Overall Process RobustnessScore

Max
Actual Audit
C : Part Specific Process Robustness Requirements Possible Score in %
Score
Score

Supplier Name : IPEC India Pvt Ltd Unit : /

Audit Date : 3.3.2023
Plant : Bangalore
Part no : TVSIPPC750 Part name : Charger Model(S) : ECN Ref :
Score
Max
Process Applicable Actual Audit
Possible
# Process Name Applicable - Audit Score : Score in % Remarks
Score 0's 1's 2's 3's
Yes / No Points
(A) (B) ( C) (D)
1 Aluminum Die Casting NO
Aluminium Machining
2
Process NO
3 Cast Iron NO
4 Hot & Cold Forging NO
5 Steel Machining NO
6 Pastic & Injection Molding NO
Procees Martix 7
Rubber & Injection Molding NO
8 Pressing NO
9 Welding NO
10 Painting / Coating (ED) NO
11 Plating Process (Metal) NO
12 Heat Treatment NO
13 Anodizing NO
14 Assembly Process YES
15 Electronics Parts Proces NO
16 Electrical Parts YES
17 Others (Specify)
20
Total
1) Process name : Pressure Die Casting ( LPDC / PDC - Aluminum ) - Applicable / Not Applicable
Score
Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)

Class Check Points Remarks

C1.1 Storage/ Identification / FIFO for each Aluminum Material.

1
Raw Material Aluminum INGOT Management ,Spec record /Management
C1.2 0
control state ( Property, structure ,inner bubble, surface contraction )
Aluminum INGOT property management ( CROSS
C1.3
CHECK/Property analysis sheet / part accept/not )
Operation Standard record & observe status (Melting temp /
C1.4
DROSS treatment /elimination of gas )
Casting operation Standard record & observe status (
C1.5
temperature,pressure,speed,position,TIME )
Sand Bath (optional allowance of the number of SHOT/high-low
C1.6
speed) Operation standard record & observe status.
Establishing the regular inspection /post/observation-self
C1.7
inspection
C1.8 Traceability system implementation
Process
C1.9 Sand Bath Problem /LOSS treatment & proportion
Management
Water Balance / Cooling water Leakage / Confirm water input &
C1.10
management to CAVITY / oil leak check
Managing sub-material( TIP OIL use amount , use of mold
C1.11
release spray dilution rate, position & amount of spray )
Process quality problem history management( establishing
C1.12
improvement for quality problem / action )- Trend Management
C1.13 Process inspection equipment management - (Calibration)

C1.14 Workplace 3C5S .

C1.15 Managing equipment history ( problem/improvement )

C1.16 Equipment's daily/regular check according to CHECK SHEET

Managing the repair SPARE PART ( quality guarantee SPARE
C1.17
PART )
Mould SHOT number and lifetime each metal mold & record
C1.18
(classification)
Storage of mold( preparation repair/produce/produce after
C1.19
quality/AS )
C1.20 Mould repair SPARE PART Management
Mould regular repair performance status.(Preventive , planned
C1.21
maintenance status)
Is Supplier having Nitrogen - Gas Striing Facility for Molten
C1.22
Material De-Gasing .

Classification: Public
 Is Supplier having "DM / RO" water plant facility for Die Sparay /
C1.23
Coolant water jackets
Facility Is Supplier is having 3D Compatable CMM Facility for
Management C1.24
Measurement
Is Supplier is having Software Simulation Facilites ( Like Magma
C1.25
Analysis )
C1.26 Is Supplier is having "X" - Ray Facility to detect the Blow Holes .
Is Supplier is having dedicated "Tool Room" facility to conduct
C1.27
Preventive Maintenance activities
Is all the PDC Machines having Closed Circuit of "Auto " Molten
C1.28
Material filling Facility
Is Supplier is having "Proof" Machining Facility ( If Supplies as
C1.29
Cast Condition )
Is Supplier is having "Spectrum " - Chemical Analyser to verify
C1.30
the Chemical Composition
Is Supplier is having Masters certified by "NABL" accredidated
C1.31 lab t for "Spectrum " - Chemical Analyser to verify the Chemical
Composition
Is Supplier is having the System of "Fixture Calibiration " for
C1.32
Machining Jigs / Fixtures
C1.33 Observation for inspection agreement
Material Dimension Inspection Result History management (
C1.34
cutting inspection )
Final Inspection
C1.35 Countermeasure & Availability status on Customer complaints.
Measurement Machine/equipment Management State (
C1.36
Calibration status )
Total

2) Process name : Aluminium Machining Process

Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)
Class Check Points Remarks

C 2.1 Is CNC Machines available in line

C 2.2 Is Auto Offset Program Facility avaialble in all CNC Machines

C 2.3 IS X Bar R Chart Facility avaialble

C 2.4 Is Leak test facility available all the Machined Engine Parts

C 2.5 Is Auto Tool life Monitoring & Alram System Available

Is Pacakaging validation System availbale for Machined Parts (
C 2.6
Like Palletisation , Single Layer Packing Etc )
C 2.7 Is CMM Facility Available with 3D Compactability

Is IOT / on-line SPC System available with machine auto shut

off / Mobile Escalation facilty on abnormaliites for both Process
C 2.8
/ Product parameters
Is CMM reports - Direct on line updation to TVS-M Portal / SAP
C 2.9
linkage facility is available .
Is Lay out inspection report - Direct on line updation to TVS-M
C 2.10
Portal / SAP linkage facility is available .
3 ) Process name : Cast Iron - Applicable / Not Applicable
Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

Class Check Points Remarks

Is incoming inspection for material executed (hardness,

C 3.1
moisture, grain size ,RCS ,bond)
Material MILL SHEET receipt (subsidiary material included), actions in
C 3.2
accordance with defects
C 3.3 3C 5S at Storage area (warehouse)

C 3.4 Work standards and operator knowledge

Electric furnace (Entrance Furnace) Temperature and
C 3.5
Equipment Standard and Observance /Record Management
Standardizing and recording inoculants, managing painting
C 3.6
(Squeeze, LADLE)
C 3.7 Set & implementation of CORE diagram standard (limit sample)
Mixing management of moulding sand and
C 3.8
bond(bond,lead,starch etc) & treatment management (treatment
Control cycle time & implementation of molding property
C 3.9
Process Control (moisture,compression etc.)
Core/molding BURR status (including operation standard
C 3.10
installation status)
Traceability in case of problems occurrence(LOT control by
C 3.11
material,shift , cavity)
Implementation status of In process self-inspection (Standards
C 3.12
and reports , operator demonstration )-important process/item

Classification: Public
 NC parts storage activity in the process and analysis , action
C 3.13
and trend.

C 3.14 3C 5S status & cyclone ( precipitate equipment ) at workplace

Periodical & Daily check on equipment (items arrangement &

C 3.15
Inspection status, action status against problems)
Setting up standard of electric furnace & Heat furnace
ReLINIING (Charge Furnace) Standard State(T/OUT,Charge
C 3.16
Furnace Daily Record-Full Charge After Production Quantity
Installation Management)
Control Management of history of equipment, operation and securing
C 3.17
parts
Management status on re-usage of moulds (periodical check in
C 3.18
case of outsourcing of core, mold)
Setting up and managing Inspection standard PIN/BUSH
C 3.19
Imported (size, heat treatment, ingredient)
Element evaluation standard after melting and action through
C 3.20
analysis
Sufficiency of machining margin on machined section(ex.over
C 3.21 0.5mm- on a drawing basis : material drawing & machining
drawing)
C 3.22 Machining control criteria & control status by cutting test

Final Inspection MISMATCH match between upper and lower shapes) (ex.,
C 3.23
within 0.5mm-material tolerance control)

Inspection agreement & inspection criteria for finished parts/

C 3.24
implementation/ measuring equipment validation status

Effectiveness of corrective Action Plan- are defect repeats ? , is

C 3.25
there fool proof action

Storing and moving of incoming part (Specified BOX/ tonnage /

C 3.26
segregated place / NO RUST / DUST )

Raw Material Incoming Inspection standards and inspection reports and

C 3.27
material test report

C 3.28 Proper identification & Systematic First In-First Out ( Lot wise )
Availability of Working Standard and execution (matching with
C 3.29
actual working)
Identification , Management of major machining process which
C 3.30
effect product quality
C 3.31 Education, Skill of Workers
Inspection-facility operating Check / Using of Limit sample /
C 3.32
Keeping First , Middle , Last samples
Clamp , tools ( drills , taps etc., ) condition check &
C 3.33
replacement , recording , TOOL Counter management , tool life

Defective , rework Component identification , segregation &

Process C 3.34
management
Control
Process defective Aggregation/Counter measure
C 3.35
plan/Validity/Field level Feedback

C 3.36 Illumination of Workplace

C 3.37 Traceability system availability

Press machine management ( Oil leak , Burr control , Gauge
C 3.38
condition etc., )
C 3.39 Calibration status of Inspection Gauges

C 3.40 Change over setup control

Daily / Periodical Inspection of machines execution (Including
C 3.41
Preventive Maintenance Activity)
C 3.42 Chucks & Tools storing & maintenance

C 3.43 Spare Part possession when Abnormality outbreak comes

Is Supplier having adequate facility for Molten Material De-
C 3.44
Gasing .
Is Supplier is having 3D Compatable CMM Facility for
C 3.45
Measurement
Is Supplier is having adequate Software Simulation Facilites to
C 3.46
verify the Mold Flow Analysis
C 3.47 Is Supplier is having "X" - Ray Facility to detect the Blow Holes .
Facility Control Is Supplier is having dedicated "Tool Room" facility to conduct
C 3.48
Preventive Maintenance activities
Is all the Machines having Closed Circuit of "Auto " Molten
C 3.49
Material filling Facility
Is Supplier is having "Proof" Machining Facility ( If Supplies as
C 3.50
Cast Condition )
Is Supplier is having "Spectrum " - Chemical Analyser to verify
C 3.51
the Chemical Composition
Is Supplier is having Masters certified by "NABL" accredidated
C 3.52 lab t for "Spectrum " - Chemical Analyser to verify the Chemical
Composition

Is Supplier is having the System of "Fixture Calibiration " for

C 3.53
Machining Jigs / Fixtures
Standardization, execution of end product inspection (as per
C 3.54
Inspection Agreement)

Classification: Public
 Illumination of Inspection place, installment of limit sample for
C 3.55
Good and Non-Confirming parts

C 3.56 Using of Statistical Technique in process (run chart)

Confirmation through Measuring machine , Gage R & R of
C 3.57
operators
C 3.58 Standardization of Pallets , Trolley & rust prevention

Final Inspection C 3.59 FIFO control of Finished parts

Correction for customer complaints , Validity of Complaints ,

C 3.60
Poka yoke for complaints
Is IOT / on-line SPC System available with machine auto shut
C 3.61 off / Mobile Escalation facilty on abnormaliites for both Process
/ Product parameters
Is CMM reports - Direct on line updation to TVS-M Portal / SAP
C 3.62
linkage facility is available .

Is Lay out inspection report - Direct on line updation to TVS-M

C 3.63
Portal / SAP linkage facility is available .

4 ) Process name : Hot & Cold Forging Process - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable
Class Check Points Remarks

C 4.1 Storage & Management (Rust, Scratch etc.)

Inspection Standard ( Dimension, Scratch)/(including LP H/T :
C 4.2
Cold Forging )
Raw Material
C 4.3 Material Testing facilities and verification/approval

C 4.4 Managing MILL SHEET(Self Inspection/Mill Sheet/None)

C 4.5 Working Standard Management

C 4.6 Managing & Recording Cut Material

C 4.7 Following Heat Treatment Condition for Forging

C 4.8 Working Condition for Forging & recording

Process Frequency Inspection for Forging Parts ( start, mid, final aspect ,
C 4.9
Management size )
C 4.10 Marking to prevent Mixed up part , stage vise identification

C 4.11 Tracking system in case of problem.

Check & Correct Wrong Process & improve., process rej trend
C 4.12
and analysis
C 4.13 Working environment , lighting , cleanliness

C 4.14 Recording Each Equipment History

Regular & Preventive maintenance (Including Heat Treatment
C 4.15
Line)
Equipment
C 4.16 Each Gage Status , verification and approval
Management
C 4.17 Mould / Die Storage , spare part management

C 4.18 Inspection of Grain Flow Pattern when Manufacturing moulds

Is Supplier si having adequate "Crack " detection Facility ( Like

C 4.19
X Raj / Magna Flux / Ultra Sound test Etc )

Is Supplier is having 3D Compatable CMM Facility for

C 4.20
Measurement ( Mainly for Machined Parts )

Is Supplier is having adequate Software Simulation Facilites to

C 4.21
verify the Mold Flow Analysis

Is Supplier is having dedicated "Tool Room" facility to conduct

C 4.22
Preventive Maintenance activities

Facility Control Is all the Machines having Closed Circuit of "Auto " Molten
C 4.23
Material filling Facility

Is Supplier is having "Proof" Machining Facility ( If Supplies as

C 4.24
Cast Condition )

Is Supplier is having "Spectrum " - Chemical Analyser to verify

C 4.25
the Chemical Composition

Is Supplier is having Masters certified by "NABL" accredidated

C 4.26 lab t for "Spectrum " - Chemical Analyser to verify the Chemical
Composition

Classification: Public
 Is Supplier is having the System of "Fixture Calibiration " for
C 4.27
Machining Jigs / Fixtures

C 4.28 Machining Margin (over 0.5mm)

C 4.29 Cracking Inspection by MPI

C 4.30 Mismatch and burr, dent (under 0.5mm)

Final
C 4.31 Inspection of Structure & Hardness of Heat Treated parts
Inspection
C 4.32 Inspecting Dimension & appearance, Inspection Report

C 4.33 Inspection Agreement, Repairing Measurement M/C

C 4.34 Effectiveness of corrective Action Plan

5) Process name : Steel ( Forging / Bars / Tubes / Sheets Etc ) Machining Process

Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)
Class Check Points Remarks

C 5.1 Is CNC Machines available in line

C 5.2 Is Auto Offset Program Facility avaialble in all CNC Machines

C 5.3 IS X Bar R Chart Facility avaialble

C 5.4 Is Leak test facility available all the Machined Engine Parts
Machiining
C 5.5 Is Auto Tool life Monitoring & Alram System Available

Is Pacakaging validation System availbale for Machined Parts (

C 5.6
Like Palletisation , Single Layer Packing Etc )

C 5.7 Is CMM Facility Available with 3D Compactability

6) Process name : Plastic - Injection Molding Process - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

Class Check Points

Remarks
Storing Mill Sheet for Raw Material &Inspection Report of 1st
C 6.1
sub-supplier

Using Proper Raw Material (Validating Perchasing&Using

C 6.2
Material-Supplier, Grade, Invoice etc., )

C 6.3 Storing Status (Separate Storing, Temperature, Humidity)

Raw
Material Dry Process (Setting Standard and Operation), Supplying
Management C 6.4
Equipment&Influx of Dirt (Auto/Hoper Loader)

Management of Trituration room & Shatter M/C(Shatter Blade,

C 6.5
Dirt Protect, Clean, Assigned Standard)

Mixer Standard & Operating mgmt (Managing Mix Standard per

C 6.6
Items-Including Scrap)

Working Standard Setting /Starting (Mould cond, Shaping

C 6.7
Condition, Standards for T/O, Setting Change over etc., )
⇒ Temperature(Resin, Cylinder, Nozzle) Hour(Injection,
C 6.8
Cooling), Injection Speed & Pressure)
Management Standard & Status of Acceptable Reworked / Bad
C 6.9
Operation Parts ( after correction )
Management
C 6.10 Parts Pick-Up (Robot/Manual) and Tooling Audit Device
Frequency of Inspection ( First / Middle /Last samples / Limit
C 6.11
samples setting )
C 6.12 Packing & Loading Standard for each Items
Managing & Recording to Repair Old Equipment, Change Screw
C 6.13
, Repair History
Injection /
Each Part of Equipment status (Gauge, Light) , Measuring for
Extrusion C 6.14
Equipment Gage ⇒ Thermometer (Nozzle, Heater 1,2,3)
Management
C 6.15 Operational Oil Management (Regular Checking/Changing)

C 6.16 Mould Preheating Time Standard & adherence

Design & Manufacture Management ( Vendor approval Self
C 6.17
mould mangement , Mould Outsourcing management )
Mould Storage & Maintenance status ( Store, Record, Clean ,
C 6.18
Mould Identification , Life History )Mould Condition, Measuring and
Management

Classification: Public
 Management Mould Temperature Management (Recording Actual
C 6.19
Temperature Data with tolerence )-in 5 degrees under 600ton ,
Using Chiller & Warmer, Temperature Standard, Mould
C 6.20
Temperature Adjuster
Setting & executing Sanding Standard for Embo(Polish ,
C 6.21
Luster&Color management )
Is Supplier si having adequate facility as below
C 6.22
1) MFI
Is Supplier is having 3D Compatable CMM Facility for
C 6.23
Measurement
Is Supplier is having adequate Software Simulation Facilites to
C 6.24
verify the Mold Flow Analysis
Facility Control
Is Supplier is having dedicated "Tool Room" facility to conduct
C 6.25
Preventive Maintenance activities
Is Supplier is having "Proof" Machining Facility ( If Supplies as
C 6.26
Cast Condition )
Is Supplier is having the System of "Fixture Calibiration " for Jigs
C 6.27
/ Fixtures
C 6.28 Inspection Agreement & Standard
Roughness Control, Finished part Inspection, Testing, Testing
C 6.29
Place
Final Inspection
C 6.30 Endurance Test, Measurement M/C, Calibration

C 6.31 Managing Bad Parts & Corrective Action Plan

7) Process name : Rubber Process - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable
Class Check Points Remarks

C 7.1 Standard of incoming inspection(inspection sheet,record sheet)

Possession of inspection facility for incoming inspection of
C 7.2
materials
Raw Material C 7.3 Control of FIFO and validity
Constant temperature and moisture for material which has
C 7.4
possibility of transform
C 7.5 3C5S(warehouse,weighing room,roll mixing milling,jobsite etc.)

C 7.6 Standardization and performance of proportion list

Proportion Weighing facility (auto,manual)-if manual, check for use of
C 7.7
Weighing exclusive container and Record after weighting test
After weighing and blending, excute to idendification for prohibit
C 7.8
of mixture.
Possession of equipment(Banbury,Kneader,Open mill,non) and
C 7.9
Possession of Batch off machine and performance
Equipment condition and control(temperature,water,Chamber
C 7.10
temperature,oil etc)
Roll mixing Standard of roll mixing miling order and observation (input time
C 7.11
milling and order)
C 7.12 Managing Dumping rubber temperature
CMB/FMB inspection term (batch/lot/non) and
C 7.13
Inspection(Pattern,density,weigh,CB degree of dispersion,flow) ,
Aging facility ( constant temperature/moisture/non) and
C 7.14
CAPABILITY of aging facility
Aging
Establishing the term of aging each material and observation
C 7.15
(incl. long term )
C 7.16 Molding standardization and observation

C 7.17 Managing for metal mold temperature

C 7.18 Observation of regular check and daily maintenance

Molding C 7.19 Managing FMB weigh/length each material

Supervision and storing according to washing term of metal
C 7.20
mold(incl.jig)
C 7.21 Managing capability of tracing (raw material∼product)

C 7.22 Molding gas elimination elimination process.

Is Supplier si having adequate facility as below

1) MFI
2) Rheometer
C 7.23 3) Weatherbility tests
4) Ash Content Test
5) Hardness / Tensile / Density
6) Chemical Composition
Is Supplier is having 3D Compatable CMM Facility for
C 7.24
Measurement
Facility Control
Is Supplier is having adequate Software Simulation Facilites to
C 7.25
verify the Mold Flow Analysis

Is Supplier is having dedicated "Tool Room" facility to conduct

C 7.26
Preventive Maintenance activities

Classification: Public
 Is Supplier is having the System of "Fixture Calibiration " for Jigs
C 7.27
/ Fixtures

C 7.28 Inspection standard & matching with other components

Product reliance (environment, endurance etc.) & Managing

Inspection C 7.29
roughness and limit sample

C 7.30 Improvement for process and complain and validity

8) Process name : Press Parts Process - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable
Class Check Points Remarks

Storing and moving of incoming part (Specified BOX / tonnage /

C 8.1
segregated place / NO RUST / DUST )

Raw Material Inspection Standards (Material test certificate) ,

C 8.2
execution /Periodical Updating

Raw Material Incoming Inspection Standards & reports, categorization

C 8.3
easiness (Pre/After inspection, Area)

Proper identification & Systematic First In-First Out ( Coils /

C 8.4
Sheet Metal )

Incoming Inspection Measuring equipment possession & Control

C 8.5
, ( calibration )
Availability of Working Standard and execution( matching with
C 8.6
actual working)
Identification , Management of major press process which effect
C 8.7
product quality

C 8.8 Education, Skill of Workers (Skill Matrix , Training)

C 8.9 Self Inspection Execution ( Visual , Checker )

Die / Punch tool condition check & replacement management ,

C 8.10
recording
Process Defective Component identification , segregation &
Control C 8.11
management

C 8.12 Inspection-facility operating Check / Using of Limit sample

C 8.13 Clearance, Illumination of Workplace

C 8.14 Traceability system availability

Press machine management ( Oil leak , Gauge condition etc., ),

C 8.15
Daily maitenance checklist

C 8.16 History management of major discrepancy

Is Supplier si having adequate facility as below

1) CMM / LMM - 3D Compatable
2) Weld Penetration / Strength test
C 8.17 3) SST ( NSS / CASS)
4) Cup Forming test
5) Hardness / Tensile
6) Chemical Composition

Facility Control Is Supplier is having adequate Software Simulation Facilites to

C 8.18
verify the Foming Analysis

Is Supplier is having dedicated "Tool Room" facility to conduct

C 8.19
Preventive Maintenance activities

Is Supplier is having the System of "Fixture Calibiration " for Jigs

C 8.20
/ Fixtures

Die (metallic pattern, jig) storing / management (storing,

C 8.21
progress) / Keeping last production sample

Facility Control Facility malfunction (Degree of Facility)/Oil leakage, Gage

C 8.22
Operating condition , range (Preventive maintenance)

F/PROOF status / Spare Part possession when Abnormality

C 8.23
outbreak, Predictive maintenance

Standardization, execution of end product inspection (Inspection

C 8.24
Agreement)

Illumination of Inspection place, installment of limit sample for

C 8.25
Good and Non-Confirming parts

Answering gauge availability for final product (Measuring

Final Inspection C 8.26
machine , checker management, GR&R )

Classification: Public
 C 8.27 Standardization of Pallets , Trolley & rust prevention

C 8.28 FIFO control of Finished parts

C 8.29 Correction for customer complaints , Validity of Complaints

9) Process name : Co2 Welding Process - Applicable / Not Applicable

Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)
Class Check Points Remarks

C 9.1 Incoming inspection method , standard and Reports

Raw Material C 9.2 Is First-in,first-out system organized?

C 9.3 Are there enough stock space? Any SCRATCH factor ?

C 9.4 Welding Process Parameter monitoring (Voltage, Current )

C 9.5 Welding condition/environment management standard

C 9.6 Prompt measures( factor analysis) for defect

Criteria and equipment for defective (half demage,welding

C 9.7
section, whole demage) , Limit samples

Removal of CHIP,foreign material , spattor etc. for quality,

C 9.8
Process inspection standard/lessons
Management C 9.9 Periodical education plan, Worker skill .

C 9.10 Facillity safety equipment, ventilization, safety wearing

C 9.11 Standization of vessel/ packing(vessel,quantity,method)

Availablity of tracking for NG Part , storage & mix-up
C 9.12
management
C 9.13 Process rejection analysis and Trend Tracking

C 9.14 LAY OUT for each line, 3C 5S

Facilities condition, facility inspection , welding allignment

C 9.15
(Fixture) , electrode changing frequency & water cooling line.

C 9.16 Facility maintenance counterplan ( weekly, monthly, year )

Facility Enough capacity of facility available ?

C 9.17
Management Does operation condition of robot BACK/UP periodically?

Is there spare product register prepared?

C 9.18
Does appropriate needed quantity secured?

C 9.19 Proper production process, JIG, periodic inspection

C 9.20 Fool PROOF for facilities accident and process omission.

C 9.21 Inspection agreement with 1st Vendor

C 9.22 Periodic monitoring of defects and actions with 1st Vendor

Quality C 9.23 End-product Inspection standards

Management
Suitability with measuring difference, Approval/revision status
C 9.24
(including CHECKER)

C 9.25 Progress quality analysis, Feedback/Validity

10 ) Process name :Painting / Coating (ED) - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

Class Check Points

C 10.1 Incoming Inspection & Control. (Inspection standard and reports)

Raw material
control C 10.2 Control of paint (First in First out, material property)

C 10.3 3C 5S at Storage area (warehouse/paint warehouse)

Control of standards for pretreatment process (concentration,

C 10.4
PH, temperature, Flushing water pollution)

Classification: Public
 Is condition standards for pretreatment- fluid executed (
C 10.5
Periodical condition record, Surface control , Film Membrane )

Pretreatment DIP'G time(4min) establishing, execution/products

C 10.6
removal analysis recording

Electro deposition Paints condition standards management

C 10.7 (unvolatillity, PH, conduction, refilling fluid, fluid change period ,
Paint supplement )

Process Control ED execution management - Sending current time/ Paint

C 10.8
temperature(standards:3min./ 28~32℃)/electric current density)

ED tank Secret Management (management standards : Filmed

C 10.9
Parts extent : Bipolar plate extent = 4:1)

ED Surplus Paint filtering , water rinse process management

C 10.10
(UF management standards, purity, 0.5 million Ω)

OVEN temperature management (170℃*30min.; ±5℃)/ OVEN

C 10.11
temperature CHK history management)

Pretreatment removal machine management, film sludge

C 10.12
filtering facility execution

Pretreatment/ upsetting progress spray nozzle management

C 10.13
(position of nozzle considering part shape)

ED Bipolar Paint facility (rust status, prevention of rust

C 10.14
stain)/electric contact)

ED / Surplus water washing(UF)/OVEN clearance period /

Facility Control C 10.15
status of clearance (1 time/2 weeks)

Conveyer /HANGER management (OIL pad installment/Dust

C 10.16
bin)

Parts electric contact EDGE: coating thickness evaluation

C 10.17
constant numerical value) / HANGER electric contact

Possession of spare parts for major facility/ functional products

C 10.18
change period (filter)

End-products inspection process standardization (inspection

C 10.19
standards/limit sample/history management of quality test)

End-product appearance inspection, disqualification record

C 10.20
(AIR POCKET, Pin hole, painting, stain)

End-product coating thickness inspection (standards: +20

C 10.21
um)/adhesion (desquamation TEST Standards : 0%)

Periodical corrosion-resistance test / Record data(480hrs; data

Quality Control C 10.22
standards)

End-product storing management (Regulated BOX, PALLET,

C 10.23
letter-paper)

Prevention of Defect Re-occurrences (correction

C 10.24
quickness/factor analysis/ prevention of recurrence)

Periodical worker education, education contents

C 10.25
(quality/operation/safety)/management protocol

11 ) Process name : Eletro Plating Process (Metal) - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

Class Check Points Remarks

C 11.1 Incoming part inspection (Inspection Standard and reports )

Warehousing of components check keeping status (first-in, first-

C 11.2
out/degreased fit rust preventive oil coating /tonnage)
Material
Management
C 11.3 In case of rain, material keeping & management/floor status

C 11.4 3C 5S(material warehouse/ raw material warehouse)

Classification: Public
 Degrease management (temperature/thickness
C 11.5
analysis/process standard /washing pollution degree)

Acid cleaning management (process standard/concentration

C 11.6
analysis/oiliness/washing pollution degree)

Presence and condition management of neutralizing on acid

C 11.7
cleaning

Presence of work condition on coating process (standard/plating

C 11.8 solution management/concentration/current
Process passage/temperature/time)
Management
C 11.9 Observance and performance of plating work standard

Plating process operation/condition/daily report history

C 11.10 management.Bath PH , Concentration , Passivation(If,Plating
free area is ok as per drawing)

Washing process operation/condition management

C 11.11
(concentration/OVER FLOW)

Drying management (drying time, temperature, charge quantity,

C 11.12
drying method)

Permission presence of environmental facilities (a waste water

C 11.13
disposal facilities/exhaust gas facilities)

C 11.14 Management state of environmental facilities

C 11.15 Cleaning cycle and status of main facilities

Management status of RACK (contact point state, presence of

C 11.16
separate keeping space)
Facility
Management SPARE PART possession of important facilities/presence of a
C 11.17
responsible worker for maintenance facilities

Marking & delimit color line for direct current, the anode, the
cathode/
C 11.18
delimit color line for cold water, warm water/water pipeline
heating facilities

Inspection/production facilities possession status(flation

C 11.19
thickness/temperature/concentration/electronic current)

Inspection method standardization for completed products(

inspection standard/acceptance sample/
C 11.20
quality test history management/plating specification within the
company/QC processing drawing)

Appearance inspection for completed products (swelling, blister,

C 11.21 breaking, pinhole, foreign material, stain)/a responsible inspector
fix
Quality
control Coating inspection for completed products (coating thickness/
C 11.22
hardness etc.)

Inspection facilities possession status (corrosion

C 11.23 resistance/water resistance/fitting on force/
enviromental performance)

Stocking management of completed products (specified BOX,

C 11.24
PALLET)

Periodical worker education status and contents

C 11.25
(quality/workability/safety)

12 ) Process name : Heat Treatment Process - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

Class Check Points

C 12.1 Storage & Management status of each material(rust, scratch)

Inspection standard keeping and performance

C 12.2
(organization and grain of material of forging)
Material

Classification: Public
 Management MILL SHEET receipt, actions in accordance with Oks & non-
C 12.3 Oks
(eachLOT/monthly/anytime)

C 12.4 Fist-in, first-out status by LOT/material

C 12.5 Workmen identification and job educational status for each .

Operation standard fixing status & post it (upper / lower limit of

C 12.6
temperature, gas quantity, time etc.

Carrying capacity/method and mixing with other products in

C 12.7
process

Temperature and Atmosphere GAS record ( auto-record,Items

Process C 12.8
classification /auto-record/manual-record)
Management
C 12.9 Quenching cooling ability and periodical inspection

C 12.10 Work standard and actual operation status

Operation condition management and self inspection execution
C 12.11
status (record management)
C 12.12 LOT management after heat treating

C 12.13 Work Place 3C 5S status

Regular check status on installation(items arranagement &

C 12.14
Inspection status,action status against problems)

Temperature / Thermocouple check (once a month/when the

C 12.15
Facility matter happen/non)
Management
C 12.16 Operation status of facilities and gauges

When the incident happen by facilities F/PROOF

C 12.17 status(installation, good working/partial installation,working/not
working )

C 12.18 Inspection Standard for inspector and observance

Inspection Fixture & inspection facility keeping ( M/PRESS,

C 12.19 hardness tester,microscope,MASTER sample , cutter , Magnetic
Particle inspection tester etc., )

C 12.20 Laboratory Constant temperature and humidity

C 12.21 Fixture & Inspection Facility Calibration

Final Inspection
Finished Goods inspection & Test sample storage ( By LOT/
C 12.22 LOT inspection ,record unsatisfied result & action / not inspected
LOT etc )

Surface treatment component( nitriding,phosphate coatings)

C 12.23
thickness inspection

Customer complaints & corrective action on insepction results (

C 12.24
Field failure etc., )

13) Process name : Anodizing Process - Applicable / Not Applicable

Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)

Class Check Points

Incoming part inspection (material control/free from oil,dust

C 13.1
/contorl control on each lot)

Material Warehousing of components check keeping status (first-in, first-

C 13.2
Management out/dunnage)

C 13.3 In case of rain, material keeping & management/floor status

C 13.4 3C5S (material warehouse/ raw material warehouse)

Precleaning management (temperature/thickness

C 13.5
analysis/process standard /washing pollution degree)

Emulsion cleaning management(process standard/concentration

C 13.6
analysis/oiliness/washing pollution degree)

C 13.7 Standard method of jigging

Process Presence of work condition on Anodizing

Management C 13.8 process(standard/Anodizing solution
management/concentration/current passage/temperature/time)

Classification: Public
 C 13.9 Observance and performance of Anodizing work standard
Anodizing process operation/thickness
C 13.10 control/Voltage/temperaturecondition/daily report history
management
Washing process operation/condition
C 13.11
management(concentration/OVER FLOW)

Rinsing (timing & temp) , sealing (PH, timing & Temperature

C 13.12 )and Drying management (drying time, temperature, charge
quantity, drying method)

Permission presence of enviromental facilities (a waste water

C 13.13
disposal facilities/exhaust gas facilities)

C 13.14 Management state of enviromental facilities

C 13.15 Cleaning cycle and status of main facilities

Management status of RACK(contact point state,presence of

Facility C 13.16
separate keeping space)
Management
SPARE PART possession of important facilities/presence of a
C 13.17
responsible worker for maintenance facilities
Marking & delimit color line for direct current, the anode, the
C 13.18
cathode/

Inspection/production facilities possession status(flation

C 13.19
thickness/temperature/concentration/eletronic current)

Inspection method standardization for completed products(

inspection standard/acceptance sample/
C 13.20
quality test history management/plating specification within the
company/QC processing drawing)

Apperance inspection for completed products(swelling,

C 13.21 blister,breaking, pinhole, foreign material, stain)/a responsible
inspector fix
Quality
control Anodizing thickness inspection for completed products(coating
C 13.22
thickness/ hardness etc.)

Inspection facilities possession status(corrosion

C 13.23 resistance/water resistance/fitting on force/
enviromentalperformance)

Stocking management of completed products(specified BOX,

C 13.24
PALLET)

Periodical workder education status and

C 13.25
contents(quality/workability/safety)

14 ) Process name : Bonding Process - Applicable / Not Applicable

Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

Class Check Points Remarks

C 14.1 Incoming Inspection Standard (inspection sheet,record sheet) YES

1
Raw Material
Glue ( FL47 & 48 C 14.2 Incoming inspection facility. (Measuring equipmets ) YES
1
) , 10B Thinner ,
Liners, Web & C 14.3 Control of FIFO and validity.( Stock Board ) YES
1
Rim , Shot Blast
Material C 14.4 Controlled temperature for the Glue preservation NO

C 14.5 3C / 5S(Material storage,cleanliness.) YES

1

Degreasing (temp, time & concentration)& Welding process of

C 14.6 rim & web , welding strength monitoring (welding allignment
Web & rim (Fixture) , electrode changing frequency & water cooling line.)
welding process

C 14.7 Shot blasting process establishment , monitoring and control.

Lining C 14.8 Pre heating of lining temp / time ( Auto control )

Standardization and proportion for Glue application. / Specific
C 14.9 Gravity / Viscosity
Process control
for lining glue
application C 14.10 Glue drying time( before bonding ) / Open air / FIFO

C 14.11 Glue applied lining storage / FIFO

C 14.12 Shoe assembly cleaning process establishment and monitoring

Classification: Public
 Standardization and proportion for Glue application
C 14.13
Process control
for Shoe
Viscosity of FL47 / Specific Gravity - monitoring
Assembly Dip C 14.14
coating
Establishment of dip coating process , & handling method and
C 14.15
Drying time monitoring after dip coating process

C 14.16 Bonding fixture Clamping ring condition

Bonding
C 14.17 Bonding conveyor speed / oven temperature / time
Process
C 14.18 Bonding strength qualification ( hot / cold shear test )

Aesthetic C 14.19 Control of Trimming process for extra glue & burr.
correction
Process C 14.20 Grinding process establishment and control
Inspection facility for Shear test / Proof test of lined shoea ssy (
C 14.21
UTM / Fixtures )
C 14.22 Bonding fixture calibration freqency

Quality C 14.23 End-product Inspection standards

Inspection
C 14.24 Managing Bad Parts & Corrective Action Plan

Stocking management of completed products(specified BOX,

C 14.25
PALLET, FIFO

15) Process name : Assembly Process ( Sub - Assembly Or Final Assy as Product )

Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)
Class Check Points Remarks

C 15.1 Incoming Inspection Standard (inspection sheet,record sheet) Yes

1

C 15.2 Incoming inspection facility. (Measuring equipmets ) Yes

1
Child part
C 15.3 Control of FIFO and validity. (Stock Board ) Yes
reciept 1

C 15.4 Controlled temperature for the Glue preservation Yes

C 15.5 3C / 5S (Material storage, cleanliness) Yes

1

C 15.6 Identification of CTQ stages. Yes 1

C 15.7 Identification of operator skill for respective CTQ stages. Yes 1

Operator skill evaluation & upgradation through trainning on
C 15.8 Yes 1
regualr basis.
C 15.9 Availability of poka-yoke at CTQ stages. Yes 1

C 15.10 Master samples availability at all poka-yoke stages. Yes 1

Verification of poka-yoke interval & master sample calibration
C 15.11 Yes 1
Sub-assy done on timely.
process Monitoring system for internal rejections & corrective action
C 15.12 Yes 1
plan.
C 15.13 Assy fixture & gauges. Yes 1

C 15.14 Performance check - test equipments. Yes 1

C 15.15 Machine maintanence frequency & adherence level to plan. Yes 1

C 15.16 Calibration status of all instruments. Yes 1

C 15.17 Rewok procedure availability & adhernce to standard level. Yes 1

16) Process name : Electronics Parts Proces ( PCB Circults Etc )

Non Availability

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable

(0)

Class Check Points Remarks

C 16.1

C 16.2

C 16.3

C 16.4

C 16.5

17) Process name : Electrical Parts Proces ( Winding / Soledering / Assembly / Testing Etc )

Classification: Public
 Non Availability (0)

Complience (3)
Avalability (1)

Aqequacy (2)
Check Point

- Yes / No
Applicable
Class Check Points Remarks

C 17.1 Functional test for products Yes

1

C 17.2 Safety tests frequency defined Yes

1

C 17.3

C 17.4

C 17.5

Classification: Public