NOTICE OF SUSPECTED SHIPMENT OF NONCONFORMING PRODUCT (NONC)

TO: FROM (SUPPLIER NAME):

ATTN: SUPPLIER CODE:
ISSUE DATE: INITIATED BY:

MASS PRODUCTION PART TRACKING #: PART NAME:

SERVICE PART* (begin with 001) PART NUMBER:
COMMON PART? IF YES, WHO ELSE? SEND NOTICE
PROBLEM DESCRIPTION AND SKETCH: Y N TO ALL PARTIES

MODEL: ISSUE DATE:

FIRST SHIPMENT OF SUSPECT PARTS

LAST SHIPMENT OF SUSPECT PARTS

SHIPMENT IDENTIFICATION #
(FRS/ORDER/MANIFEST/ETC.)

TOTAL QUANTITY OF SUSPECT

PARTS SHIPPED
ESTIMATED QUANTITY OF
NONCONFORMING PARTS
HOW TO IDENTIFY SUSPECT PARTS:

SUPPLIER PERSONNEL SUPPORT AT NAMC:

NAME TITLE ARRIVAL DATE ARRIVAL TIME REMARKS:
/ /
/ /
/ /
PLANNED DISPOSITION AT NAMC: REMARKS
(INSPECTION/REWORK METHOD):
SORT SUSPECT PARTS REWORK NONCONFORMING PARTS

SCRAP SUSPECT PARTS SCRAP NONCONFORMING PARTS

TEMPORARY COUNTERMEASURE AT SUPPLIER: SHIPMENT IDENTIFICATION METHOD:

(INVENTORY AND CURRENT PRODUCTION)

IMPLEMENTATION DATE: / /
SUPPLIER NAMC QC/QE*
QC RECEIVING INSPECTION COPY PC
* FOR SERVICE PARTS SUBMIT TO TMNA-PC Form workbook 4-3.1 Issue 6 ; Rev A
 NOTICE OF SUSPECTED SHIPMENT OF NONCONFORMING PRODUCT (NONC)

TO: FROM (SUPPLIER NAME):

ATTN: SUPPLIER CODE:
ISSUE DATE:
1 INITIATED BY:

MASS PRODUCTION PART TRACKING #: PART NAME:

SERVICE PART* (begin with 001) PART NUMBER:
COMMON PART? IF YES, WHO ELSE? SEND NOTICE
PROBLEM DESCRIPTION AND SKETCH: Y N TO ALL PARTIES

MODEL: ISSUE DATE:

FIRST SHIPMENT OF SUSPECT PARTS

LAST SHIPMENT OF SUSPECT PARTS

SHIPMENT IDENTIFICATION #
(FRS/ORDER/MANIFEST/ETC.)

2
TOTAL QUANTITY OF SUSPECT
PARTS SHIPPED
ESTIMATED QUANTITY OF
NONCONFORMING PARTS
HOW TO IDENTIFY SUSPECT PARTS:

SUPPLIER PERSONNEL SUPPORT AT NAMC:

NAME TITLE ARRIVAL DATE ARRIVAL TIME REMARKS:
/ /
/ /
/ /
PLANNED DISPOSITION AT NAMC: 3 REMARKS
(INSPECTION/REWORK METHOD):
SORT SUSPECT PARTS REWORK NONCONFORMING PARTS

SCRAP SUSPECT PARTS SCRAP NONCONFORMING PARTS

TEMPORARY COUNTERMEASURE AT SUPPLIER: SHIPMENT IDENTIFICATION METHOD:

(INVENTORY AND CURRENT PRODUCTION)

IMPLEMENTATION DATE: / /
SUPPLIER NAMC QC/QE*
QC RECEIVING INSPECTION COPY PC
* FOR SERVICE PARTS SUBMIT TO TMNA-PC Form workbook 4-3.1 Issue 6; Rev A
 MODEL: KATASHIKI: SUPPLIER RESPONSE
Countermeasure:

PART NUMBER: PART NAME: QUALITY IMPROVEMENT REQUEST (QIR)

DATE FOUND: VIN / SEQ / BODY #:

ISSUE TO:
DEPT./SUPPLIER: DEPT./SUPPLIER:
DESCRIPTION:

CODE: CODE:

ATTN: ATTN:

MSKETCH:
ODEL: REQUEST:
987T M C X10L-AEP GKA

QUALITY IMPROVEMENT REQUEST

Response(QIR)
Required 4
P AR T NUM B ER : P AR T NAM E:
Supplier Action Only - No Response

DEPT./SUPPLIER: DEPT./SUPPLIER:

ATTN: ATTN:

1
2

RIVET MISSING

SORT RESULTS
QTY INSP QTY NG QTY REJECT/SCRAP

IMPROVEMENT PLAN
C/M Date: C/M parts @ NAMC

5
NAMC
QTY INSP
SORT RESULTS
QTY NG QTY REJ ECT/SCRAP
RESPONDING DEPT. (SUPPLIER, DESIGN, NAMC)
# INSP # OK # USE AS IS # REWORK # REJECT APPROVER APPROVER APPROVER ORIGINATOR
TITLE

DATE CODE STAMP

C/M Date:
6 C/M p arts @ NAM C
Sign &
ORIGINATOR (IF NOT QC/QE)
8 Name
APPROVER APPROVER APPROVER ORIGINATOR Send Reply To: RESPONDING DEPT. (SUPPLIER, DESIGN, NAM C)
Date / / / / / / / /
TITLE
7 QIR RESPONSE: q ACCEPTED q REJECTED
NAMC QC/QE
Sign & Due Date:
ORIGINATOR (IF NOT QC/QE) SIGN &
Name APPROVER APPROVER APPROVER ORIGINATOR
APPROVED APPROVED CHECKED ORIGINATOR
Date / / / / / / / / QIRQUALITY
RESPONSE:CATEGORY TITLE
TITLE
NAMC QC/QE CODE
3 AREA CODE NAM C AREA
QC/QE
SIGN & APPROVED APPROVED CHECKED Sign
ORIGINATOR &
DATE / APPROVER
/ / / APPROVER
/ / APPROVER
/ / ORIGINATOR 01
QUALITY CATEGORY SPECIFICATION TITLE 09 BRAKES Name
TITLE NAM C QC/QE CODE AREA CODE02 REGULATION
AREA 10 TEMPERATURE CONTROL Date / / / / / / / /
APPROVED APPROVED CHECKED ORIGINATOR 01 SPECIFICATION 09 SIGN &
03 WIND NOISE 11 ELECTRICAL & ACCESS ORIGINATOR CONFIRMATION
Sign
TITLE & 02 10 TEM PERATURE CONTROL DATE / / / / / / / /
Name 03 WIND NOISE 11 04 ELECTRICAL
WATER LEAKS
& ACCESS 12 INTERIOR
ORIGINATOR CONFIRM ATION APPROVER APPROVER APPROVER ORIGINATOR STATUS
SIGNDate
& / / / / / / 04 WATER LEAKS
/ / 12 05 INTERIOR
SQUEAKS & RATTLES APPROVED
13 APPROVED CHECKED
EXT. PAINT ORIGINATOR
& MOLDING STATUS
TITLE
DATE 10 /15/19 9 7 10 /15/19 9 7 10 /15/19 9 7 10 /15/19 9 7 05 SQUEAKS & RATTLES 13 EXT. PAINT & M OLDING TITLE 01 OK
QIR NO: EMAIL DATE: Copy additional NAMC(list)___________
06 14
06 BODY STEERING & HANDLING
SIGN &
14 BODY 01 OK
Sign &
q q YES q COORDINATING 07 ENGINE 15 AXLE 02
Name NOT
NO Y 02
q NO q SqEC ONDAR q 0 8 SECONDARY
TRANSM ISSION 16 08 OTHERTRANSMISSION
( ) / /16 /OTHER
/ / ( / / / )EF F EC TIVE
Date / / / / / / / / EFFECTIVE

Q IR R O UT IN G : (C OP Y) Form 2.14-1: Issue 4, Rev.B Form workbook 4-3.1 Issue 6 ; Rev A

QC R I QC /QE

S UP P LIER
(OR IGINAL)
 MODEL: KATASHIKI: SUPPLIER RESPONSE
Countermeasure:

PART NUMBER: PART NAME: QUALITY IMPROVEMENT REQUEST (QIR)

DATE FOUND: VIN / SEQ / BODY #:

ISSUE TO:
DEPT./SUPPLIER: DEPT./SUPPLIER:
DESCRIPTION:

CODE: CODE:

ATTN: ATTN:

MSKETCH:
ODEL: REQUEST:
987T M C X10L-AEP GKA

QUALITY IMPROVEMENT REQUEST

Response(QIR)
Required 4
P AR T NUM B ER : P AR T NAM E:
Supplier Action Only - No Response

4
2
DEPT./SUPPLIER: DEPT./SUPPLIER:

1
1 ATTN: ATTN:

RIVET MISSING

SORT RESULTS
QTY INSP QTY NG QTY REJECT/SCRAP

IMPROVEMENT PLAN
C/M Date: C/M parts @ NAMC

5
NAMC
QTY INSP
SORT RESULTS
QTY NG QTY REJ ECT/SCRAP
RESPONDING DEPT. (SUPPLIER, DESIGN, NAMC)
# INSP # OK # USE AS IS # REWORK # REJECT APPROVER APPROVER APPROVER ORIGINATOR
TITLE

DATE CODE STAMP

C/M Date:
6 C/M p arts @ NAM C
Sign &
ORIGINATOR (IF NOT QC/QE)
8 Name
APPROVER APPROVER APPROVER ORIGINATOR Send Reply To: RESPONDING DEPT. (SUPPLIER, DESIGN, NAM C)
Date / / / / / / / /
7
TITLE
3 QIR RESPONSE: q ACCEPTED q REJECTED
NAMC QC/QE
Sign & ORIGINATOR (IF NOT QC/QE) Due Date: SIGN &
Name APPROVER APPROVER APPROVER ORIGINATOR
APPROVED APPROVED CHECKED ORIGINATOR
Date / / / / / / / / QIRQUALITY
RESPONSE:CATEGORY TITLE
TITLE
NAMC QC/QE CODE
3 AREA CODE NAM C AREA
QC/QE
SIGN & APPROVED APPROVED CHECKED Sign
ORIGINATOR &
APPROVER APPROVER APPROVER ORIGINATOR 01 SPECIFICATION 09 BRAKES Name
5
DATE / / / / / / / / QUALITY CATEGORY TITLE
TITLE NAM C QC/QE CODE AREA CODE02 REGULATION
AREA 10 TEMPERATURE CONTROL Date / / / / / / / /
APPROVED APPROVED CHECKED ORIGINATOR 01 SPECIFICATION 09 SIGN &
03 WIND NOISE 11 ELECTRICAL & ACCESS ORIGINATOR CONFIRMATION
Sign
TITLE & 02 10 TEM PERATURE CONTROL DATE / / / / / / / /
Name 03 WIND NOISE 11 04 ELECTRICAL
WATER LEAKS
& ACCESS 12 INTERIOR
ORIGINATOR CONFIRM ATION APPROVER APPROVER APPROVER ORIGINATOR STATUS
SIGNDate
& / / / / / / 04 WATER LEAKS
/ / 12 05 INTERIOR
SQUEAKS & RATTLES APPROVED
13 APPROVED CHECKED
EXT. PAINT ORIGINATOR
& MOLDING STATUS
TITLE
DATE 10 /15/19 9 7 10 /15/19 9 7 10 /15/19 9 7 10 /15/19 9 7 05 SQUEAKS & RATTLES 13 EXT. PAINT & M OLDING TITLE 01 OK
QIR NO: EMAIL DATE: Copy additional NAMC(list)___________
06 14
06 BODY STEERING & HANDLING
SIGN &
14 BODY 01 OK
Sign &
q q YES q COORDINATING 07 ENGINE 15 AXLE 02
Name NOT
02
q NO q Sq NO Y
EC ONDAR q 0 8 SECONDARY
TRANSM ISSION 16 08 OTHERTRANSMISSION
( ) / /16 /OTHER
/ / ( / / / )EF F EC TIVE
Date / / / / / / / / EFFECTIVE

Q IR R O UT IN G : (C OP Y) Form 2.14-1: Issue 4, Rev.B Form workbook 4-3.1 Issue 6; Rev A

QC R I QC /QE

S UP P LIER
(OR IGINAL)
 Quality Problem Report (QPR) / Quality Improvement Request (QIR)
llPROTECTED 関係者外秘
Issue To: Document Tracking # Reply To:
Supplier Codes: Department:
Response By: NCD Type Rank LTCM Plan Due Resp QC/QE:
Email: Email:
Response Required

Part Name: Part Number: Model:

Katashiki: Criteria: Non-Conformity Description: Call Location: Resp. QC/QE:

Date Problem Found: Shift: Shipping/Mfg Date: Occurrence: q First Time q Recurrence Direct Supply: qY qN
Previous NCD #: PPO: qY qN
Where NC Found: Order # : Date Closed: Common Part: qY qN
If yes, who else?
SQA Rank: Other ID:
Will Parts Be Quarantined? q Yes q No Issue Report to all NAMCs using this part

DESCRIPTION OF NONCONFORMITY (WITH SKETCH):

Standard: Actual:

> Standard Image< >Actual Image<

Part No. Color # Insp # OK Use Rework Reject Scrap Tag No. Sort Time Rework Time

CONTACT MADE BY... NAMC: Supplier: Date/Time:

Temporary Countermeasure Plan: Supplier Sort Results:

Mfg. Date
(Qty NG/Qty Insp) /
/
INFORMATION PROVIDED

Raw Material
Finished Goods /
BY SUPPLIER

APPROVALS
Action Name Date

Implementation Date: Effective Arrival Date:

ID Method for STCM Parts: ID for STCM Parts:

NAMC QC/QE Opinion: Document Tracking #: Official Issuance Date:

APPROVALS Action Name Date

Form workbook 4-3.1 Issue 6; Rev A

llPROTECTED 関係者外秘Quality Problem Report (QPR) / Quality Improvement Request (QIR)
Issue To: Document Tracking # Reply To:
Supplier Codes: 1 Department:
Response By: NCD Type Rank LTCM Plan Due Resp QC/QE:
Email: Email:
Response Required

Part Name: Part Number: Model:

Katashiki: Criteria: Non-Conformity Description: Call Location: Resp. QC/QE:

2
Date Problem Found: Shift: Shipping/Mfg Date: Occurrence: q First Time q Recurrence Direct Supply: qY qN
Previous NCD #: PPO: qY qN
Where NC Found: Order # : Date Closed: Common Part: qY qN
If yes, who else?
SQA Rank: Other ID:
Will Parts Be Quarantined? q Yes q No Issue Report to all NAMCs using this part

DESCRIPTION OF NONCONFORMITY (WITH SKETCH):

Standard: Actual:

3
> Standard Image< >Actual Image<

Part No. Color # Insp # OK Use Rework Reject Scrap Tag No. Sort Time Rework Time

CONTACT MADE BY... NAMC: Supplier: Date/Time:

Temporary Countermeasure Plan: Supplier Sort Results:

Mfg. Date
(Qty NG/Qty Insp) /
/
INFORMATION PROVIDED

Raw Material
Finished Goods /
BY SUPPLIER

APPROVALS
4 Action Name Date

Implementation Date: Effective Arrival Date:

ID Method for STCM Parts: ID for STCM Parts:

NAMC QC/QE Opinion: Document Tracking #: Official Issuance Date:

5
APPROVALS Action Name Date

Form workbook 4-3.1 Issue 6; Rev A

llPROTECTED 関係者外秘 Long Term Countermeasure Reply

Issue To: NCD Type: Reply To:

Supplier Codes: Department:
Response By: Document Tracking #: Resp QC/QE:
Email: Email:
Part Name: Part Number: Model:

LTCM Plan Due: LTCM Plan Submitted: Original LTCM Actual Due: Revised LTCM Actual Due: LTCM Actual Submitted:

A. Root Cause of Nonconformance: Why Made Category:

Activity Responsible Planned Actual

B. Root Cause of Non-Detection: Why Shipped Category:

Activity Responsible Planned Actual

C. Nonconformance Recurrence Prevention:

Required SQAM Documentation Responsible Planned Actual

Inspection Standard Change
MQC Update

Method for Confirming Countermeasure Effectiveness (and Results): ID Method for LTCM Parts:

ID for LTCM Parts:

The first shipment of permanent countermeasured parts must be identified with a securely attached 5x7 green Certified Stock Tag located in the Toyota KANBAN indicating the
related QPR #, nonconformance description and ship date of the countermeasured parts (tag can be located in SQAM).

Sort Results
Qty Suspect: Qty OK: Qty NG: Qty Rework:

Implementation Date: Effective Arrival Date: Parts Confirmed Date:

APPROVALS Action Name Date

Form workbook 4-3.1 Issue 6; Rev A

llPROTECTED 関係者外秘 Long Term Countermeasure Reply

Issue To: NCD Type: Reply To:

Supplier Codes: Department:
Response By: Document Tracking #: Resp QC/QE:

Part Name:
Email:
Part Number:
1 Email:
Model:

LTCM Plan Due: LTCM Plan Submitted: Original LTCM Actual Due: Revised LTCM Actual Due: LTCM Actual Submitted:

A. Root Cause of Nonconformance: Why Made Category:

Activity Responsible Planned Actual

B. Root Cause of Non-Detection: Why Shipped Category:

Activity Responsible Planned Actual

C. Nonconformance Recurrence Prevention:

Required SQAM Documentation Responsible Planned Actual

Inspection Standard Change
3
MQC Update

Method for Confirming Countermeasure Effectiveness (and Results): ID Method for LTCM Parts:

ID for LTCM Parts:

The first shipment of permanent countermeasured parts must be identified with a securely attached 5x7 green Certified Stock Tag located in the Toyota KANBAN indicating the
related QPR #, nonconformance description and ship date of the countermeasured parts (tag can be located in SQAM).

4
Sort Results
Qty Suspect: Qty OK: Qty NG: Qty Rework:

Implementation Date: Effective Arrival Date: Parts Confirmed Date:

APPROVALS Action Name Date

5
Form workbook 4-3.1 Issue 6; Rev A
 Parts Nonconformance Handling Forms Explanation

Document Item # Description Who

Key Contact & Supplier Information: Information needed regarding Toyota Quality (Coord.
1
Mfr.) contact and supplier identification.
Part & Problem Information: Key part identification information, problem description &
2
suspect part details, etc.
NONC Supplier Submission
NAMC Supplier Support & Disposition: Detail regarding supplier support and planned
Supplier
3
disposition activity.
Temporary C/M: Temporary countermeasure activities to prevent occurrence of issue and
4
necessary shipment identification.
Part and Problem/Situation Information & Issuance Detail: Key part identification
1 information (part number/name, vehicle), problem/situation description, and issuance
information (originator/NAMC approvals, QIR #, email date, etc).

Supplier Contact Info & Toyota Request: Key supplier identification & contact information.
2
Specific Toyota request to supplier regarding problem/situation & whether a response is
Problem / Situation Description required or not. Toyota

NAMC Sort, Reply Contact & Due Date, Quality Category: Results of NAMC sort (total #
parts inspected: how many designated OK, used as is, reworked, or rejected).
3
Key Toyota contact to reply to and reply due date.
QIR (pre-
production) Quality category of problem/situation.

Countermeasure Detail / Improvement Plan, Sort Results, Approvals: Supplier

countermeasure detail, include countermeasure date & when countermeasure parts shall
arrive at the NAMC in the improvement plan.

Supplier Response 4 Share results of Supplier sort activity (total # parts inspected: how many no good, Supplier
rejected/scrapped).

Supplier signatures/approval, at least 2 levels of signature required (the document originator

Submission Approvals
and a higher level of management).
Toyota Approvals: Toyota Quality (Coord. Mfr.) signatures and dates of approval. Includes
5 Toyota
originator confirmation whether status is effective or not effective.
Identification Information: Indicates the LTCM Plan Reply Due Date (within 15 calendar
days from official issuance if a response is required), NAMC contact information, supplier
information, rank (based on severity of the problem), and if a response is required (QPRs
1
require a response, however, Toyota Quality (Coord. Mfr.) may designate 'no response
required' for QIRs). The NCD number is based on the NAMC and/or supplier location and
sequential number.

Part and Non-Conformity Description: Describes the Part (Name, Number, history,
actions taken, common part, PPO, direct supply), model version, problem description
(criteria, date found, shift, location, where NC found, non-conformity description, responsible
QC/QE) and traceability information (shipping/mfg date).

2 criteria: describes the standard used to make judgment (e.g., I/S, drawing, TIS, boundary
sample, or other); an explanation is required if "other" is listed
Problem Description Toyota
where NC found: describes the NAMC specific location of where the non-conformance was
found. If 'SQA' is selected, then the corresponding 'SQA Rank' will display. If 'SQA' is not
selected, then 'N/A' will be displayed.
QPR / QIR
Detailed Non-Conformity Description: Explains the details of the nonconformance.

Actual: describes the part non-conformance as quantitatively as possible (e.g., hole #4 depth
= 13mm, connector pin broken, etc.)
3
Standard/Spec: specific line item from Criteria (e.g., per I/S hole #4 depth = 15±0.3mm, per
I/S requirement #8 - no broken pins allowed, etc.)

Describes the part (number, color, actions taken) including NAMC and supplier information.

Temporary Countermeasure Plan: Indicate the STCM countermeasure details with

STCM Response 4 implementation date (within 24hours after initial issuance date of an NCD) with the Supplier
respective approvals (action, name, date, implementation, ship date, ID) and sorting results.

5 QC/QE Comments: Indicates the specific requests by the Toyota Quality (Coord. Mfr.)
Toyota Response Toyota Approvals: Indicates the actions taken after analyzing the countermeasure plan Toyota
6
submitted by supplier including signatures and dates of approval.
Identification Information: Indicate the NCD type, Document Tracking number, Toyota
1 Quality (Coord. Mfr.) and supplier contact information. Indicate the part name, number,
model. Due dates and submitted dates to be displayed.
 Parts Nonconformance Handling Forms Explanation

Document Item # Description Who

Why Made / Why Shipped: If LTCM Actual is unknown, then list the short term plan
activities (investigation and containment) with responsibility and plan completion date.

Once LTCM Actual is known, document the Root Cause of "Why Made" and "Why Shipped."

Identify the category for "Why Made" and "Why Shipped."

Attach method for determining Root Cause (e.g., 5-why analysis, fishbone diagram, etc.)

Root Cause & Countermeasure Update the risk analysis (PFMEA or equiv.), with the findings.
Identification
2 Document any countermeasure(s) with responsibility and plan and actual completion dates.

Note1: If permanent countermeasure is not determined within 15 days:

1) The supplier is expected to provide a summary of activities, schedule of completion, and
planned completion dates.
2) Resubmission of the form is required upon completion of the countermeasure plan.
Supplier
Note2: For changes:
LTCM 1) Meeting the PCR standard submit a PCR.
2) Not meeting the PCR standard and:
a) To the MQC, submit to the Toyota Quality (Coord. Mfr.) for review.
b) To the I/S, submit an I/S Change Request Form

Recurrence Prevention: Identify if the I/S and MQC require updates related to the
3 countermeasure(s). Document responsibility with plan and actual completion dates. Attach
drafts of the updated documents.

Verification: Verify the countermeasure(s) prevent nonconforming product.

Use the "Special" column controls from the MQC and enhanced part inspection from the I/S
Recurrence Prevention and to mitigate against further flowouts.
Countermeasure Verification
4 Document the results to prove the countermeasures are effective in preventing recurrence of
the issue.

Yokoten Plan (Spread Learning): Determine if any of the countermeasures implemented

can be shared anywhere within your plant or at another facility within your company and
document your plan to implement.

Supplier and Toyota Approvals: Supplier and Toyota Quality (Coord. Mfr.) signatures and Supplier &
Submission Approvals 5
dates of approval. Toyota

Form workbook 4-3.1 Issue 6; Rev A

 CERTIFIED STOCK TAG

container on the Kanban holder side.

SPECIAL NOTE: Please securely attach this tag to the
PART NUMBER (#):

PART NAME:

NON-CONFORMANCE:

QPR / QIR NUMBER (#):

PART CERTIFICATION ID:

CERTIFIED BY: CERTIFICATION DATE:

QC VERIFICATION BY : (AT SUPPLIER LOCATION)

Form workbook 4-3.1 Issue 6; Rev A

Legend:
Yellow = Temporary C/M
Green = Permanent C/M