow the Suzuki IMDS operational manual for IMDS common errors prior to sending
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any part IMDS to MSIL Company ID 63415.

https://public.mdsystem.com/documents/10906/16811/suzuki_imds_operation_manual_4.1_
en.pdf/ce5e0b20-5141-4d27-b4e7-1a4c331a7fe6
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3.3 GHS: Globally Harmonised System regulation

3.3.1 OBJECTIVE
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Globally Harmonized System of Classification and Labelling of Chemicals (GHS), addresses

classification of chemicals by types of hazard and proposes harmonized hazard communication
elements through labels and Safety Data Sheets (SDS).

ANNEXURE-VI
3.3.2 Parts under the category of GHS

The following products, when supplied in separate sachets/ pouches/ bottles along with export
spare parts to EU, Japan and Australia are covered under GHS by MSIL.
i) Functional: Products that are mixtures (e.g. Oil, Paint, grease, adhesive, wind-washer
fluid, etc.) or products that contain substances intended for release from an article (e.g.
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Airbag Inflator, pretensioners, etc.).
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ii) Non-Functional: Packaging material (e.g. VCI Paper, VCI Bag, Desiccant, etc.)
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3.3.3 Process Flow for Suppliers

i) Identify & confirm usage of the GHS chemicals in export spare parts.
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ii) Submit SDS of the applicable chemicals to identify hazardous property.

iii) Ensure GHS Labels (if GHS product is Hazardous).
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iv) Stamp the supply carton as “GHS” Parts (if GHS product is Hazardous)
v) Incorporate GHS in PDI (if GHS product is Hazardous)
vi) Submit Report for Notification.
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3.3.4 Important characteristics of Safety Data Sheet (SDS) & GHS Label
Suppliers should ensure following things before submitting SDS to MSIL:
i) All SDS should be compliant to GHS or should be as per EU CLP Regulation 1272/2008;
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and/or Japan ISHL; and/or Australia WHS Act as requested by MSIL.

ii) All GHS Compliant SDS should have 16 Sections.
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iii) All SDS should be resubmitted after 5 years from their date of issue.
iv) Section 2 of the SDS should provide information about the hazards.
v) Label must be provided as per MSIL specified format in the following languages English,
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Japanese & 22 Other European Languages.

ANNEXURE-VI
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4. Conclusion
Till now Quality is an obligatory requirement in vehicle, parts and raw materials. However with
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stringent government regulations, it is our responsibility to adhere to these rules and standards
thereby ensuring a new category of Quality which is “Environment Quality”.
For SOC Declaration letter & Test Report refer Formats : VI.1, VI.2 and VI.3.
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Prepared by
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3rd Edition - January, 2020

2nd Edition - May, 2008
1st Edition - January, 1999
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Printed in India
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COPYRIGHT MARUTI SUZUKI INDIA LIMITED. All rights reserved.

All information provided herein is solely the Intellectual Property and Proprietary of
Maruti Suzuki India Limited and cannot be produced,
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reproduced or copied in any manner or form without the prior written consent of
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For any clarifications, contact :
Manager

Palam Gurgaon Road,
Gurgaon - 122015
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Palam Gurgaon Road, Gurgaon 122015 Haryana - India

MSIL - Vendor Quality Manual (VQM)

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d

MARUTI SUZUKI INDIA LIMITED

COPYRIGHT MARUTI SUZUKI INDIA LIMITED. All rights reserved.

Maruti Suzuki India Limited and cannot be produced,

MARUTI SUZUKI INDIA LIMITED

MARUTI SUZUKI INDIA LIMITED

VENDOR QUALITY ASSURANCE MANUAL i

16 Lot Control and Traceability............................................................................................... 117

19 Process Audit..................................................................................................................... 143

22 Quality Abnormality Measures........................................................................................... 161

25 Continual Improvement ..................................................................................................... 177

29 Sub vendor (Tier-2) Control............................................................................................... 209

Annexure – I Policy Guidelines for Vendors (Supplying Parts to MSIL)....................... 221

Annexure – III Dispatch Suspension System................................................................. 226

VENDOR QUALITY ASSURANCE MANUAL ii

1.3 Definitions of words and phrases used by MSIL.

VENDOR QUALITY ASSURANCE MANUAL 3

1.3.4 Functional Part:

1.5 Documents to be submitted to MSIL:

1.6 Model Codes:

& Functional parts / items.

1.7 Vendor Acknowledgement:

4 VENDOR QUALITY ASSURANCE MANUAL

VENDOR QUALITY ASSURANCE MANUAL 5

• Focus on human resource development, develop and maintain training procedures.

• Develop customer feedback monitoring and handling process.

• Monitor cost of Poor Quality.

• Adhere to problem containment and traceability procedure

VENDOR QUALITY ASSURANCE MANUAL 15

• MSIL related performance measures

• Internal / External audits results or findings

2.3 Nomination of Quality Assurance Incharge

2.3.2 Qualifications and selection of the QA Incharge:

16 VENDOR QUALITY ASSURANCE MANUAL

2.3.2.2 Deputy QA Incharge:

(4) Type of business:

Write the date of nomination or change of the Q.A. incharge(s).

received from MSIL.

VENDOR QUALITY ASSURANCE MANUAL 17

2.5 Communication of Requirement

2.6 Quality Management System Expectations

Quality Management Systems IATF 16949:2016 / ISO 9001:2015

2.7 Emergency Contact Information

18 VENDOR QUALITY ASSURANCE MANUAL

3. STARTING DEVELOPMENT OF PARTS

(c) Applicable standards (in the form of SES / International standards)

3.2 Technical Review Meeting

meeting will be informed to vendor, normally, 7 days in advance.

3.3 Specification Meeting:

VENDOR QUALITY ASSURANCE MANUAL 23

o Requirement of vendor drawing / prototype approval

o Flow of manufacturing process and important process control parameters

critical inner parts & raw material.

o Peak Production Verification Trial (PPVT) requirements

o Classification of , functional & general parts / items

24 VENDOR QUALITY ASSURANCE MANUAL

to the vendor by MSIL.

3.4 Development Monitoring

the progress of activities against MSIL development milestones at fixed intervals.

VENDOR QUALITY ASSURANCE MANUAL 25

3.7 Colour and Grain Approval

26 VENDOR QUALITY ASSURANCE MANUAL

4. Preparation & Control of Drawings