HKMC Supplier Quality Assurance Manual - ENG - 22 April

S218100266 / 10.123.24.
45 / Apr 27, 2022 00:48 (UTC+9) /This document is not allowed to copy or distribute illegally as a information property of HMMC. If you violate this rule, you can be punished by policy of HMMC and related local law.
Supplier Evaluation Systems
. Quality 5 Star System
2.
Terms and Definitions
S218100266 / 10.123.24.45 / Apr 27, 2022 00:48 (UTC+9) /This document is not allowed to copy or distribute illegally as a information property of HMMC. If you violate this rule, you can be punished by policy of HMMC and related local law.
The Supplier Quality Assurance Manual is important to guarantee quality of products supplied by tier 1
suppliers of Hyundai Motor Company/Kia Corporation (HMC/KIA).
It defines requirements and activities issued from HMC/KIA to bring understanding and establishment of
quality management system of suppliers.
This manual contains the minimum quality requirements from tier 1 suppliers to Hyundai Motor Company/Kia
Corporation in Korea (hereinafter, HMC/KIA) and special activities not included in this manual could be
required to ensure the quality of parts.
1) HMC/KIA and tier 1 suppliers have been cooperating consistently to improve quality to satisfy end customers.
Necessity to maintain and manage high level quality through quality management process has continuously
suppliers.
2) Based on the Manual, all of tier 1 suppliers shall establish the quality management process satisfying end
capabilities(Quality 5 Star) as well as annual quality performance of suppliers and its evaluation results
reflects in bidding of new business.
This manual defines the key work procedures for all tier 1 suppliers of HMC/KIA to help stabilize quality
control activities and it consists of 19 chapters of main processes and descriptions of evaluation system
(Quality 5 Star).
As this manual is made to explain the essential quality management procedures for all tier 1 suppliers that are
officially registered with HMC/KIA, it is strongly prohibited to sharing of this manual to suppliers and institutions
irrelevant to HMC/KIA. Therefore, all tier 1 suppliers of HMC/KIA need to take care the leakage of the document and
if the leakage of the document is found, it is necessary to notify HMC/KIA immediately.
HMC/KIA welcomes feedback from suppliers to improve this manual. Suppliers can submit any opinions or
(1) Top management shall establish a quality management system to establish and achieve quality policies and goals
for the organization.
(2) Top management shall review prevention and improvement activities to achieve the goal by ensuring the
availability of resources required for the process to maintain a quality management system and confirm the degree of
achievement of the goal.
(1) Top management shall share the quality policy and goals established to effectively maintain/manage and
improve product quality and quality assurance system with all employees.
(2) Based on the quality policy and goals, specific operation plans shall be established according to the characteristics of
each work, and the achievement of the goals shall be checked on a regular basis.
(3) Goal setting and audit activities shall be repeated to improve quality.
(1) HMC/KIA recommends that suppliers establish a motivational quality policy to achieve quality consistency through
reflected in the 5 Star evaluation report in alignment to the above.
1) Quality Operation System Management
: To improve the quality management system through audit and continuous improvement of work procedures
and systems to ensure quality consistency.
2) Quality Control Status Check
: To improve identified problems affecting quality by evaluating 4M management status and process capability
for newly developed products and products in series production.
1) HMC/KIA has established the following audit process for suppliers to inspect quality and the suppliers shall
conduct internal audits in addition to HMC/KIA audit.
2) The above audits are essential for maintaining a business relationship with HMC/KIA, and if necessary
(major quality problems occur), supplier audits can be conducted with the consent of the supplier.
1) Process Audit [based on development criteria]

Evaluate 4M preparation and process capability for new development
If all three evaluation criteria is accepted, the pass will be given and the supplier shall also conduct a
process audit for all their tier 2 and below suppliers
2) 5 Star Evaluation
Regular evaluation activity conducted to check the quality management system of suppliers and
compliance with on-site standards after mass production.
Tier-1 shall submit the evaluation results after conducting regular inspection (once/year) to check the
customer-specified requirements (refer to the manual and evaluation form).
Quality 5 Star rating for all Tier-1 suppliers every year. For details, refer to the supplier evaluation system
(quality 5 Star) manual
3) On-site evaluation
As a self-inspection activity of the supplier's production process to check the implementation status of
quality management in accordance with the established work procedures and guidelines, a person in charge
other than the production operator shall be designated to check the status of compliance with the
on-site work procedures.
4) SQ Evaluation
In the case of outsourcing production for HMC/KIA's designated industries [19 major industries and 47 detailed industries] ,
the supplier shall conduct regular inspection activities (once/year) and submit the evaluation results.
Criteria for evaluation and operation.
The documents required by the quality management system include quality manuals, documents for process
management, work guides for fixed tasks, standard forms for data collection and reporting, and quality records.
By describing the system, it is intended to be used as a basis for the execution and maintenance of the system.
All suppliers shall prepare documents defining the processes necessary for establishing a sustainable quality
management system in advance, and these documents are internal standards that are regularly checked to
ensure that appropriate documents are used in the place where they perform their functions and, if necessary,
continuously revision activity is required.
1) All documents shall be structured and links between documents shall be secured.
2) When managing documentation, all suppliers shall review whether products and services that meet customer
requirements and legal/regulatory requirements are consistently provided.
3) All documents shall be maintained with documented information for proper process operation and shall
be readily accessible to all relevant personnel.
- Management methods suitable for the characteristics of each document shall also be specified.
[Electronic documents, printed materials posted on-site, etc.]
4) Management of documented evidence of implementation history shall be implemented to ensure confidence
that the intended process is being implemented as planned.
5) In all documents, the person in charge and responsible manager for each process shall be clearly designated,
and appropriate details for the purpose shall be defined.
The quality manual shall define necessary plan and adequate policy to practice quality management and
shall include below.
1) Purpose, policy, objective of the organization and its achievement methods
2) Core process to maintain quality consistency
3) Verification method of established core process
Procedure is based on processes defined in the quality manual that describes organization, design, documentation,
outsourcing management, process, test, etc. It shall regulate its main management criteria considering each
1) Quality Procedure Creation Requirement

Process shall be defined clearly and intuitively to understand
shall be applicable and realistic
shall be helpful for improving quality and the needs shall be reviewed thoroughly
shall be reviewed whether it meets customer satisfaction
shall be prevention oriented, not to detect problem
2) Quality Procedure Creation Notes
shall be clear how each relevant functional department performs the process
shall be clear to understand responsibility, authority and interrelation
shall establish detailed implementation method for all requirements of applicable standard
shall not overrule the quality policy or manual reviewed in advance
shall be written in detail, process focused (who, when, what, how, where) and controllable to plan and
control quality activity. Flow chart can be used if necessary
shall be documented by the responsible department who in charge of the process and reviewed by
related departments
shall establish the recording methodology to assure process is accomplished according to the procedure
1) Instruction is a document that standardizes the method of performing specific works (tasks) for each process
(task), such as work Instruction.
2) Instruction Creation Steps
Application target setting
Work/task analysis
Key management criteria selection
Procedure, method, detailed content documentation
Coherence check with other documents
3) Notable Points in Instruction Creation

Instruction on detailed unit process task
Clarification about OK/NOK determination, tolerance etc.
Establish process result record method
Identify and mark of specified criteria such as special characteristics
Check compatibility with the usage purpose and the users [Readability by foreign operators]
Evaluate coherence with upper-level document
(drawing process chart work standard inspection standard)
4) Kernel Structure of Main Instruction Documentation
1) Document shall be reviewed or revised in case of below

Change in organization or new task begins
New product development or process to be implemented
In case of non-conformity in current work process
Each rule shall be clear to understand its responsibilities and authorities.
3) Quality related documents, including instruction shall be written/revised by the responsible department and
be reviewed by the department manager and get final approval of CEO.
1) Supplier shall archive and preserve work outputs based on quality document (policy and procedure) and be
able to track down on exact case when needed.
2) Documented quality records shall be utilized as preventive action on quality problem
Quality Inspection Record: Critical Check point trend tracking analysis, etc.
Special Characteristics Process : Quality performance tracking, process capability stabilization level, Etc.
(1) Clearly mark the special characteristics designated by the customer specific requirements in procedures and work
instructions on shopfloor (work standard). E.g. customer drawings
(2)
(3)
(4)
management rules
(5)
(6) Need to monitor processed tasks are being recorded/managed and periodically check whether tasks are being
performed as described and matching with the record
In manufacturing business, it is a key management concept to secure good quality of products as well as raw
materials by identification and exact quantification to eliminate waste, ultimately creating a pleasant working
environment, improving productivity and assuring quality. Generally, 3R stands for Right quantity,
Right material, Right position as management through human eyes and 5S Sort-out, Set-in-order, Shine,
Standardize, Sustain.
1) 3R
Right Quantity (Amount) : Set optimal stock quantity and maintain
Right Material : Purchase of right materials, components in accordance with work standard
Right Position : Set in place materials, components, tools and machines
2) 5S
Sort-out : Set what is needed or not and eliminate irrelevances to work
Set-in-order : Sort necessary things to be ready to use and to find easy
Shine : Shine workplace without dust
Standardize : Maintain the state of sort, set, shine and eliminate contamination causes
Sustain/self-discipline : Ensure the 5S approach is followed by self-discipline
1) Shopfloor layout needs to identify production relevant processes and inspection points. 3R 5S management
criteria need to be established accordingly.
2) Suppliers shall perform daily inspection and internal audit of 3R 5S regularly. Daily inspection to be
performed by operators, team leader, supervisors and shall be completed before start of work, during work
and after end of work. Regular internal audits shall be carried out on a monthly, quarterly or half-yearly basis
for the partial or entire shopfloor.
1) Supplier shall continuously manage shopfloor to maintain best work environment to produce quality products.
2) Distinguish raw material warehouse, test lab, assembly and production process, finished products storage,
idling machine storage, tool repair/storage area at shopfloor. Set management standard and maintain
appropriate temperature, humidity, cleanliness, lighting, ventilation, foreign matter and noise.
3) Preventive actions against chemical/physical/biological hazard at work for operators in working environment
and work methods shall be established and continuously improved.
4) Illuminance of the inspection area such as, measurement/visual inspection within the process shall be managed
to maintain consistent inspection environment.
- Illuminance management requires periodical check up of per inspection process and it is suggested to verify
after sunset
5) If a product is suspect to physical deformation, designate the product as temperature/ humidity management
criteria and establish preventive measures and plan inspection activity
6)
checked and washed.
1) Supplier shall provide training and exercises to enable active, efficient, effective work performance of
operators, including safety and quality training. Sub-supplier employees shall be included.
2) Annual training curriculum for all employees new/experienced/transfer/contract/foreigner/sub-supplier
per organization/position shall be documented and completed.
If one is unable to complete the training, there shall be substitute courses to complete.
3) Training effectiveness of on-the-Job training and exercises shall be checked. Manage the level of competency
by having level test or providing certification and shall be reflected when assigning the roles.
4) Qualification and proficiency evaluation shall be conducted management by reliable evidence

(test history, etc).
5) Professionalism of internal trainer shall be verified, and candidates shall be selected according to apt
(education, work experience) and qualification (major, qualification, course entitlements) set by own standard
6) Internal trainers shall make/update curriculum
(1) Temperature/humidity and cleanliness management methods of outsourced products, required by process
characteristics shall be established and managed
(2) Management standard of lighting per process and regular check activity shall be established and executed,
if operators and inspectors are designated to quality check visual/measurement/weight within control plan
or standard.
(3) Trainings required for tasks such as on-the-job training, exercise, safety and quality training shall
be planned/executed for all employees including sub-suppliers and implementation status should be checked.
(4) Process input materials and process characteristics shall be trained to new operators or if process changes.
Qualification evaluation of the operators shall be performed for special characteristic processes or relevant
important processes.
(5)
measurement tool (variable R&R) and ability to find non-conformance (attribute R&R).
It means to determine whether a measuring instrument enters or fails within the specified tolerance .
It refers to comparative measurement and inspection of changes in the degree of lower-class equipment
according to the procedure in order to maintain traceability with the national standard.
Calibration validity period to maintain the accuracy of the measuring instrument refers to the period from
the date of completion of calibration to the date of next calibration.
It is to confirm the measurement reliability of the measuring instruments and measurement personnel,
and it refers to the activities to evaluate in terms of repeatability and reproducibility.
When the test/inspection equipment is received, the person in charge shall check whether it conforms to the
equipment requirements and whether the calibration inspection report is attached and conduct the inspection in
accordance with the incoming inspection regulations for measuring equipment (instrumentation).
The head of the department in use assigns a management number as follows only to the inspection facilities that
have passed the incoming inspection and records it in the instrument management ledger and history card for
efficient management. The assigned management number shall be managed by attaching a tag to the instrument.
1) Inspection equipment is used in a designated place, and when not in use, it shall be placed in a designated storage
place or storage box to prevent loss or damage.
2) The inspection facility storage area and storage box shall not be affected by dust contamination,
temperature/humidity change, vibration, shock, etc. as much as possible.
Calibration subject and period are generally set with reference to Guidelines for Calibration Subject and Period
Setting - National Institute of Technology and Standards Notice No. 2020-0105 (KOLAS G-013) ,
and the conditions of use, frequency of use, in consideration of the characteristics of measuring instruments,
reasonable self-management standards for each partner shall be established.
1) The person in charge shall check the calibration criteria list and identify the equipment to be calibrated 15 days
before the expiry date and conduct entrusted calibration (certified calibration) or self-calibration
(in-house calibration) activities to the authorized national verification/calibration institute.
2) The main object of calibration shall be operated according to the criteria of
Guidelines for Calibration Subject and Period Setting .
3) When using the inspection equipment after completion of the calibration test, it is necessary to check the calibration
test certificate, whether the calibration test passed in the calibration test report, and whether the calibration
is adjusted.
4) Calibration test results are recorded in the measurement equipment management log and calibration criteria log,
and the passed calibration test equipment shall attach the calibration test certificate to the body or case.
5) In case the adjustment of the adjustable part affects the performance of the inspection equipment, this adjustment
part shall be able to prevent the user other than the person in charge of the calibration inspection from touching it
without approval.
6) Since the precision and accuracy of the instrument can change due to various factors such as the passage of time,
frequency of use, work and environment, it is necessary to establish and maintain a routine calibration procedure in
addition to periodic calibration activities.
7) For calibrated measuring equipment, the Gauge R&R verification activity for the purpose of securing measurement
validity and reliability shall be carried out by itself, and the validity of the execution result shall be secured.
NG Repair Requesting calibration to an external authorized institution

Scrap Identify subject parts and manage disposal history
OK
Qualification and training of Compare and verify with activity evidence Perform repeat test of same instrument
calibration personnel traced measuring equipment history management Verification of instrumentation error
Completion of professional variation
Measurement of standard Qualification / Calibration Method
training
substances (weights, etc.) / Calibration Results
Secure Calibration Place
Issuance of calibration -proof
(specify expiration date)
1) In case of malfunction or abnormality of measuring equipment, record the defect details and repair the measuring
instrument by itself. If self-repair is not possible, the repair shall be requested by an external company.
2) In case of the measuring instrument cannot be used due to an end-of-life or breakdown, a management plan such as
isolation shall be established to prevent it from being put into the manufacturing/inspection process.
(1) It shall be checked whether measuring instruments necessary for inspection/testing are secured and used in
the right place.
(2) An annual calibration plan for measuring instruments shall be established and inspection activities for supplier
shall be carried out.
(3) A repeatability evaluation plan for calibrated instruments shall be established and implemented.
(4) Standards for storage, identification, cleanliness, and management personnel of measuring equipment shall be
established and implemented.
(5) Verification procedures (e.g., weight meter division inspection, etc.) for measuring equipment in operation other than
regular inspection activities according to the calibration cycle shall be established.
(6) For items whose quality control standards are not mentioned in our company's quality manual, refer to the detailed
notice of the recognition organization by each overseas region.
In accordance with the Occupational Safety and Health Act, internal regulations shall be established and
managed to effectively promote work by clarifying the responsibilities, authority, and work relationship
between the team in charge of safety and health work and the department (team) performing on-the-job affairs..
The organization for effective operation of safety and health management activities shall be established and
operated in accordance with the circumstances of the partners by prescribing (standard) the composition, roles,
responsibilities, and authority of safety and health organizations, such as safety managers, supervisor,
department safety personnel.
<Organize and operate a safety management organization to suit the characteristics of the supplier>
It refers to the task of creating and maintaining a safe and pleasant work environment by systematically
identifying, evaluating, managing, and improving potential direct/indirect harmful and risk factors due to
production and support activities. Suppliers shall prevent and manage safety issues through regular risk
assessment.
In accordance with the Occupational Safety and Health Act, training for new employees and regular training for
existing employees, such as safety and health education and training, fosters operators' safety and health
awareness and the ability to exclude harmful and risk factors during work. activities to promote and maintain
health. Suppliers shall establish an annual plan and manage their performance.
Regular and frequent check to eliminate hazardous instances at machine, tool and equipment.
In accordance with Occupational Safety and Health Act, protection for hazardous machine, tool and equipment
shall be installed and safety inspection shall be performed.
Documentation of process safety report, submission, review and confirmation shall be executed to prevent
serious accidents caused by leakage, fire and explosion from hazardous equipment.
All tasks related to prevent loss of life and protect assets by enforcing to work safely when working with fire,
electricity, heavy materials, etc. during machine maintenance, improvement or install.
All safety standard tasks defined to prevent safety accident caused by forklift and other unloading machines
while operating, inspecting and maintaining.
Set standard to provide protective gears and provide to operators to wear and protect operators from hazardous
work.
Protective gears shall be provided to operators in consideration of the characteristic of unit process
Self-disciplinary action to protect safety and health shall be encouraged and awarded to contribute industrial
accident prevention act.
Safety and health management of sub-suppliers shall be done to prevent accidents and thereby securing stable
supply chain and protect property from loss.
Relevant tasks to comply with the chemical handling legal regulations, to attain, review, post and training of
material safety and health safe and health
General tasks to prevent various accidents/damages from hazardous material which could harm the environment,
threating safety to operators and neighborhood.
Tasks to prevent illness of all employee from diseases, improve employee health and thereby create pleasant
work environment
General tasks to prevent and minimize potential fire hazard which could cause lose of life, properties, and
environment contamination. Fire is a major safety accident which can cause t
that it requires mock exercise and pre-defined contingency manual
Fire/disaster prevention facility shall be located within the boundary of operators for fast response and
emergency exit map needs to be documented and posted. Operators training and mock exercise shall be
performed
Tasks to fast response to accidents and investigate the cause to prevent reoccurrence and provide convenience to
affected patients.
Relevant tasks to rewards/acknowledge those who carry out safe and health activity or punish violators who
cause safety accidents, thereby bring out awareness of safety, fire prevention, traffic and environment to
prevent loss of life/properties
(1) Supplier shall organize a responsible organization and document safety and health management rule based on
the Industrial Safety and Health Act .
(2) Internal management rule shall continuously be revised and renewed. Roles and responsibilities shall be clearly
stated.
(3) Safety manual and management methods shall be established and implemented reflected on shopfloor.
(4) Motivate operators to acknowledge the importance of safety and to prevent accidents by regular risk assessment
and safety training.
(5) Safety and Health relevant documents shall abide binding internal work standard and legal law, yet if not
regulated by standard shall be archived at least 3 years.
(1)
equipment/layout shall reflect
e.g. Welding : Wear protection gears (Glasses/helmet/mask/gloves), safety sensor, shading screen and Control button with both hands.
(2) Post safety promotion poster/rules per unit process and train operators within shopfloor
(3) Install and identify preventive measures (gears/facilities) against hazardous materials at shopfloor
(4) Organize a team, responsible for safety and health to react spontaneously per situation
risk evaluation
(1) In case supplier safety accident occurs HMC/KIA can deduct Quality 5 Star points from tier-1 supplier and tier-1
: Loss of life(Death), Fire (Causing delivery delay longer than 30 minutes to HMC/KIA)
In case of safety accident at Tier 1 supplier, Quality 5 Star points will be deducted
In case of safety accident at Tier 1 and SQ certified supplier, disqualification of Quality 5 Star
To manage, store, package, preserve and ship all materials used in production plants effectively and rationally
and maintain traceability in case of quality problem
All material supplied to the customer for domestic and oversea new/face lift/tuned/improved model vehicles
On-site Evaluation(1-4)
1) Process of production, from raw material, sub-material to finished product, shall be recorded for all product
history, status and usage at every steps. Material purchasing, usage and product production history shall match.
2) Responsible department shall be able to track when non-conformance or failure occurs.
3) Raw materials and sub-materials shall be abled to track before and after usage.
4) Raw material including outsourced parts shall mark PASS stamp to check quality.
1) Identification shall be selected and done as below.

Establish internal control standard and manage identification based on the established standard.
In case requested by the customer, manage identification according to the criteria of the customer standard.
2) Identification shall satisfy below requirements
Shall be clear..
Shall not be erased or changed easily.
Shall be tagged at designated area, never mis-tagged and get out of position.
1) All non-conforming materials found during incoming inspection shall be returned
2) Material shall be stored per its category and sizes under first in first out (FIFO) rule and the aisle shall always
be maintained in order to comply FIFO when procuring stocks.
3) All materials shall be managed via stock management system to ensure safety stock with considering
customer orders.
4) Material responsible employee shall store OK materials after incoming inspection in designated storage area.
5) Material responsible employee shall immediately isolate non-conforming materials and handle them
according to non-conformance management regulations when incoming or final inspection.
6) Material responsible employee shall monitor and record each material to manage inventory status
7) Material shall be checked regularly to prevent damage, loss and deterioration. Establish long term inventory
management standard and follow to prevent quality deterioration.
8) Material with expiration date, such as paint and silicon shall be managed not to be used after expiration date.
9) Material shall be transported in individual unit to avoid mixing and proper transportation method to prevent
potential deformation and damage.
1) Material LOT number shall be managed according to internal rules or customer specific requirement, if requested.
2) LOT numbering shall be given per production unit which has same quality characteristics under same mold,
material, operator, condition and process condition.
Die, mold and tool with various cavity shall be numbered as different LOT.
3) Products LOT numbering can be applied to daily production volume, yet different number could be used
according to characteristics of products by internal management standard.
1) LOT tracking shall be possible from all raw material/sub-materials to finished products with part number,
name and production date.
2) Outsourcing parts LOT tracking shall be ensured and assured that the incoming LOT and test report are same
LOT
1) Safety stock management process shall be established for outsourcing materials and finished products for
consistent production and supply and shall be checked regularly.
2) Safety stock level shall consider continuous production UPH
ordering to delivery.
This chapter describes the definition of special characteristics and control methods.
It shall be applied to all mass-produced vehicle parts currently being produced. They are specified by HMC/KIA
and self-
It refers to the major parts and process characteristics that are selected/managed by the parts supplier, including
those specified in drawings, etc. by the customer as the parts and process characteristics that have a key
influence on the quality of parts such as laws and regulations, safety, appearance, function, and assembly.
1) Special characteristic parts shall be assigned by designation of customers in case of parts related to the laws
and regulations, and the selection criteria shall be in accordance with the HMC/KIA's business standards.
In addition, if it is judged that it is necessary to manage quality intensively, such as the occurrence of
important quality problems or multiple claims during the supplier's self-examination, it shall be designated as
a part subject to its own special characteristics and then established and managed by quality control standards.
2) The supplier shall establish and verify the reliability verification plan suitable for the specified part
characteristics, and the cycle is as follows.
Test criteria : All criteria of reliability specified in ES/MS/drawing cycle notes.
Applicable parts : According to the classification of legal parts prescribed in the BOM and drawings of
the R&D, follow the table below.
3) The supplier shall conduct regular reliability verification in accordance with the test standards and ensure that
the required quality-related matters are satisfied, and the records of detailed test results shall be preserved and
submitted to the consumer.
Establishment of self-management standards and regular verification activities for detailed management
standards of test results are required (internal audit, etc.)
If inappropriate quality assurance activities, such as preparation of false documents, are identified,
they may be subject to sanctions according to the frequency of occurrence, as they fall under eight criteria
of violation of quality basic order.
1) Special characteristic process is a core process that is judged to require special management to ensure
consistent quality when designating a customer and reviewing its own production flow chart,
and all management requirements in the process shall be verified within their own standards.
2) In the case of a core process that directly affects the requirements for designation of the HMC/KIA, such as
drawings, it shall be designated and managed mandatory, and in other cases, the designation of a special
characteristic process shall be considered
When new production technology / manufacturing method is applied
In the case of parts/processes delivered to HMC/KIA for the first time by building a new production line
When new technology/new design structure/new material is applied
When parts are supplied from new sub-suppliers
In the case of a core process that can cause important quality problems such as heat treatment/welding
When the D/P-FMEA review has high severity, occurrence, and detection
(1) The supplier shall establish a review plan for handling, assembly, application, and inspection measures necessary
to ensure the safe and reliable performance of the product.
(2) The supplier shall establish and manage the management standards according to the importance of the special
characteristics process in advance, and the implementation status shall be checked regularly.
(3) Special characteristics process identification methods shall be established and followed in standard documents
and standard documents posted on site so that all employees, including all operators and managers, can easily
recognize and manage them according to procedures.
(4) In order to ensure that the quality control capabilities related to special characteristics in-process equipment and
assembly are within the control range, preventive inspection activities suitable for importance and
characteristics shall be performed.
1) Special characteristic criteria are managed at a high level (such as full inspection or statistical process control)
2) Critical control criteria are managed at an appropriate level
(process capability control, sampling inspection, etc.)
special characteristic process production capacity is secured, and management of the evidence of the verification
result and the establishment of a regular inspection plan for the quality control status and verification activities
shall be carried out.
(6) The placement criteria for operators deployed in the special characteristic process shall be established, and the
distributed quality assurance manual shall be referred to for qualification certification and 4M change
management procedures.
As a quality assurance activity for all mass-produced parts provided to HMC/KIA, it means a test conducted
regularly to confirm the satisfaction of customer requirements to maintain the original quality and performance.
1) The inspection cycle shall be conducted in accordance with the inspection agreement.
2) In the case of combustibility and light-

the characteristics of parts and suppliers.
1) Test standards (conditions, methods, sample quantities) for each part shall be established, and regular tests
with the annual test plan by qualified personnel.

Inspector Qualification: The reliability of the inspector shall be secured through periodic qualification
certification-related measurement (measurement equipment R&R) and attribute type
(nonconforming material detection) evaluation, history management, and continuous training for
quality inspection personnel.
It is necessary to perform periodic calibration of test equipment to maintain optimal conditions. CAPA
analysis records shall be secured and applied to the annual test plan to establish and implement measures for
regular testing and non-executable test criteria.
2) Regular test (reliability) result management
recorded (registered) and preserved.

Detailed data on regular test results shall be maintained and provided upon request by HMC/KIA or related
departments, and reliability and traceability of test results shall be secured by managing the production lot
records of test samples.
1) If the substances used in the materials and parts supplied to HMC/KIA is included as 'P (prohibited)' and
'D (substances subject to notification)' on the Global Automotive Declarable Substance List (GADSL),
IMDS must be registered.
1) Vehicles produced at factories in regulated areas should be applied with improved products two months
before the expiration of the ban on the use of regulated substances.
2) Vehicles exported to regulated areas shall be mass-produced to vehicles six months prior to the expiration of
the prohibition on use of regulated substances.
1) It shall be linked with ISIR, and history shall be managed to prevent omission of analysis, confirmation and
registration of hazardous substances or high-risk substances
(four heavy metals, brominated flame retardants)
2) Standards for consistency check of IMDS registered data shall be established and implemented.
3) In relation to IMDS, data reliability shall be secured by establishing and implementing management
measures for second and third sub-suppliers.
(1) All suppliers shall ensure the quality of mass-produced parts by complying with the test cycle, number of
samples, and methods for regular reliability test criteria agreed by HMC/KIA (ISIR approved standards)
(2) The results of regular reliability implementation shall be recorded/managed, and the results shall be established
and complied with so that reliability can be secured.
(3) Update activities shall be carried out when material changes such as IMDS registration and design changes for
parts being delivered, including secondary subcontracting related to the use of hazardous substances.
It refers to a situation in which at least one of the 4M (Man, Machine, Material, Method) factors for
guaranteeing quality changes is changed, and the following quality assurance activities shall be carried out to
ensure consistent quality.
1) 4M Change criteria
Man : Change of operators in main processes and critical processes, etc.
Machine : Change of facilities, molds, and secondary sub-suppliers, etc.
Material : Change of material and localization of imported parts, etc.
Method : Change of manufacturing method, relocation of production plant, relocation of process,
change of surface treatment, etc.
1) In order to ensure consistent quality of production, appropriate measures and history management shall be
taken before and after the 4M change, and traceability of the product shall be ensured.
2) Before applying the 4M changed product, the customer's approval shall be obtained, and if approval cannot
be obtained inevitably due to an emergency change, etc., the post-process input of the unapproved product
shall be consulted in advance with the customer and the evidence shall be preserved.
(Evidence retention period: ~ Vehicle phase out)
1) Changes to be managed (change content and reason for change), when to apply WHAT, WHY, WHEN
2) Standard forms and procedures for management HOW
3) Change management department, change product verification manager WHO
1) Changes Application
How to notify changes: The appropriate route for reporting and the person in charge shall be handled in
accordance with internal procedures and customer-specified requirements.
Decision to implement changes: For the first product that has been changed, it is necessary to guarantee
whether customer requirements such as dimensions/reliability are satisfied, and the final person in charge
shall make a final decision on mass production after reviewing the contents.
2) Mandatory Preparation Criteria
In order to prevent defects, a verification plan shall be established in accordance with quality assurance
requirements, such as inspection agreements, and the results shall be shared with subsequent persons,
such as related parts and customers.
3) Check When Changes Occur
When a 4M change occurs for each production process, the time of application shall be recorded and
managed by using standard documents, and the 4M management department within the business
regulations shall conduct management and verification activities for each process.
For products applied with changes, check whether there are any abnormalities in accordance with the
quality assurance requirements, and work cooperation shall be carried out so that the person in charge of
follow-up work can conduct preliminary verification.
According to the 4M detailed type, some criteria shall be re-approved for the first article by the customer
other than the 4M notification, and the detailed type shall follow the reference.
4) Evidence Preservation
Records such as production history and inspection results shall be preserved so that problems occurring in
the subsequent process can be identified later due to changes, and in the event of unexpected issues,
the customer may request evidence from the supplier.
(1) The 4M change point management team shall inspect the 4M change criteria frequently after ISIR approval to
establish and implement a procedure for checking whether the 4M management tasks have been properly
performed.
(2) The person in charge of 4M shall check whether there are any occurrences such as omission of verification of
change criteria, omission of customer notification and approval, and input of change product follow-up process
before approval.
(3) When violations of customer requirements criteria for 4M change is identified, the management team (in charge)
and manager in charge shall immediately notify the top management and the customer of the circumstances of
the occurrence and the follow-up action plan.
Quality assurance activities for all parts and raw materials (raw substance) provided by partners or customers,
which are measured, investigated, and tested in accordance with the customer requirements and self-inspection
standards given for each product, and the results are compared to the standards to identify good and
nonconforming products.
1) Daily inspection: Inspection performed according to incoming inspection standards such as pre-warehousing
inspection standards for each lot on materials purchased and delivered from outside.
2) Regular inspection: Regularly checking/inspecting all criteria in the inspection standard for materials
purchased and delivered from outside.
1) Incoming Inspection Quality Control process for outsourced parts shall be established and it shall be followed.
- Mandatory review criteria in the process
Work flow
: Waiting for inspection Inspection Approval inspection(Identification mark) Receiving handling
Inspection standards for incoming parts
: Inspection or no inspection, Change of inspection, Sampling quantity, etc.
Responsible department (person): Conducts inspection by the designated department and person when
parts enter warehouse
Inspection parts
: Local and imported parts, customer-supplied products, CKD outsourced parts, and including raw materials
2) Incoming Inspection Quality Control Result Management
The person in charge of incoming inspection shall conduct inspection according to the relevant standards or drawings and record(register)
the results in the incoming inspection report and manage the real name system and sample lot of inspectors to secure reliability and
traceability of inspection.
The incoming inspection report and periodic inspection report submitted by the supplier shall be maintained and continuously managed
and provided to the relevant sector if necessary.
After the incoming inspection, the inspector enters the acceptance/rejection on the incoming inspection report and product identification
table and manages it.
In the case of nonconforming product occurrence, the nonconforming product identification and isolation procedures shall be followed by
the intermixing prevention procedures.
3) Incoming Inspection Quality Control management subject
The incoming inspection of outsourced parts shall be conducted on all subsidiary materials received for the production of finished products
and shall guarantee that the subsidiary materials received for each LOT are meet with its prescribed criteria.
In case consigned parts(including direct transactions) designated by the HMC in consultation with suppliers in order to maintain quality,
improve and upgrade safety, it shall be ensured that incoming inspection by the provider in accordance with the signed inspection
standards shall be conducted. if necessary, If incoming self-inspection shall be carried out by consumer.
Provider who supplies consigned parts(including direct transactions) shall submit the incoming inspection standards agreed with
HMC/KIA to the parts consumer and shall submit the results after carrying out the incoming inspection according to the standards agreed
with HMC/KIA.
(1) Quality assurance management standards shall be established for all parts supplied from outsourced suppliers
(including HMC/KIA designated consigned parts).
(2) Appropriateness of subcontracted parts incoming/regular inspection standards and criteria establishment shall be secured and complied with.
(3) The standards and procedures for incoming/regular inspection of outsourcing parts shall be located in a place recognized by designated inspectors,
and inspections shall be conducted in accordance with the relevant standards. (Daily, Regular, Reliability Check)
(4) When receiving applicable parts for incoming inspection, in order to confirm the supplier's shipment inspection report, raw material report, etc.,
and to secure the reliability of measurement results, inspection of the specified criteria through consultation between supplier and consumer shall
be confirmed, omission of inspection criteria compared to specifications such as product drawings shall be confirmed.
(5) The criteria for inspection are clear and when converting to inspection from no inspection, the person in charge of the incoming inspection
shall manage the history of the reason for the conversion(problem).
(6) For non-inspected criteria, the supplier's shipment report, product name, specifications, quantity, packaging status, etc. shall be checked.
(7) In case of incoming products produced by molds such as injection, casting, rubber, etc., standards for quality inspection by CAVITY shall be
established and implemented.
In terms of production management, it refers to the production plan and progress management to secure
productivity, but in terms of quality control, it refers to the maintenance and improvement of quality in the
process for securing quality.
Continuous occurrence of manufacturing activities such as production and inspection of products
It refers to the inspection in the production department to determine whether it is okay to send the semi-finished
or finished product of the manufacturing process to the next process.
Defect is a case in which the processing state of the product is out of the specified work content requirements
during production. Process defects are classified into work defects, material defects, design defects, etc. according
to the source of the defect from the viewpoint of product quality and market quality assurance.
It refers to the activities that are actually carried out for each unit work that composes the project.
It is the basis of all computational and analytical tasks and requires time and resources.
In order to ensure, maintain, and improve product quality and process conditions, the relationship between
manufacturing quality and factors (4M) shall be clarified and the material quality control, compliance with the
work procedures, quality inspection and facility management shall be specified in the quality inspection
standard.
In addition, these standards shall be followed and, if necessary, revised.
the beginning to the end of the work. The resulting values shall be used to maintain and improve process
capability and can also be used as feedback data after design or process changes.
1) Operational Status and Quality Control at the Start of Work

In the daily production process, the operation status shall be properly set and inspected at the start of the
work in order to secure the quality of products produced under the same conditions, the quality of the first
product (initial parts) produced according to the conditions shall be checked.
2) Operational Status and Quality Control During Work

In the daily production process, to ensure the quality level of the products produced, it is necessary to
regularly check the operating status during operation, and to check the quality of the products produced
continuously under the same conditions.
3) Operational Status and Quality Control at the End of Work

Immediately before the end of the daily production process, the operating conditions and quality of the last
product (the last part) produced under the same conditions shall be checked to ensure the stability of the
process as well as the quality level of the product produced between the beginning and the end of the work.
1) All parts shall be stored in consideration of external environmental factors (rain, dust, etc.) under appropriate
safety stock standards and shipped in order of production lot (first-in, first-out).
2) During design change, it is necessary to prevent the mixing of parts produced before the change with the parts
produced after the change.
3) Traceability procedures shall be standardized and managed to track the production date (lots) of major
components and raw materials.
1) The most effective maintenance and improvement of production equipment, productivity, quality, safety and
ease of maintenance by visualizing proper machine condition and preventive maintenance with
facility trend monitor.
2) Periodic inspections shall be conducted on the operating F/P devices to prevent nonconforming products from
being leaked in the post-process.
A change point refers to various points in time when one or more conditions among the 4M
(man, machine, material, and method) factors to ensure quality change. Appropriate actions shall be taken before
and after each change point to ensure consistent quality production.
1) The following matters shall be clarified for the management of change points:
Changes to manage
Document form to use
Who, When, How?
Who does change management? (responsible person)
2) Change point management shall be carried out step by step.

Change Point Reporting and Implementation Decision
Checking quality assurance requirements to prevent leakage of defects
Verify that the quality is equal to or as good as before applying the change point
Preservation of production history/inspection result records so that problems occurring in the subsequent
process can be identified in the future due to change points.
The on-site inspections of the overall quality control of the manufacturing process shall be conducted regularly, and
cooperation shall be made to smoothly conduct on-site inspections. If non-conforming criteria or NG products are
found during on-site inspection, necessary measures shall be taken immediately, and the results shall be reported to
the internal or customer for follow-up management.
(1) verification procedure shall be established for the work-in-process before and after the change.
(2) Traceability and identification of changes in the manufacturing process shall be secured.
(3) When changes in the control range and setting conditions of various process condition standards, they shall be
recorded in their standards and stored to ensure traceability.
(2) Specificities and changes in the manufacturing process shall be shared within HMC/KIA so that all employees
can recognize them. (On-site meeting / operator handover, etc.)
(3) Development T/O to establish control standards for process and working conditions shall be carried out and
the results shall be archived.
(4) Regular check activities to check the occurrence of changes in the manufacturing process shall be carried out,
and if any problems occur, corrective actions and quality verification activities for products produced after the
occurrence of the changes shall be carried out immediately.
(1) Inspection : To compare the test results of a product with the criteria for determination and decide pass or fail
(2) Sampling: taking representative samples from all products
(3) Process Inspection: Inspection to determine whether semi-finished products or products in the manufacturing process
can be sent to the next process
(4) Nonconforming product: Raw and subsidiary materials, process products and final products do not meet the stipulated
requirements
(5) Repair: To convert a non-conforming product into good quality meeting the specified requirements.
(6) Deviation: Non-conforming products with minor quality characteristics without affecting the function and allowing
use without repair or after repair
(7) Returned Products: Returned raw materials, subsidiary materials, etc. to sub-suppliers because they do not meet
the requirements prescribed.
(8) Disposal: Disposal of waste products because in-process and final products do not meet the prescribed requirements
and cannot be reworked or treated with deviation.
(1) Full Inspection: To determine whether specific range(quantity) of production lots meets the inspection criteria.
(2) Sampling Inspection: To determine whether some samples of the production lot meet the inspection criteria.
The inspection of the product shall be carried out only by the qualified inspector, and the certification of the
qualification shall be provided by preparing and operating its own standards according to the product characteristics
and supplier's situation by referring to the following matters:
(1) Experience in quality management or inspection work;

(2) Satisfy the recognition status of critical quality inspection criteria for inspection items
(3) Having the ability to use the instrument for product inspection
(4) In the case of new or transferred employees, the completion of training and verification of the above conditions shall
be guaranteed.
(1) Process inspection shall be performed by qualified inspectors in accordance with the qualification procedure.
(2) All inspections are carried out according to the relevant inspection standards or drawings, and the process and
shipment shall not be carried out before approval for each process.
(3) Process inspection is carried out by dividing it into process tour inspection conducted by the quality department and
self-inspection conducted by the person in charge of manufacturing in the production department.
(4) The process tour inspection shall tour the work site in accordance with the inspection standards and shall be conducted
periodically, and the results thereof shall be recorded and presented when necessary.
In particular, objective basis shall be secured to establish management standards for initial settings and to prove the
reason for setting them.
(5) The operator shall frequently inspect the process control criteria of the work standard sheet during work in progress,
and immediately stop production when nonconformity occurs, report it to the production department head and
take corrective action before proceeding with the work.
(6) When nonconforming products occur during process tour inspection or self-inspection, they shall be identified so they
are not mix with good products and stored in a designated location and treated with the nonconforming product
management regulations.
(7) Quality control standards for the vulnerable times (nighttime, weekend production, etc.) shall be established and
managed according to the standards.
(8) Inspection records shall be maintained and managed according to the management regulations and shall be provided
to the relevant departments if necessary.
(9) Analysis of major process inspection history such as special characteristic process shall be conducted for the purpose of
quality level trend, process capability stability, and prevention of major quality problems.
(1) Nonconforming product shall be clearly identified such as labeling, and isolated at the designated location for
nonconforming products so they are not to be mixed with good products.
(2) The inspector shall decide the treatment plan according to the nonconforming product handling procedure,
and the result shall be recorded in the nonconforming product treatment report.
(3) The person in charge of quality shall check the result of measures for nonconforming products and check whether
the recorded quantity and the actual quantity of action are the same.
(4) When screening or rework is carried out, the basis for the history of actions shall be possible to maintain and provide.
(5) If rework is performed on nonconforming products, re-inspection shall be conducted and records shall be stored and
in the case of disposal, the history of actions such as an approval letter for disposition shall be clearly recorded.
(6) The quality manager shall collect the results of treatment of nonconforming products every month and report them to
the head of the quality department and the CEO and take corrective actions to prevent the same quality problem to
reoccur by analyzing the cause of the problem and conducting improvement actions.
(1) All requirements for inspection procedures (4.) and control of nonconforming products (5.)
Raw and subsidiary materials, process products, and final products do not meet
the prescribed requirements
This refers to corrective actions for identification and elimination of cause in the event of an unintended
nonconformity in all products provided to the customer and to conduct preventive activities to occur similar
nonconformities again.
Nonconformity
corrective action
1) Procedures for handling nonconformities are established and shall be followed.

2) Product identification for nonconformities identified from incoming inspection to finished products shall be
clearly identified and stored in isolation in a designated location to avoid mixing with good products.
3) Nonconformity items found in incoming inspection/process/customer receipt/field shall be dealt with in
accordance with the nonconforming product handling procedure, registered, accumulated and managed.
4) A corrective action process for registered problems has been established and shall be implemented.
(cause analysis and improvement measures establishment, implementation, etc.)
5) The person in charge of nonconformity control shall report the processing results and progress to
top-management regularly.
1) Corrective Action
Corrective actions shall be shared with relevant departments, suppliers and customers,
and the countermeasures shall be returned and verified.
In case of judging with nonconformity, the reports shall be prepared, corrective action requests issued,
and countermeasures shall be established to prevent recurrence.
After reviewing the reported corrective action results, check whether they have been implemented effectively,
and depending on the result, the corrective action shall be terminated or re-requested.
Validation checks shall be established according to the characteristics and importance of the components and
shall have and comply with the specified criteria.
The results of corrective actions shall be regularly shared with relevant personnel such as on-site and
management personnel, and periodically reported to the top-management.
2) Preventive Control
The subject of preventive measures is all matters that are estimated to have potential causes of nonconformity,
and if nonconformity is expected, the person in charge of the relevant department shall prepare
a nonconformity report and notify the relevant department.
Prevention of recurrence of past problems and quality prevention control through Product/Design-FMEA
activities of nonconformity occurrences shall be implemented.
Validation review before and after nonconformity remedial measures and any changes to controlling
specifications/standards are reflected in the standard class, and improvement activities such as preventive
checks to prevent recurrence shall be connected.
History control of preventive activities such as counting and analyzing nonconformity of outsourced products
as a whole and by each supplier and intensive control of worst items (process inspection and incoming
inspection reinforcement) shall be carried out.
Regular management review of monitoring activities such as implementation and review of corrective and
preventive action history control shall be conducted.
It means the final inspection of the product that is performed according to the inspection standard reflecting the
criteria/number of samples/cycle, etc. set in consultation with the customer in advance to ensure the quality of
the finished product.
1) Ordinary inspection : To inspect based on items that can be immediately judged as good/nonconforming
among the inspection items required by drawings and inspection standards
2) Regular inspection : To Inspect the selected items by setting a period among the inspection items required by
drawings and inspection standards.
(1) Inspection standards in accordance with finished products inspection procedures

(good/nonconforming product handling procedures), drawings, control plans, and inspection agreements shall be
established and posted on-site.
(2) In principle, all inspections shall be conducted on a lot basis by item, and an inspection cycle shall be established
by setting separate standards for subsequent production. For safety/legal certification items, a margin shall be
secured compared to regulations.
(3) The inspector shall be identified to prove that he/she is a qualified person, and shall provide and use valid
inspection equipment, limit samples or inspection jigs, etc. to judge good/NG products in the process.
(4) In order to prevent some omissions or ineffectiveness of the inspection, comparative verification and monitoring
of records and real products shall be performed, and the inspection results shall be recorded/stored to secure the
reliability of the inspection.
(5) When the measuring equipment is linked with a computer, the result data shall be saved/retained.
(6) For products treated with critical processes such as heat treatment/welding, a separate sample storage standard
shall be established and managed for the purpose of verification when critical quality problem occur.
(7) All finished products at the site(finished goods inspection ledger/shipment waiting ledger) shall be inspected
immediately after production and shall be managed first-in-first-out.
(8) In the event of nonconforming products, the prevention of mixing of defective parts and rework procedures shall
be established and followed.
Repairing defective parts and manufacturing quality defects free of charge to customers through the maintenance
network within a certain period (quality guarantee period) under normal maintenance and use of vehicles
produced and sold by our company and overseas factories (including CKD).
General Claim
Claims due to paint defects
Claims arising when repairs are made free of charge in advance to prevent customer
nds.
Claims arising when customer complaints have been filed but there is no problem with
the vehicle as a result of the inspection.
(1) The organization and the person in charge shall be designated to manage the monitoring and performance of the
claim information received from the customer.
(2) For claim information, standards shall be established to differentiate and manage improvement procedures according
to importance (safety/regulation/commonization parts, etc.).
The improvement procedure shall include details such as the period of product recall / cause analysis / improvement
measures establishment period, improvement areas by type, standardization / Yokoten (Drill-wide) relevancy,
customer approval procedure, effectiveness (on-site) check, reflection of past differences, etc.
(3) For NTF-related quality problems, defective product analysis and continuous reduction efforts shall be carried out,
and if necessary, improvement shall be continued through TFT organization and consultation with HMC/KIA.
(4) For the analysis of defective products, a system such as standardization of analysis methods, aggregation of analysis
results, and management of defective products shall be established, and infrastructure such as analysis-capable
personnel, high-quality analysis room, analysis facilities, and measuring instruments shall be secured.
(5) The organization shall operate an improvement meeting to reduce quality costs and claims, and report to
the management level so that improvement can be promoted by analyzing domestic/foreign claim types and quality
costs every month.
(6) Procedures shall be established so that potential problems that are not recognized by the customer revealed through
field claim analysis can be reported immediately.
(7) For field claims arising due to reasons attributable to business partners, the same problem shall be prevented from
recurrence by Yokoten (Drill-wide) other vehicle types (including other lines of the same factory, other factories,
and enterprises).
- Overseas production of the same car model, reflection of standards (manufacturing process chart, work standard,
inspection standard, test standard, etc.) in similar car models, etc.
Product quality is unreliable, or the quality of the finished product is expected to be negatively affected because
a problem is found in the packaging specifications, product identification, and required quality required by
HMC/KIA.
(1) Poor packaging: Poor packaging, damaged packaging box, non-compliance with packaging quantity, etc.
(2) Different kind parts : Incorrectly attached identification table (part number, lot no, intermixed products, etc.),
products not approved by ISIR
(3) Defective appearance: Scratches, damage, peeling, color difference, deformation, etc.
(4) Poor assembly: Dimensional defect, processing defect, poor assembly, missing assembly, insufficient S/W version
control, etc.
(5) Function/operation failure: Malfunction, non-operation, malfunction of related parts, etc.
(6) Non-conforming parts for periodic inspection: material test, ES/MS specification not met, etc.
(1) Responsible organization and employee shall be designated to monitor and track performance of 0km failures
(2) Supplier shall establish 0km failures handling and corrective action process
(3) Responsible department and employee shall be designated in 0km failures handling process to confirm receiving
method/internal transfer/improvement check/action results.
(4) Improvement shall be categorized into containment and systemic corrective action. Saving time on improvement,
management report and Yokoten (Drill-wide) shall be distinguished considering the importance
(safety/regulations/common parts)
-process quality. If permanent

application of the improved part is needed, the supply shall abide the design change process first.
(6) Monitoring responsible employee shall validate (on-site) effectiveness of the corrective action to prevent
reoccurrence and shall re-perform if the problem reoccurs. Monitoring of 0km failures/analysis and monthly
review of major failure type shall be managed to prevent reoccurrence
(7) Establish self-disclosure process for product issue identified during business or 4M changes and shall prevent
potential problem which can cause line stop at the customer or end-customer claims in advance
General actions to efficiently operate equipment with precision and performance.
Preventive actions to find possible equipment failure in advance and partly or totally repair or change parts before
breakdown.
Actions to repair or change parts after breakdown to maintain equipment performance
Tools to locate, hold and support to prevent bending due to weight of the manufacturing subject. Components of
jig consists of base, sub-blocks, angle bracket, locator, clamp, pin and cylinder
Management history of equipment since the initial set up, safety criteria according to equipment characteristic,
breakdown and repair, planned maintenance, inspection, improvement, re-location and disposal record.
and the user of equipment shall utilize the document for maintenance, repair, part changes history
Equipment registered as assets shall be uniquely identified and managed within shopfloor. Equipment name/
number / maintenance date / next maintenance date / abnormality shall be clearly indicated to be managed on a
daily basis.
1) Equipment maintenance responsible employee shall inspect equipment that can affect the quality of products
according to the inspection standard which indicates equipment location and layout. To ensure the validity of
data, temperature and pressure shall be recorded, and if needed a detail explanation shall be provided.
2) Users of the equipment shall check abnormality regularly and need to report immediately to production
manager, if found. Procedure of this case shall be clearly documented and its history such as, the cause of
problem, down-time and which corrective actions performed shall be recorded.
Production manager shall request for calibration qualification report of the equipment with measurement that
can affect quality to the manufacturer. If not possible, verification and calibration period shall be decided
according to the national standard.
1) In case of production equipment, immediately stop the equipment and initiate follow-up process according to
the internal response action. (Spare equipment needed to prevent supply delay)
2) If repair or calibration of the equipment is not possible, it shall be isolated/disposed to avoid being used in
production.
(1) Check equipment maintenance daily/regular checklist is documented in consideration with the product/process
characteristics and managed.
(2) Check equipment maintenance timing (check if equipment abnormality has been verified before start)
(3) Plan internal/external regular maintenance schedule and clearly define the role and responsibility of
the employees in charge
(4) Establish production restart process after equipment breakdown (escalation/response/responsibility definition)
and check documented history
(5) F/P, Establish automated inspection equipment validity checking process
Generally, mold consist of upper and lower metal parts used to produce products in mass production
1) New mold : Mold made for new model during the new vehicle development or replacement of old mold
2) Production mold : Mold currently being used for current production
Tool with locating mechanism to locate manufacturing subject material at right position and fixing clamps
to guide
Tool for final checking and measuring of each point of part
Storage of mold to safeguard quality of production mold and life span of mold
Maintenance on a daily, regular basis to safeguard quality of product and life span of mold.
1) When a mold is completed, its specification and quantity shall be checked and stored with test report and final
mold drawing before incoming.
2) When a mold is stored, unique numbering shall be tagged and managed to keep the record in such case as using
copy mold.
3) For every stored molds, TRIAL planning shall be established, and TRIAL Tested under supervision of
production department. Check quality of produced part to see the conformity with quality standard, if
non-conform, process the part according to the non-conformance management procedure and establish
corrective action.
4) Any problem found during mold TRIAL shall be notified to the manufacturer to make correction.
5) After the manufacturer makes correction of all problems found, mold TRIAL run shall be performed.
1) Transfer completed molds shall secure spare parts from the manufacturer along with test report, drawing.
TRIAL passed mold shall be categorized considering the number of punch holes and preventive maintenance
plan shall be established.
2) Mold responsible employee shall tag identification with vehicle type/part name on mold and register in the
mold management system after produced parts are approved by the customer and manage continuously.
(
Mold shall be stored on designated storage area(rack) and managed with address by mold location bulletin.
Action plan to prevent contamination from foreign matter shall be established when storing mold and storage
standard to wash/dehydration of cooling water shall be clearly stated. Internal washing process
(procedure, machine, wash liquid, persons) shall be established and performed with no excuse.
Mold responsible employee shall check possibility of internal repairing of mold which is causing quality problem
due to the disorder. If internal repair work is possible, the mold responsible employee shall order repair to the
internal repair responsible employee.
The repaired mold production output shall be confirmed by the production manager.
If internal repair is not possible, the responsible employee shall notify the problem to production manager and
request repair to the designated external repairing company. Safety stock of mold spare parts shall be
standardized and monitored for emergency.
Establish mold grade management standard according to the record of history of repair, quality problem,
number of punch holes and frequency of use. Daily/regular inspection period shall be set according to the
management standard. Daily/regular inspection checklist shall be separately operated and composed of effective
measures.
Internal/customer mold quality problem shall be consistently updated and set major inspection criteria to avoid
the problem reoccurrence. Mold life span shall be ensured by checking reliability of data.
(1) Establish mold daily/regular inspection process and perform to prevent potential mold quality problem.
(2) Establish mold inspection/wash/maintenance/storage process and perform by mold quality risk assessment
(3) Establish mold inspection/wash process to ensure preventive assessment action.
(4) Mold data and history shall be recorded all time and verify data linkage and reliability
e.g. Mold grade shall be set depending on number of punching holes and inspection/wash/overhaul shall be done
according to the grade
(5) Establish mold identification/management process
1) Identify and manage molds with unique numbering in case of same mold to be produced
2) Establish development/production/AS mold identification/management standard
1,177 suppliers(379 domestic and 798 overseas) that deal with 12 domestic and overseas plants
of Hyundai/Kia.
Individual scores of evaluation items are used as bidding scores,

and total scores of evaluation items are used as data for selecting a Quality 5 Star rating.
Incoming part defect occurrence date

(Vehicle assembly and inspection/repairing line: PDI/VPC included, storage warehouse excluded)
R/O Notification Issue date
Quality performance shall be classified into 34 parts categories and the score shall be calculated
based on the supplier's performance compared to the standard value for each part category.
The standard values for each category shall be based on the average performance of the suppliers
in the part category over the past three years. (However, the 2022 standard value reflects the level of change
of +0% to -10% compared to the 2021 standard value.)
A supplier that supplies parts of one part category shall apply the standard value of the part category
to the standard value of the supplier, but a supplier that produces parts of various parts shall apply
the individual standard value of supplier in consideration of the proportion of sales based on the
category. (However, less than 10% of sales is not reflected)
The quality performance score shall be calculated based on the Standard Value and
Quality Performance of each supplier, but the negative value shall be treated as zero point.
Quality management items are comprised of essenital evaluation items for all overseas plants and
optional evaluation items for each overseas plant.
(However, overall score of quality management shall not exceed 20points.)
Essential evaluation items for all overseas plants are calculated as basic points,
and optional evaluation items for each plant are reflected as added or deducted points in total score.
PLA is conducted regularly based on the evaluation cycle selected for each overseas plant
(Korea: every 3 years) and special PLA is conducted for suppliers with a grade of 2 Star or less
in the previous year or a history of field campaigns.
Each year, the PLA score, which is reflected in the annual total score of the Quality 5Star, reflects
the average score of all supplier factories, and the PLA score of each factory applies the latest
evaluation score.
shall meet the PLA score required by each grade.
If the PLA required score for each grade is not satisfied, the total score of Quality 5 Star will be
adjusted to the highest score in the lower grade.
Supplementation level",
the overall level of the relevant item is selected as " Supplementation ".
Level Grading Criteria

Standard Establishment
Management standards are clearly established for inspection items and industry
requirements (see SQ evaluation sheet), and consistency and efficiency are continuously
reviewed/supplemented
Case 1) Continuous review of consistency and effectiveness of management standards by

identifying problems improvement/complementation of management standards
Case 2) Encourage compliance with standard tasks and promote activities to reduce worker
error by operating a reward and incentive system for excellent worker quality control
Case 3) It has superior management standards/competencies compared to other partners,
Excellent
so it can be used as a benchmarking case
Implementation status
Detailed implementation history can be checked 100% without missing data,

and continuous inspection activities are carried out for data abnormalities/misses.
Case 1) The computer system is operated and recorded/checked without omission of
performance records by process and parts, and the data is checked regularly
Case 2) SPC linkage management to conduct continuous inspection activities for important
quality control items and prevent problems from occurring
The management criteria for inspection items and industry characteristic requirements
presented in the On-site Evaluation satisfy all of the following conditions
In-house management standards and field-posted work standards are consistent

All customer designation requirements (drawings, inspection agreements) are reflected
Management standards include clear work procedures (method/cycle, etc.), work division
(qualification certification, input criteria, etc.), action procedures when nonconformities
occur, and can be managed at the same level as before even if the person in charge
is changed
Good The basis for setting management criteria for management items is clear
(management cycle/method/judgment criteria, etc.)
Inspection plan and inspection method/procedure/management standards are
established for the subcontractor's own regular inspection items
(facilities, molds, parts, safety inspection, Shopfloor 3R / 5S, qualification of gauge R&R, etc.)
No missing performance, 100% view of past performance
Case 1) There is no omission or false statement of current and past performance, but
regular monitoring of omission or inconsistency of performance is not conducted
Management standards for evaluation items specified in the on-site evaluation report are
established, but some detailed management standards are omitted, management standards
(procedures/methods, etc.) are unclear, and there is no basis for setting management
standards
Case 1) Facility/mold inspection items and inspection cycle are established, but inspection methods
and criteria for determining abnormalities are not established, and the management standards
are not established
Case 2) Business procedures, division of duties, and procedures for handling nonconforming products
Supple are not clear, which may lead to poor management
mentation Case 3) The subcontractor's own regular inspection plan has been established, but the inspection
criteria such as inspection method/procedure/post management method are unclear
There is no missing execution history data, but no detailed data (only recording pass/failure)
and determination error confirmed
Case 1) When recording performance, accurate conditions are not recorded numerically or clearly,
but only conclusions are recorded through OK/NG, etc
Case 2) Final data on performance is recorded without omission, but it is difficult to secure reliability
of final data due to lack of evidence on the data
Some of the management standards (less than two items) for inspection items specified in
the on-site evaluation are not established, or the established standards are inconsistent with
the actual operating standards
Case 1) Criteria for one or two evaluation items out of all detailed items specified have not been
established
Case 2) Production conditions are specified in the management plan and work standards,
but are different from those specified in the actual production facility setup/management
conditions
Case 3) Part of the inspection plan for the subcontractor's own regular inspection items has not been
implemented
Partial Case 4) Customer designation requirements are not reflected in the management criteria or managed
Inadequacy on a different basis
Implementation status is intermittently missing or inconsistent

Case 1) In the case of self-inspection of parts or routine inspection of facilities, certain items are
intermittently missing or the inspection method/period/number of samples are inconsistent
Case 2) Delayed implementation of some inspection items or delayed improvement of problems
Case 3) Intermittently failed data are passed or omitted during inspection/inspection of parts,
facilities, and molds
(incoming inspection, frequent/daily inspection, reliability/regular inspection, etc.)
A number of management standards (more than 3 items) for detailed inspection items
specified in the site evaluation are not established or temporary workers are assigned
Case 1) Detailed requirements for each inspection item Not established based on more than 3 items
Case 2) Input of temporary workers who are dissatisfied with input criteria such as
production process worker training/qualification, etc
Majority
Inadequacy Implementation status
Implementation status confirm that a large amount of data is missing or intentionally

incorrectly written (including many conclusion errors/mistakes)
Case 1) As a result of checking the history of self-inspection of parts or daily inspection of facilities,
many items are missing or frequently missing
Case 2) Regular inspection was not conducted due to the absence of a person in charge of facility
inspection, but the results of the regular inspection data confirmed that it was falsely stated

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S218100266 / 10.123.24.

Terms and Definitions

reflected in the 5 Star evaluation report in alignment to the above.

1) Process Audit [based on development criteria]

Criteria for evaluation and operation.

1) Quality Procedure Creation Requirement

3) Notable Points in Instruction Creation

4) Kernel Structure of Main Instruction Documentation

1) Document shall be reviewed or revised in case of below

4) Qualification and proficiency evaluation shall be conducted management by reliable evidence

NG Repair Requesting calibration to an external authorized institution

1) Identification shall be selected and done as below.

2) In the case of combustibility and light-

with the annual test plan by qualified personnel.

recorded (registered) and preserved.

Continuous occurrence of manufacturing activities such as production and inspection of products

1) Operational Status and Quality Control at the Start of Work

2) Operational Status and Quality Control During Work

3) Operational Status and Quality Control at the End of Work

2) Change point management shall be carried out step by step.

(1) Experience in quality management or inspection work;

1) Procedures for handling nonconformities are established and shall be followed.

(1) Inspection standards in accordance with finished products inspection procedures

-process quality. If permanent

Actions to repair or change parts after breakdown to maintain equipment performance

Tool for final checking and measuring of each point of part

Individual scores of evaluation items are used as bidding scores,

Incoming part defect occurrence date

R/O Notification Issue date

Level Grading Criteria

Case 1) Continuous review of consistency and effectiveness of management standards by

Detailed implementation history can be checked 100% without missing data,

In-house management standards and field-posted work standards are consistent

No missing performance, 100% view of past performance

Implementation status is intermittently missing or inconsistent

Implementation status confirm that a large amount of data is missing or intentionally

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