MUSASHI SOUTH CAROLINA

AMENDMENTS
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DOC NO:MSC-QM1 SECTION: AMENDMTS

TS Manual Amendment Record
REVISION REVISION DATE NUMBER CLAUSE 7/30/03 1 5- Mgmt. Resp. 7/6/04 2 5- Mgmt. Resp. 9/13/04 1 Forward 3/1/05 3 5- Mgmt. Resp. 5/3/05 1 1-Scope 8/31/05 4 5- Mgmt. Resp. APPROVED BY RSS RSS RSS RSS RSS RSS

CHANGE Updated for organization changes Updated for organization changes Distribution list revised to post on "S" Updated for organization changes Revised scope statement, & expanded 7.3 Product design exclusion detail Updated for organization changes of responsibilities

Issued by: Ralph Sulser Approved by: Keith Shepard

Edition: 01 Date: 04/02/03 Rev. 0

MUSASHI SOUTH CAROLINA

INTRODUCTION
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SECTION NO.
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TITLE Introduction

CL. REF.

REVISION NO.
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Table of Contents 0.1 Foreword 0.2 Structure of the Manual 0.3 Manual Issue Procedure 0.4 -Manual Revision, Updating & Amendment Procedure 0.5 Company Profile Distribution List + 0.6 -0.7 1

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Scope
General Application (Exclusions, if any)

1 1.1 1.2 3 4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4

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Terms and Definitions Quality Management System
General Requirement Documentation requirement General Quality Manual Control of Documents Control of Records

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+May not be part of the "Uncontrolled Copy” of this Manual which is meant for distribution to External Agencies.

SECTION NO.

TITLE

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REVISION NO.
3 Updated positions resp. 3/01/05

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Management Responsibility
- Management Commitment - Customer Focus - Quality Policy Planning Quality Objectives Quality Management System Planning - Responsibility, Authority & Communication Responsibility & Authority of Managers Management Representative Internal Communication Management Review General Review Inputs - Review Outputs

5 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.5 5.5.1 5.5.2 5.5.3 5.6 5.6.1 5.6.2 5.6.3

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6

Resource Management
Provision of Resources Human Resources General Competence, Awareness & Training Infrastructure Working Environment

6 6.1 6.2 6.2.1 6.2.2 6.3 6.4

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2

Note: Printed documents are not controlled copies-check master computer files for latest revisions

Issued by: Ralph Sulser Approved by: Keith Shepard

Edition : 01 Date: 09/13/04 Rev. 1

MUSASHI SOUTH CAROLINA

INTRODUCTION
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DOC NO.:MSC-QM1 SECTION#: 00

SECTION NO.
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TITLE Product Realization

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7 - Planning of Product Realization 7.1 - Customer Related Processes 7.2 - Determination of requirements related to the product 7.2.1 -Review of Requirements related to the product 7.2.2 - Customer Communication 7.2.3 Design & Development 7.3 Purchasing 7.4 Purchasing Process 7.4.1 Purchasing Information 7.4.2 Verification of Purchased Product 7.4.3 Production & Service Provision 7.5 Control of production and service provision 7.5.1 *Validation of processes for 7.5.2 production and service provision Identification & Traceability 7.5.3 Customer Property 7.5.4 Preservation of product 7.5.5 -Control of Monitoring and Measuring Devices 7.6 Measurement system analysis 7.6.1 Calibration/verification records 7.6.2 Laboratory requirements 7.6.3 Internal Laboratory 7.6.3.1

SECTION NO.
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TITLE

CL. REF.
8 8.1 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.3 8.4 8.5 8.5.1 8.5.2 8.5.3

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Measurement, Analysis and Improvement
General Monitoring & Measurement Customer Satisfaction Internal Audit Monitoring & Measurement of Processes Monitoring & Measurement of Products Control of Non-conforming Product Analysis of Data Improvement Continual Improvement Corrective Action Preventive Action

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Section 2- Customer Specific requirements Amendment Record Product Process Flow Chart , Process Approach Charts Organization Chart 0 0

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Annex Annex

Note: Printed documents are not controlled copies-check master computer files for latest revisions

Issued by: Ralph Sulser Approved by: Keith Shepard

Edition : 01 Date: 09/13/04 Rev. 1

This Section titled "Introduction" explains the Structure. Additional copies of the Manual. The Manual lists the Procedures and measures stipulated for ensuring the quality of products manufactured by this unit. This list is used as reference for updating of the respective controlled copies. Revision no. The current revision numbers and edition numbers on each page is also indicated. The Quality Management System has been formulated on the basis of ISO/TS 16949:2002(E) for MSC.4 MANUAL ISSUE PROCEDURE The TS16949 Coordinator/Management Representative is authorized by the Quality Control Manager. This indicates that the copies are not controlled by virtue of the non-red stamp due to the copy process. and the President to carry out the activities of preparing. maintaining and updating of this Quality System Manual. required by external agencies. This master manual is available in English Language only. Uncontrolled copies issued to designated individual s (as per distribution list) are legibly photocopied from the Master Copy. with restricted access. All pages of the Master Copy of each Section of the manual contain electronic signature(s) of the Issuing and Approving Authority of the manual.2 FOREWORD This Quality Manual describes the Quality Management System – Requirements adopted by Musashi South Carolina. The distribution of the Manual and the amendment(s) are con-trolled and the TS16949 Coordinator/ Management Representative carries out this activity. issuing. 1 . Printed documents are not controlled copies-check master computer files for latest revisions.3 STRUCTURE OF THE MANUAL This Quality Manual is structured as shown in the content pages of the Manual. Issue and Updating procedure of the Quality System Manual. For all Sections.:MSC-QM1 SECTION#: 00 Introduction 0.MUSASHI SOUTH CAROLINA INTRODUCTION Page 5 of 45 DOC NO. and are not used within the Company. It must not be reproduced in whole or in part or otherwise disclosed without prior consent in writing from MSC. Quality System Manual pages are numbered serially with page number indication. are issued by the TS16949 Coordinator/Management Representative and such copies of the Manual issued are not stamped in red. Printed Controlled Copies are red stamped "Controlled Document" on the first page. relevant sub-clause numbers under the main clause of QMS Standard have been indicated in the text. ”0” has been given to first issue of the Section. The main clause number of QMS Standard has also been indicated along with title of each Section. The TS16949 Coordinator / Management Representative maintains a record of the distribu-tion list of the Quality System Manual. This Manual and the information incorporated herein are the property of Musashi South Carolina. These uncon-trolled copies do not come under the control of the document amen-dment procedure. and are used for reference only. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition : 01 Date: 09/13/04 Rev. The Master files are in the controlled in the TS16949 Coordinator’s computer files. Different sections are arranged sequentialy as per clause number of ISO/TS 16949:2002(E) and ISO 9001: 2000 (herein after called QMS Standard). if any. and copies may be available in Japanese if required 0. 0. The Master Copy contains the electronic signature of the approving and issuing authority in original.

Toyohashi. QUALITY. Quality Control. Business flourished and they soon became a major supplier of precision automotive components worldwide. including General Administration. was established on October 25th. When revisions take place. South Carolina. 1 . Musashi Seimitsu Industry Co. superior in international world-class quality expectations. 0.4 acres of land near Bennettsville. If there are more than 20 revisions. Thailand. Brazil. Teamwork is essential. United Kingdom. Inc. Musashi continually upgrades technology and customer focus for quality. Purchasing. Tokyo. The 120. and open communication is the cornerstone of all our processes. Musashi Seimitsu has grown to include facilities in the United States. The TS16949 Coordinator/Management Representative retains one copy of the earlier version of the Section(s) in archives for Five Years. All old sections so removed are crossed with an inscription of the marking "OBSOLETE" and returned to the TS16949 Coordinator/ Management Representative who ensures that the same are destroyed. Human Resources. LTD. and started production in 2001. Indonesia and Canada. CUSTOMER FOCUS. Japan started its first Manufacturing operation in Musashino City. No revision is implemented unless it has been approved by the Senior Manager Quality Control. AND CUSTOMER SATISFACTION is a way of life at Musashi South Carolina. E/H/S. Each revision is introduced formally by the TS16949Coordinator/ Management Represen-tative by issue of revised section(s) for each of the copies as per the Distribution List.000 square foot main plant and 10. MSC is dedicated to the Team Philosophy. Our products are sold in the international automotive and ATV markets. then formally issued. Musashi South Carolina. Engineering. UPDATING AND AMENDMENT PROCEDURE The TS16949 Coordinator/ Management Representative in consultation with the related departments reviews the Quality System Manual periodically.000 square foot assembly plant were built on 40. 1999.5 MANUAL REVISION. MSC's production areas are supported by several departments. Maintenance and Tool and Die. Musashi products have an established reputation in the world market for excellence in quality.6 COMPANY PROFILE In 1938. The insertion of the additional/amended sections and the removal of the old sections in the individual controlled copies as per the distribution list of the Manual are the responsibility of the person holding the individual copy. to optimize product performance. MSC produces ATV gears and assemblies and automotive differential gears. and customer focus. the revisions are indicated by the revision number in each of the revised sections and recorded in the Amendment Sheet (Refer Amendment Sheet) supplied with the controlled copies of the Manual.MUSASHI SOUTH CAROLINA INTRODUCTION Page 6 of 45 DOC NO.:MSC-QM1 SECTION#: 00 0. the complete manual is revised to the next edition number. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition : 01 Date: 09/13/04 Rev.

:MSC-QM1 SECTION#: 00 DISTRIBUTION LIST (Distributed uncontrolled copy by electronic e-mail) Posted on the "shared" computer file TS16949 Coordinator (Printed Controlled copy) Master Copy Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition : 01 Date: 09/13/04 Rev. 1 .MUSASHI SOUTH CAROLINA INTRODUCTION Page 7 of 45 DOC NO.

and Gear Assemblies for the Automotive Industry” Application a) Demonstrate ability to consistently provide product(s) that meet(s) customers’ standards. including the processes for continual improvement of the system and the assurance of conformity to customer and applicable regulatory requirements. which specifies the requirements for a Quality Management System in order to: “Manufacture of Gears.3 activities related to Product Design and Development.2 The following ISO/TS16949:2002 requirement is not applicable to MSC QMS. and therefore excluded from our scope: Clause 7. The scope of implementation of this standard is as given below: 1. MSC does not have product design responsibility.1 SCOPE General SCOPE 8 of 45 DOC NO.MUSASHI SOUTH CAROLINA 1 1. SC. 1 . Bennettsville. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 05/03/05 Rev. and b) Enhance customer satisfaction through the effective application of the system. All products are manufactured to customer drawings. The established system is applicable to the activities of the company plant located at One Musashi Drive. ISO/TS 16949:2002(E) and Visteon Customer Specific Requirements.:MSC-QM1 SECTION# :1 MSC has adopted Technical Specification. and applicable regulatory requirements.

following terms / definitions and abbreviations have been used: 3. parts and /or services to MSC Customer: The Customer /end user who buys the MSC products.2 Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev.0 TERMS.:-QM1 SECTION#:3 3.MUSASHI SOUTH CAROLINA TERMS and DEFINITIONS 9 of 45 DOC NO. 0 .1 Terms and definitions: Organization: Musashi South Carolina (MSC) Supplier: Organizations supplying the materials. DEFINITION & ABBREVIATIONS In this Quality System Manual and related procedures / instructions. It is also used for Internal Customers Abbreviations: QMS OPI T/L PC MT PC MGT SP Quality Management System Operator Process Instructions Team Leaders Production Control Maintenance Production Control Management Standard procedure NC FMEA PPAP APQP PH PD CP CAR Non-conformance Failure Mode Effect Analysis Production Part Approval Process Advanced Product Quality Planning Purchasing Production Control Plan Corrective Action Request 3.

2). have also been identified. These processes are managed by MSC in accordance with the requirements of the QMS Standard. b) determined the sequence and interaction of these processes (QC-PM-001 &001b) .1 General Requirements The MSC has established. These have been determined and verified at the time of planning the e) decided to monitor. 0 .0 (Refer 1. (Refer Section 7. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev.MUSASHI SOUTH CAROLINA QUALITY MANAGEMENT SYSTEM Page 10 of 45 DOC NO. The company maintains and continually improves the effectiveness of our QMS in accordance with the requirements of ISO/TS 16949:2002 MSC has therefore: a) identified the processes needed for the quality management system. the continual improvement of these processes. 4. Apart from their identification. (located in the front of manual) c) determined the criteria and the methods needed to ensure that both the operation and control of these processes are effective.0 Quality Management System 4. and f) implemented actions necessary to achieve the planned results and deciding.1. d) ensured the availability of resources and information necessary to support the operation and monitoring of these processes (Refer Section 6 & 7.:MSC-QM1 SECTION#: 4 4.1 MSC assures control over any outsourced processes and responsibility of same conforming to all customer requirements. and a typical bevel gear Process Flow Diagram(s) shown in each part’s PPAP/QAV booklet.1). and implemented a Quality Management System.1). documented. and their application throughout MSC. except for the exclusion as mentioned at Section 1. measure and analyze the above identified processes (Refer Section 8). the Company has also identified the controls over their processes in order to ensure product conformity. if any. The outsource processes. that affect product conformity with requirements. This has been done while planning for the processes.

3 & 5. (Refer Section 5.2. The Company has developed document structure as given below: Level Level Level 1.1 of this Manual) b) Quality System Manual.MUSASHI SOUTH CAROLINA QUALITY MANAGEMENT SYSTEM Page 11 of 45 DOC NO. c) Documented procedures wherever required by ISO/TS 16949:2002 and where the absence of these procedures can affect the quality of the product. complexity of the processes and the existing competence of the personnel. While planning for the processes. operation and control of its processes.4.1 Documentation Requirements General The Quality Management System documentation of the MSC includes: a) Documented statement of Quality Policy and Quality Objectives. other procedures and guidelines / work instructions have also been identified based on the type of the activity.Quality System Manual 2. d) Applicable documents needed by the Company to ensure the effective planning. apart from the required procedures.Standard Procedures 3 -Operator Process Instructions Work Instructions Process Flow Diagrams Drawings / Specifications 4. and e) Quality Records specified by this standard required for demonstrating the objective evidence of having carried out the activity. implemented and maintained.Checksheets. Charts. These have been established. Tags Level MSC has established procedures to conform with those specified in the Standard and identified as “Documented Procedures”.2 4. documented. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. 0 .:MSC-QM1 SECTION#: 4 4. Forms.

and corresponding document changes Procedure No.2.3 Control of Documents Documents required by Quality Management Systems (refer documentation structure under 4. as a part of improvement of the management systems and re-approve the documents after modifications by the designated approving authorities. the MSC has determined. The interaction between the processes(QCPM-001) of the Quality Management System have also been described in the Manual and by including the Process Flow Diagram(s) of the product(s) processed by the Company. g) To prevent the unintended use of obsolete documents by eliminating same and substituting with revised version.1 A system has been established and maintained to assure timely review distribution and implementation of all customers engineering standards/specifications and changes.MUSASHI SOUTH CAROLINA QUALITY MANAGEMENT SYSTEM Page 12 of 45 DOC NO. b) To review and update.1) are controlled. d) To ensure that relevant versions of applicable documents are available at the points of use. readily identifiable and retrievable.4. as necessary.4 Control of Quality Records While planning for the processes (Refer Section No.2. A record will be maintained of the date each change is implemented. remain legible and are readily identifiable by their document numbers. MSC has established a documented procedure which defines the controls needed for identification. 0 . while distributing and use. and to apply suitable identification to them if they are retained for any legal / reference purposes. established and maintained applicable “Quality Records” which provide evidence of conformity to requirements [including regulatory and customer requirements] and of the effective operation of the Quality Management System.2. and disposition of records. These quality records serve as the objective evidence and are part of the Quality Management Systems. the required methodology as adopted and implemented to meet the requirement of the standard have been explained in the Manual itself. 7. Timely review shall not exceed two working weeks.1) . 4. from designated approving authorities. Wherever no procedures are required.1 Records retention controls shall satisfy regulatory. Procedures established have been referenced in the relevant Sections. retrieval. The Company has established a “Documented Procedure” which defines the controls needed to effectively implement the Quality Management Systems. protection.2. Quality records are maintained in such a manner that these remain legible. international / other national standards are identified and updated periodically and their distribution controlled. retention time. storage.2 Quality Manual MSC has established and maintains a Quality Manual that includes the applicable Scope of the Quality Management System (Refer Section 1.Control of Records Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. e) To ensure that documents.2.: QC SP 004 . The controls defined in the procedure include the methods: a) To approve documents for adequacy prior to issue. and customer requirements if these differ from MSC company policies. Procedure No. c) To ensure that changes and the current revision status of documents are identified through establishing distribution and maintaining revision / issue number.2.: QC SP 003 -Document Control 4.3.:MSC-QM1 SECTION#: 4 4. f) To ensure that documents of external origin like customer drawings. 4.1). 4. revision status and/or titles.

These are conveyed to the respective functions for ensuring that they are met.. a focus is made for communicating the customer requirements to all functions and ensuring product conformance. As a part of Management Review (Refer 5.MSC-QM1 SECTION #: 5 5.1 Management Commitment The MSC management is committed to the development and implementation of the quality management system and continually improve its effectiveness by: a) Communicating to all employees of the company: the importance of meeting customer as well as statutory and regulatory requirements through regular training programs. d) e) is communicated to all employees of the company and is understood at all levels in the company. 4 . Methods of determining customer requirements.3 Quality Policy The Management of the company has defined the quality policy ensuring that the quality policy a) is appropriate to the purpose and organizational goals of the company. and e) Ensuring the availability of resources for improvements when required. NO. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev. display of documents and departmental meetings. While reviewing the requirements. the implied needs and expectation of the customer are also identified.2 Customer Focus The Top Management of MSC ensures that customer requirements are determined and fulfilled with the aim of enhancing customer satisfaction. b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality management system. and manag b) Establishing the quality policy based on the improvement objectives. is periodically reviewed for continuing suitability. c) Ensuring that quality objectives are established. c) provides a framework for establishing and reviewing quality objectives.6 below) . expectations and satisfactions are defined in the procedures MGT SP 001 QC SP 023 QC-SP-007 Contract Review (Product Requirement Review) APQP (Planning for product realization) Failure Mode And Effect Analysis 5.0 Management Responsibility 5. f) Product realization process and support processes are reviewed for their effectiveness and efficiency 5. communication meetings. d) Conducting regular management reviews.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 13 of 45 DOC.

Deliver on time.” Dated: 03/20/2003 S. implemented and maintained by all personnel in their respective division / department / section. and inputs of the department management to focus on objectives.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 14 of 45 DOC. and customer satisfaction. Our mission is to make Musashi South Carolina a synonym for a world-class organization excelling in gear. Necessary measures are also taken towards product safety. Okubo President Process interactions of achieving product realization are described on QC-PM-001. The policy of Musashi South Carolina is to achieve total customer satisfaction by delivering products and providing services that meet or exceed customer quality requirements and expectations.MSC-QM1 SECTION #: 5 The Policy of the company has been displayed at strategic locations and also distributed to all employees. MSC Senior Management. and timely deliveries – QCD (Quality. employee support. QUALITY POLICY “MSC will continually strive to produce quality products that meet or exceed customer expectations. and customer communication. Periodic Training Programs are held for understanding by all the functions through out the organization. and environmental needs to minimize potential risks to employees.R. Outlined below are typical duties. Ultimate goal of working towards achieving zero defects. cost competitiveness. and gear assembly manufacturing. Quality Policy distribution and display records are maintained. 4 . Current plant organizational charts are on file in H. Cost. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev. NO. and area Team Leaders shall ensure that this policy is understood. It is implied that all people at all levels in our organization be committed to comply with requirements and continually improve the effectiveness of the Quality Management System and their performance. Delivery) – through exercise of continual improvement. and subsequent end users. and at the most competitive prices in domestic and export market for our entire product range. Assistant Managers. Department Managers..

 Reviews customer scorecards for Visteon. and b) the integrity of the quality management system is maintained when changes to the quality management system are planned and implemented. Projects.  Supporting QMS activities including regulatory requirement if any. 1.  Developing facilities. pump house and LPG and all utilities  Manages.Musashi South Carolina  The senior most executive at the plant and designated as President. Senior Manager Engineering/Maintenance  Overall responsibility for planning.  Approves customer and supplier contract review actives. 4 .  Approves the company's policies and gives directions for managing the objectives. and in which a QMS can operate effectively. and has responsibility for the entire operation. authority and communication 5. 5. Maintenance. The quality objectives are measurable and consistent with the quality policy.  Preventive/Predictive Maintenance.5. the President creates an environment where people are fully involved.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 15 of 45 DOC. Top management defines quality objectives and measurements that are included in the business plan and used to deploy the quality policy.  Approves the MSC's quality policy and objectives.  Responsible for effective implementation of the quality management system.1.4. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev. as well as the quality objectives.MSC-QM1 SECTION #: 5 5.4. 5.  Reports to the Plant President. including those needed to meet requirements for product [see 7. and coordinates any modifications to be carried out in the existing operations or enhancing the efficiency of the plant. on their web sites  Chairman of the Management Review Committee.  Responsible for building the required competency level in the employees reporting to him.  Assisted by Manufacturing Engr. Electrical. and other customers. President . and quality management system. processes and equipment. Mechanical. and company activities. Manager.1 a)] are established at relevant functions and levels within the organization.  Through leadership and actions.. Maint.4 Planning 5.. coordinating & managing activities related to functions of Manufacturing Engineering. Tool/Die. NO.2 Quality management system planning Top management ensures that a) the planning of the quality management system is carried out in order to meet the requirements given in 4. Mgr.1 Responsibility and authority Top management ensures that the responsibilities and authorities are defined and communicated within the organization. Quality objectives address customer expectations and achievement goals within a defined time period.  Responsible for providing essential resources and personnel for implementation of the quality policy. for the products. Compressor.  Authorized for taking corrective & preventive action in case of deviations in the operations.5 Responsibility.1 Quality objectives Top management ensures that quality objectives.  Authorized to “STOP PRODUCTION” if systems are not being implemented.  Authorized for approval of production processes in the plant. 2. and contingency plans.

 Providing Test Status on In-coming.  Representing the needs of the customer in internal functions in addressing the ISO/TS 16949 requirements. process standards. measuring and test equipment. selection of special characteristics. In-process and Final Inspection Stages  Calibration of all identified inspection.  Controlling of non-conforming products. setting quality parameters.  Obtaining waivers from customer on non-conforming finished products.  Authorized for providing inspection and test status on all products. Control Plans and Process Standards. 4 . in process and final stages  Controlling the procedures for In-coming. procedures.  Authorized to “STOP PRODUCTION” if systems are not being implemented.  Inspection and testing at incoming.  Monitoring and Measuring Customer Satisfaction metrics. In-process and Finished Products  Documenting trends in quality and current quality levels.  Assessment of Preliminary (Ppk) and on going process capabilities (Cpk). and contact for quality issues.g.MSC-QM1 SECTION #: 5 3. TS16949 Coordinator  Reviews and maintains scorecards for Visteon. and Inspection Standards.  Production Part Approval Process (PPAP&PSW) and liaison with customers for same  Establishing. ·  Representing the needs of the customer in internal functions addressing the product realization planning (APQP) for ISO/TS 16949 requirements (e.  Assisted by Quality Control Mgr. weekly on their web sites  Designated as Customer Representative to ensure customer requirement are met. drawing and documents of external origin. and other customers.  Authorized for dispositioning deviations on Non-conforming products for use at next stages. Reports to the Plant President Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev.  Issuing and maintaining originals and withdrawal of obsolete APQP documents.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 16 of 45 DOC. FMEAs. QC.  Developing and implementation of plans for customer complaint resolution. and maintaining customer communication channels. and instructions for the plant  Monitoring the Process for outputs. QC Technicians.. NO.  Verifying the effectiveness of corrective and preventing actions.  Identifying and implementing statistical technical techniques for process and product.  Preparing details for Production Part Approval Process.  Authorized for release of finished product. QC Associates.  Develops manufacturing process design quality controls including Process Flow Diagram. Senior Manager – Quality Control Responsible for quality systems.

and packaging Receiving. and supplier monitoring. storage. Accounting Manager  Overall responsibility for all accounting. Assistant. Reports to the Plant President 5. ISO14001 and assisted by the EHS Administrator Assisted by Managers. and implements training. WIP and finished product. and the Assistant Manager Purchasing/Buyer. approving and maintaining effectiveness of the procedures for the above activities. 4 . and Assistant Managers for Forging. coordinating & managing activities related to functions of Production Purchasing of manufacturing materials. and employee motivation needs. Production scheduling of all products Control of customer-supplied products. if systems are not being implemented. Determine the training needs related to managers.  Reports to the Plant President.  Assists in guiding and supporting QMS related activities in those functions such as purchased supplies. and other customer rating systems Authorized for approval of production processes in the plant. Guiding and supporting QMS activities including regulatory requirement if any. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev. and IT Administrator for these activities. Supplier performance tracking Supporting QMS requirements related to these functional areas. Also responsible for public affairs. Assisted by Production Control Manager.MSC-QM1 SECTION #: 5 4. Communicating customer’s requirement to concerned personnel in the company. tooling. for these activities. Review of customer’s order for correctness. and waste. and stores. and packaging. and trainees. 6. Checking adequacy of FIFO. NO. on their web sites Preparing and submitting the quotation offer to customers. and Coordinators. and other customers. Assisted by the H. Inventory management of purchased products. for the products. preservation. Senior Manager Production/Production Control/New Sales                              Overall responsibility for planning. associates. finance. identification and test status of all products during receipt. temporaries. Reviews customer scorecards for Visteon. Assistant Manager of Accounting. and industrial relations to enhance productivity. Reviews customer scorecards for Visteon.       Manager– Human Resources Responsible for coordinating with departmental heads to obtain staffing. Identifies. Lathing. storage and issue of products. and Payroll Coordinator. Reviewing. Interaction with Customer for product development and all contract review activities Also responsible for EHS. Authorized for taking corrective & preventive action in case of deviations in the operations.R. staff.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 17 of 45 DOC. Handling storage. Ensuring 100% on time delivery to customer.  Assisted by the. Disposal of scrap. Accounting Coordinator.. Receipt of order / dispatch schedules from customer. and supplies purchasing functions in the plant. probationers. Authorized to “STOP PRODUCTION” in his area. Reports to the Plant President. Heat Treat/Assembly. Resolving any differences between the inquires and potential orders.

 Reviewing customer engineering specifications and standards.     President . Quality Controlare responsible for  Establishing. Reports to President Musahi North America 9. Detroit.. irrespective of other responsibilities. all work instructions. who. NO. 5.5. as Management Representative. Personnel responsible for product quality have the authority to stop production to correct quality problems. and summary of the Preventive Actions for Management Review.Japan  Reviewing. has the responsibility and authority that includes: a) ensuring that processes needed for the quality management system are established. has the responsibility and authority that includes: Management Representative (MR) / TS16949 Coordinator.  Developing guidelines of new products planning. recommending and providing guideance for effectiveness of the procedures on Product requirement Review – Manufacturing Process Designing and Development.  Organizing Audit Summary Report.2 Management representative Top management has appointed the TS16949 Coordinator-Quality Control who. Management Representative ( Ref. b) reporting to top management on the performance of the quality management system and any need for improvement. Plant Facilities and Equipments Provisioning. and Procedures Manuals  Maintaining original documents and their master lists and issue of Quality System Manual. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev. irrespective of other responsibilities.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 18 of 45 DOC.  Approving and ensuring effectiveness of procedures on Document Control.5. d) liaison with external parties on matters relating to the quality management system. MSI Engineering. and passes thyrough to Musashi South Carolina Coordinating with MSI.1. which forms the basis for improvement of Quality System. Production operations across all shifts are staffed with personnel in charge of.Sales and Marketing-Musashi North America. or delegated responsibility for.2 ) The Management of the company has appointed the TS16949 Coordinator. and samples of all formats Identification of training needs for building a team of internal quality auditors 5.  Ensuring timely management review of the Quality System. Quality Management System Auditing and Records Control. 8. 5. implementing and maintaining quantity system in accordance with ISO/TS 16949:2002 (E)  Reporting the performance of the Quality System for Management Review. and c) ensuring the promotion of awareness of customer requirements throughout the organization.5.1 Responsibility and authority of managers Managers with responsibility and authority for corrective action are promptly informed of products or processes that do not conform to requirements.  Liaison with internal and external parties on matters relating to Quality System. implemented and maintained. 4 .  Preparation and issue of Quality System. ensuring product quality. MSC President for planning future business Assists in assessments of customer satisfaction. all Quality System Procedures. review.MSC-QM1 SECTION #: 5 7. MI Receipt of Inquiries from the customers.

6. The output from the management review in the form of minutes of meeting and action plans include any decisions and actions related to: a) Improvement of the effectiveness of the quality management system and its processes.2. and actions to be taken on nonconformances encountered in the activities including customer communication.5. However. and trends for continual improvement.2.6 Management review 5. k) Status and results of Quality objectives and Quality Improvement Programs.1 The Sr.6.1 Review input The input to management review in the form of Agenda for Management Review Team meeting includes information for the period under review on sections of applicable QMS STANDARDS. and reported with summary results. safety. i) Planned changes that may affect the quality management system. The review includes assessing opportunities for improvement and the need for changes to the quality management system. (Customer perceptions & Complaints) d) Analysis of actual and potential field failures and their impact on quality. f) Results of internal/external audits including the trends.6. Monitoring quality objectives Regular reporting and evaluation of cost of poor quality Evidence of achieving: quality objective specified in the business plan Evidence of customer satisfaction with products supplied 5.6. g) Process performance and product conformity. feedback. 4 . analyzed. Manager-Quality Control has been designated as Customer Representative to assure customer requirements are addred within MSC. The Quality Management System of the company is reviewed by the Management Review Team that comprises all Managers of Departments under the Chairmanship of the President.3 Internal communication The Management of the MSC ensures that appropriate communication processes are established within the company and that communication takes place regarding the effectiveness of the quality management system.MSC-QM1 SECTION #: 5 5.a. 5. and delivery 5. or the environment. NO.1 General Top Management of MSC reviews the company’s quality management system. Visteron will be notified of any changes to customer rep. 5. critical paths.. safety or the environment e) Follow-up actions from previous management reviews. l) Performance of Suppliers. including the quality policy and quality objectives. and their impact on quality. at planned intervals to ensure its continuing suitability. performance.5. and c) Resource needs support Procedure No. 5. e. 5. lead times. Management Representative maintains records of management reviews. costs..3 Review output The minutes of the management review meeting are recorded and maintained for a specified period. QC SP 001 – Management Review Management Review Form: QC-F-MR418 Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 08/31/05 Rev. monthly ratings for quality. Items such as quality risks. more focus is placed on the following: a) Business Plan/Quality objectives b) Cost of poor quality c) Customer satisfaction.1 Additional Review Inputs a) Management analysis of actual and potential field failures.. or senior mgmt. adequacy and effectiveness.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 19 of 45 DOC.6.1. h) Status of preventive and corrective actions. b) Measurements at specified stages of design and development will be defined. and others as appropriate.1 Quality Management System Performance-Input All requirements of the quality management system. b) Improvement of product related to customer requirements. and j) Recommendations for improvement especially for product / process characteristics.

are assigned the tasks on the basis of defined competence. such as competent personnel. b) To evaluate. These resources are identified at the time of planning for product realization and periodically reviewed (Refer Section No. technical college courses. continual improvement and promote innovation. During this training. These records also help in determining the need for multi-skill training requirements. On the job training is provided to all the personnel including temporary/contract personnel whenever there is any new or modified job/process affecting product quality is incorporated.2. 7. procured. Awareness and Training MSC has established a documented procedure for Training. the training needs of personnel are identified to ensure competence for carrying out their activities. Hence the personnel performing such work. skills and experience for the specific jobs. Procedures are issued to ensure that these are fit for use in carrying out work and verification activities. Procedure: HR SP 001 Training HR SP 002 Resource Management Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev.2 Competence. d) To maintain records of education. which affects product quality.2. 6. if any.e. proper working environment and adequate infrastructure needed to implement and maintain the Quality Management System and continually improve its effectiveness. Department Managers identify the resources required for implementing. For process design responsible personnel this includes competence on design tools and techniques a) To provide structured / unstructured training (i. training. on job training / coaching under the supervision of their seniors) to the identified personnel to satisfy and meet their training needs. toward progress in their achievements: c) To ensure that the MSC associates are fully aware of the relevance and the importance of their activities including their involvement and contribution to the achievement for the identified quality objectives.1 ).2 6. A process is in place to ensure that personnel are aware of the relevance and importance of their activities and contribution in achieving quality objectives.1 Resource Management Provision of Resources MSC determines and provides the resources. skills and experience of all associates as quality records.1 Human Resources General MSC has identified the competence level required for the personnel carrying out the activities in different areas of operations and production departments. (Refer to Skill Maps for each department) f) A documented procedure has been established and maintained for employee motivation and empowerment for achieving quality objectives. The job descriptions are also used for identifying the training needs of the personnel to ensure they are competent to do their assigned activities. associates are informed of the consequences to the customer of non-conformity to quality requirements. performing and verification activities related to MSC’s quality management systems. training. after a defined period. 6.2. Through this procedure.1 above). The controls exercised for making the personnel competent are: a) To determine the required minimum competence for the personnel performing work affecting product quality in terms of criticality of the process through defined “Job Description (Profiles) (Refer Section 6.: MSC-QM1 SECTION#: 6 6 6.MUSASHI SOUTH CAROLINA RESOURCE MANAGEMENT Page 20 of 45 DOC NO. reviewed and provided as and when required to enhance customer satisfaction by meeting customer requirements.: 0 . These are further examined. the effectiveness of the structured / unstructured training provided. Equipment and instruments needed for work and verification are identified. Necessary identified resources are planned and provided to meet the requirements. The “Job Description (Profiles) for all functions have been defined on the basis of requirements related to appropriate education.

key equipment failure and field returns.. Procedure: QC SP 024 Contingency Plan MT-SP-001. the required infrastructure at the time of Planning for Product Realization (Refer Section No. At the time of planning for Product Realization (Refer Section No. and preventative maintenance schedule matrix for maintaining the above infrastructure by conducting preventive. noise.Procedure for Preventative Maintenance(update-CG) 6. as appropriate to the nature of the work being performed. 7.MUSASHI SOUTH CAROLINA RESOURCE MANAGEMENT Page 21 of 45 DOC NO. cleanliness and repair. g) A contingency plan is prepared and followed in all manufacturing departments to ensure supply of products in the event of emergency such as utility interruptions.  Human factors such as ergonomics (space required for effective working). The work conditions and environment are continually improved for meeting the product requirements.1 Personnel safety to achieve product quality Product safety and means to minimize potential risks to employees. and can meet the customer requirements. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. and need for the use of personal protective equipment (PPE). e) supporting services. and repair consistent with the product and manufacturing needs. 6. with a multidisciplinary approach. and customers are addressed by MSC.: MSC-QM1 SECTION#: 6 6.4 Work Environment MSC determines and manages the required work environment needed to achieve conformity to product requirements as per documented process.2 Cleanliness of premises MSC maintains the premises in a state of order. handling and value added use of floor space. condition monitoring and break-down maintenance in order to ensure continuing suitability. air quality.: 0 . and facilitates a synchronous flow of material. processing and storage c) required associated utilities like power. The data related to maintenance is analyzed and maintenance objectives are established for continual improvements. fuel supply. processing. water supply. especially in the design and development process and in manufacturing process activities. Cleanliness of premises is maintained using 5S check lists to ensure the premises in a state of order. A system is in place to evaluate and monitor the effectiveness of existing operation. These requirements are met by providing the adequate facilities and conducting regular maintenance for their upkeep. MSC has also established a documented procedure. reviewed upgrading. cleanliness. 6. humidity. The following applicable work environment factors are considered at the time of planning:  Temperature. As per the identified requirements.4. vibration.1 ). d) required process equipment / machinery (both hardware and software) which can meet needs for converting the inputs into required outputs at relevant stages of processing.1 ). compressors. 7. inspections b) adequate workspace for working and house keeping.3 Infrastructure MSC identifies and determines. the requirements of Work Environment are considered and examined and wherever required.4. lighting. MSC provides the infrastructure needed to achieve conformity to product requirements. The infrastructure considered during planning includes: a) adequate buildings for storage. labor shortage. such as transport for movement within and outside of MSC and required means of communication. utilities etc. f) Plant layout is developed in such a way so that it optimizes material travel.

amendments of relevant documents if product requirements are changed. conformity to customer requirements for designation.e. then action plans are initiated. as appropriate. packing requirements are clearly defined. Procedure No. The following are considered.1. the FMEAs (failure modes).2 Customer Related Processes 7. updating / modification for improvement in the existing process: a) identified quality objectives and requirements for the product. Severity.4 A system is in place to control and react to changes that impact product realization. 7. Product and process regulatory requirements are also given due consideration during the development and preparation of relevant Process Control Documents. quality inspection plans are made and provided at the relevant stages of processing for implementation. verification. and ability to communicate necessary information in customer specified language and format 7. review of requirements related to product prior to supply and resolving any differences. infrastructure. and approved by the customer if required. Acceptance criteria for attribute data sampling is zero defects.1.0 Product Realization 7. inspection and test activities specific to the products processed at relevant stages of processes and the criteria for the product acceptance. [7. If upgrades are required for improvements.1. e) records needed to provide objective evidence that the realization processes and resulting product fulfill requirements. The acceptance level for attribute data sampling is always zero defects. The output of this planning in the form of a Control Plan. the customer requirements are confirmed before acceptance by: phone calls. QC SP 023 Advanced Product Quality Planning 7. documented and controlled 7.:MSC-QM1 SECTION#: 7 MSC uses a multi-disciplinary approach for Planning for the products realization [using advance product quality process]. d) 7. conforming and documenting the manufacturing feasibility of the proposed product determining and implementing effective arrangements with the customer. work environment and competency of required personnel are identified. it is ensured that the requirements of the other processes of the Quality Management System (see 4. e-mails. letters. Detection criteria) are studied and the required controls are identified.2.2.1. and control of special characteristics. 7. The business risks. documents. Where the customer provides no documented requirements. 0 . Occurrence. and Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. meetings.1 Determination of Requirements Related to Product The organization has established a documented procedure to determine: requirements related to product including those specified by the customer.2.MUSASHI SOUTH CAROLINA 7.1 Planning of Product Realization PRODUCT REALIZATION Page 22 of 45 DOC NO. documentation. not stated by the customer and statutory and regulatory requirements. validation is done for the changes including the changes by the supplier. Operator Process Instructions. their current status (i. c) required verification.1 Customer designated special characteristics are identified for conformance according to customer requirements of the designation. or process control standards (PCS).] b) the need to establish processes. FMEA.2 Acceptance criteria are defined by the company. and provide resources specific to meet the requirements of the product.3 Confidentiality of customer contracted product/projects and related product information. While Planning for product realization.1. b) Contract or order requirements differing from those previously expressed are resolved.1 Customer requirements and references or differences to the specified technical specifications are included in the planning.2 Review of Requirements Related to Product MSC reviews the requirements related to the product. The resources. at the time of development.1) are consistent with the anticipated requirements. This review is conducted via a check list prior to the organization's commitment to supply products to the customer and ensures that: a) Product requirements including delivery schedules. investigating. monitoring. validation. MGT-SP-001 Contract Review Procedure No. Assessment.

analyzed and reported with summary results in the management reviews. Process approval acceptance criteria data for quality.2 Design and Development Planning MSC only manufactures products from customer provided designs and specifications. 7. prior authorization from the customer is obtained before proceeding with the contract. MGT SP 001 . (process failure mode and effective analysis). MGT-SP-001 Contract Review Procedure No.3. Inspection methods. FMEAs. The modified documents are conveyed to relevant functions for making them aware of the changed requirements for immediate compliance.MUSASHI SOUTH CAROLINA PRODUCT REALIZATION Page 23 of 45 DOC NO. 7. If any amendments to product requirements are received from the customer. meetings.3. utilizing appropriate mistake proofing methodologies with efforts on defect prevention rather than detection and. confirmed and documented before contracting. and the relevant documents are amended accordingly. and c) Customer feedback.:MSC-QM1 SECTION#: 7 c) MSC has the ability to meet the defined requirements. as appropriate as an output. 7. Programs of design and development is monitored at defined stages / frequency.e.2 The design and development inputs are then identified.2. e-mails. verification and validation requirements and responsibilities / authorities for design and development. i. e-mail. creating internal awareness on safety considerations. prepares process flow diagrams. contracts or order handling. Pre-launch and Production as appropriate including listing all controls used for process control. develops Control Plans and identifies special characteristics for products giving due care to product safety.Procedure for Contract Review QC SP 019 . including resolving customer complaints. which directly affect the quality of products. The team carries out feasibility studies. Methods of rapid detection and feed back of manufacturing process non conformities are defined. e) In case any formal review of the contract is not applicable.. or becomes in-capable / unstable. Procedure No. Control Plans are reviewed and updated if the product or process changes. All production processes. PFMEA. b) Inquiries. QC SP 023 APQP 7. Control Plans are developed at the system. electronic data exchange) Procedure No.2.2.3. sub system and component levels for the products supplied at the different phases via Prototype. (web sites. maintainability and measurability results of error-proofing activities. Records of the results of the review and actions arising from the review as quality records are also maintained. Control Plans. and web site. work instructions or process standards. d) Where required by the customer. These are marked with the customer’s special characteristics symbols. letters. Process Standards and Operator Process Instructions. Upon receiving a Letter of Intent (LOI) or Purchase Order (PO) from the customer the organization develops a process design and development plan defining the development stages design review. and therefore performs only manufacturing process design and development activities in conjunction with Planning for product Realization. documented and reviewed based on product and customer requirements and experience from previous developments.Procedure for internal & External Customer Satisfaction 7. are considered during quality planning. The decisions taken for corrective and preventive actions including further improvements in the products / processes.3 Customer communication MSC has determined and assigned responsibilities for implementing effective arrangements for communicating with customers in relation to: a) Product information through customer visits.3 Manufacturing design outputs consist of process control guidelines. MSC ensures that these are reviewed for ability to supply. d) Manufacturing feasibility including risk analysis is investigated. 0 .Corrective Action (Includes Customer complaint response) QC SP 011 . including amendments. Such feedbacks from customer are reviewed and analyzed for root cause of the problems through problem solving techniques. if specified by the customer on the drawings/documents supplied. of the design and development activity in the form of procedures. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev.2. reliability.3.1 The organization uses cross-functional teams for manufacturing process design and development. and frequencies are also revised if necessary. necessary information including data is communicated to customers in their specified language and format.

Tooling. verified and validated after production part approval.6 Purchasing – Materials/Components (Production Control Manager) PH-SP.6 Purchasing-Materials/Components (Production Control Manager) PH.4. MGT-SP. premium freight. Records of results of reviews.6. delivery schedule performance.002 Approved Supplier List 7.SP. Manager Production Control and President) PH-QP-4. The authorized Production Control Manager or Purchasing Manager reviews the purchase information to ensure the adequacy of specified purchase requirements prior to their communication or issue to the suppliers.3. procedures. and equipment.1 Purchasing Purchasing process MSC has established a documented procedure to ensure that purchased products conform to specify purchase requirements [including conformity to applicable regulatory requirements].2 Purchasing information MSC has established criteria for detailing adequate “Purchasing Information” in the Purchase Documents (in hard copies / through emails ) for the products to be procured. verification and validation of the newly designed and developed manufacturing process is carried out at sample / prototype. b) Requirements for qualification of personnel.MUSASHI SOUTH CAROLINA PRODUCT REALIZATION Page 24 of 45 DOC NO.3 A procedure has also been established for production part approval process (PPAP) addressing the following activities as applicable: -identification of need for submission / preparation of PPAP -decision on submission level -Preparation of Part Submission Warrant and submitting a copy of PPAP document / sample to customer. Supplies (Purchasing Manager) Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. Criteria for selection. evaluation and periodical re-evaluation have been established [monitoring of the supplier is done using documented process which considers the indicators like quality. including where applicable: a) Requirements for approval of product. Records of the results of evaluations and any necessary actions arising from the evaluation at company or supplier end are maintained. customer notification].001 Contract Review (Sr. Manager Production Control and President) PH-QP.001 Contract Review (Sr. QC SP 009 – Parts Submission Warrant/PPAP 7. 0 . and Quality management system requirements.4. The Company evaluates and selects suppliers based on their ability to supply product in accordance with the Company’s requirements [where specified by the customer. purchasing is done from customer approved sources only unless waived by the customer. verification and validation of manufacturing process design and development activities are maintained. The product and supplier details are described in Purchase Documents or e-mails. MGT-SP.005 – Purchasing Indirect Materials. processes.4.:MSC-QM1 SECTION#: 7 7. Developed product is reviewed at sample / prototype stage. as appropriate -Maintaining original PPAP documents / records -Maintaining master sample (s) -Incorporating changes required by customer in the documents and processes Part approval process is used for suppliers.4 7. The type and extent of control applied to the supplier and the purchased product depends upon the effect of the purchased product on subsequent product realization or the finished / final product. production part approval and pre-launch stages of production respectively. Procedure No. The system ensures that the engineering changes are properly validated. field return and special status. Review.

7. When it is proposed to verify the purchased product at the supplier's premises by either customer or company’s representatives. setup.1.MUSASHI SOUTH CAROLINA PRODUCT REALIZATION Page 25 of 45 DOC NO.3 First piece set up is approved. Procedure No. 7. If in the future Service Provisions become a requirement. and Appearance Items are not currently a contractual part of Musashi South Carolina customer requirements.3 Verification of Purchased Product a) MSC has established a documented procedure for implementing the Inspection / Testing or Verification of the products. and Operator process Instructions.1. and not part of MSC’s current manufacturing operations.5.5 A system for maintenance of production tooling has been established including maintenance personnel storage and recovery. e-mail.5.5. logistics.5. Suitable equipment. A system has been established to assure minimum stocks of replacement parts for all key manufacturing equipment.5.5.6 The production scheduling is customer order/ forecast driven and supplies are made just in time based on customer schedules/releases and electronic dispatch instructions (EDI). as necessary.5.1 Controls Plans are developed at the system.) Test Report from accredited laboratory. and checklists for employee responsible for the operation of process including set up personnel.4 Detailed checklists developed for each process equipment are used for preventive maintenance and predictive maintenance as per the maintenance plans developed yearly and reviewed monthly. 7. 0 . documentation. Production is controlled by way of preparing and implementing Operator Process Instructions. 7. before allowing mass production by authorized person during each job change of each operation. and phone calls. we would develop a procedure to incorporate those requirements Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev.5 Production and service provision 7. 7. prototype pre-launch and production. (Rec. tool and tool design modification. 7. Control Plans are reviewed and updated when any change occurs effecting product. we will address them in accordance with the applicable specification. b) During verification of purchase product one of the methods as given below are followed: Receipt and evaluation of statistical data Receiving inspection and testing on the basis of sampling Assessment of supplier by customer or third party supported through acceptable product quality record.1. for ensuring that purchased products meet the specified purchase requirements.5. Control Plans.7 Customer feedback from service or field performance concerns is transmitted to the company via web customer web site. supply source or FMEA.1. and/or standards. tested/verified for conformance to the specified requirements.2 The manufacturing departments carry out production based on the Operator Process Instructions and prepare any additional work instructions necessary. all material at incoming stage are inspected.1. QC SP 014 Receiving Inspection-Bar Stock Work Instruction PD-WI-017 Receiving Steel Bars Work Instruction PD-WI-HF-109 Receiving and inspection of ATV Billets 7. which are accessible for use at the work station. the company also allows its customers or their representatives to verify that the purchased materials at supplier end for ensuring materials conformance to specified requirements.e. As a first phase suppliers are encougred to pursue and obtain third party certification to ISO 9001-2000 and finally to ISO/TS16949-2002 if applicable.8 MSC currently does not have any service agreements with customers. for different stages of process development i.4. and X bar & R Charts. c) If contractually agreed. These are then modified to reflect MSC actual conditions. Other methodology as advised by the customer.:MSC-QM1 SECTION#: 7 A goal has been established for quality management system development of suppliers That goal is eventual supplier conformity with ISO/TS 16949-2002.1. Equipment. Work Instructions. tool change program for perishable tools. MSI Engineering Departments during Manufacturing Process Designing and Development process prepares initial FMEAs. The company ensures that through this procedure for receiving inspection and testing.1.1 Control of Production and Service Provision Servicing. from the process FMEA output. 7. tool identification and tool status. If in the future these become a requirement.1. and monitoring and measuring devices are provided and maintained. 7. Release and delivery activities are implemented.5. Check Sheets. component and / or material level for the product supplied. manufacturing process.Insp. the verification arrangements and the method of product release are specified in the purchase order or its attachments. tooling and gages not likely to be used for a considerable time are packaged and preserved per a checklist. Maintenance objectives are developed in the beginning of financial year which are evaluated and improved at planned intervals. subsystem. measurement. 7.

5.5. samples. The traceability lot tags are assigned at each operation and logged in and out. methods / procedures. drawings and packaging from the customers. equipment approval. Packing. Identification of all products at different stages of activity in the plant is maintained from the beginning billet shear operation through finished product to final packaging operation to the customer for all products. The validation process is defined by the customer. or PPAP for specific criteria for review and approval. QC SP 005 Lot Control 7. If any customer property is lost. verifies. Procedure No. designated staging/storage areas and placards. Storage.2 Validation of Processes for Production Before starting mass production. QC SP 015 Product Identification & Traceability Procedure No. it is reported to the customer and the necessary records are maintained. protects and safeguards the customer property provided for use or incorporation into the product. and is also provided on packaged products sent to the customers. The inspection and test status of items are identified through lot identification tags. These sheets become quality records at each operation. 0 . Procedure No. Preservation Customer Supplied Parts and Packaging Final Inspection & Packing of Visteon Gears PRODUCT REALIZATION Page 26 of 45 DOC NO. and non-conforming items. These are then stored at designated locations. damaged or otherwise found to be unsuitable during verification for further use. equipment and personnel is performed. part name. Validation is performed by determining CPks at run rate on customer designated characteristics. A documented procedure identifies. Incoming materials.5. Separate areas have been identified and marked for incoming materials. The identification.HF. or being used by the MSC.102 &103 PD-WI-HF-105 PD-WI-HT-100 PD-WI-FSB-101 PC SP 001 PH SP 001 PD-WI-HT-109 7.SH-101 PD-WI. WIP. inspection and test status of incoming items are identified based on supplier’s tags/labels. personnel qualification.:MSC-QM1 SECTION#: 7 PD-WI. Procedure No.3 Identification and Traceability The Company has established a system for product identification and traceability. which requires that products be identifiable to the applicable specifications. Work In-Process is also identifiable and traceable by part number lot tags. and certificate of conformance and / or the inspection and tests performed. as applicable. MSC may receive products. validation of processes. and finished packaging are identified by a lot tag giving details of part lot numbers. and records are maintained.MUSASHI SOUTH CAROLINA Related procedures/Instructions: Shear Operations Hot Forging Press Start Up Hot Forging Press Die Change Heat Treatment Shot Blast-Billets and Forged Gears Handling. inspection records. QC-SP-009 PSW/PPAP 7. A system has been established and maintained for revalidation of the processes. The products lot traceability is also identified through the data documented on the each part’s check sheets. and are traceable to date of production operations. records requirements and revalidation. as appropriate.4 Customer Property MSC takes due care with customer property while under the MSC’s control. PH SP 001 Customer Supplied Parts and Packaging Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. and part number. inspection/testing / packing.

7. 0 . Any measuring devices that fail during operation.1 Measurement System Analysis is carried out for each type of measuring and test equipment. Packing. Obsolete products are treated as non-conforming.6. for particular items. Provisions to safeguard the calibrated equipment from adjustments and setting are also made as and where applicable. Every employee is responsible for safe handling of the products at various stages of processing. All raw materials are issued on First In-First Out basis.1 Appropriate storage areas are provided for materials and products for protection. Persons using the calibrated equipment are trained to handle. including test software if necessary.6 Control of monitoring and measuring devices The range of measurements and required accuracies are determined by the gage control technician.:MSC-QM1 SECTION#: 7 MSC has established a documented procedures for preserving the product quality from receipt of materials through internal processing up to the delivery of finished products to the intended destination. or color coded mark indicating the calibration status.5 Preservation of Product PRODUCT REALIZATION Page 27 of 45 DOC NO.5. storage and transportation of products is to be controlled to prevent damage. any out of specification reading as received for calibration with their assessment of impact.5. for all such devices. and to prevent damage and deterioration of the product quality. packaging. Work instructions have been established for inventory management. revisions following engineering changes. special instructions are issued and monitoring is carried out to check satisfactory implementation. Validity of inspection and test results of parts checked with measuring devices found to be out of calibration is assessed as applicable.6. a label. marking. The calibration is carried out under controlled conditions as detailed in the relevant procedures. and due dates for re-calibration. test software and test hardware used for inspection purposes are checked at prescribed intervals to assess their capability to verify the acceptability of product. Measuring devices. Storage. Handling. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. An inventory management system is also used to optimize inventory turns. If it has been determined that suspect material has been shipped. against measurement standards traceable to national / international measurement standards. including suitable preservation wherever necessary. referred in the control plan. are selected based the capability of meeting the necessary accuracy and precision. store and preserve them appropriately to prevent damage and maintain the accuracy and fitness for use. using appropriate statistical techniques.5. considering customer packaging standard and labeling / marking requirements have also been established. 7. Where no such standards exist. PC SP 001 Handling. are suspect. When necessary. The appropriate handling of products is followed to avoid any deterioration of quality of product while in transit. measurement standard used for calibration. storage and protection of the products. FIFO is utilized for issuing and using stock. They are identified with a suitable indication through use of an engraved code number. A system for packing. deterioration or loss. Preservation PC WI 002 Production Planning PC WI 010 Monthly Inventory Corrections in the AS400 PC WI 011 Process Count Inventory Adjustment 7. or notify customer if already delivered. Master list and calibration records containing necessary details are maintained in a controlled computer "Master file" by the QC Gage Calibration Technician. If applicable. statement of conformance to specification after calibration and notification to customer if suspect material or product may have been shipped are maintained as defined in the relevant procedure. MSC will recall that material from transit. used for conforming product quality.MUSASHI SOUTH CAROLINA 7. the basis used for calibration is recorded. 7. known to be outside its designated criteria or show evidence of physical damage affecting accuracy are removed from the location of use and isolated by the Gage Control Technician. handling. This preservation includes the product identification. The analytical methods and acceptance criteria used conform to those in customer reference MSA manual. packaging.2 Records of calibration / verification of all measuring devices include: equipment identification. The measuring devices that can affect products are identified and calibrated / verified / adjusted / readjusted at prescribed intervals. The condition of the products in stock is assessed at appropriate intervals. This ensures that the measurement uncertainty is known and is consistent with the required measurement capability.

6. qualification of the laboratory personnel conducting test.3. the same are again re-validated and the results are re-confirmed. testing of commodities and capability to perform these test correctly. Computer Software. and its accreditation of ISO / IEC 17025 or national equivalent or its acceptability to customer. are validated at the time of installation and records are maintained.3.1 MSC has an established system and procedure for the internal laboratory with a defined scope. test and calibration services. when used in the monitoring and measurement of specified requirements. Such software is re-confirmed at specified frequency as referred in the documented procedure. The ability of computer software to satisfy the intended application is confirmed. which includes the capability to perform the required inspection.2 External laboratories selected for inspection.6.:MSC-QM1 SECTION#: 7 7.MUSASHI SOUTH CAROLINA PRODUCT REALIZATION Page 28 of 45 DOC NO. QC SP 017 QC SP 026 QC SP 008 PD-HT-703&705SM Gage Control Gage Calibration Scope Internal Laboratory Scope Laboratory System –Skill Maps Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. Procedure Nos. ASTM) and review of related records. traceable to relevant process standard (e. test or calibration purposes are based on capability to perform the required inspection/ test / calibration. As and when such software is updated.g. The technical requirements for compliance by the laboratory include: adequacy of the laboratory procedures. 7. 0 .

:MSC-QM1 SECTION#: 8 8.1 Process capability of each new process is studied and verified during production part approval process (PPAP). Process control procedures established within the organization ensures maintaining manufacturing capability or performance as specified by the customer part approval process requirement by following the manufacturing process design and development process output documents such as process / inspection / packaging standards and other work instructions.The organization has a procedure for performing internal audits at planned intervals to determine if the quality management system conforms to the planned arrangements and is effectively implemented. and customer satisfaction expectations. test and maintenance instructions.QC or Asst. delivery. and maintained continually and evaluated for performance of the product realization process. and measured as: Percents /$ /PPM / DPM and results presented in Management Review Meetings. Customer satisfaction and expectations are evaluated on both perceptive as well as performance measures. 8. The customer satisfaction ratings are monitored.2.A procedure has been established for evaluation of customer satisfaction. and systems.1 General Processes have been established for monitoring. Corrective actions are taken on the non-conformance observed. Related Procedures QC SP 006 Control Plans QC SP 007 FMEA HR SP 001 Human Resource – Training QC SP 013 Statistical Process Control 8. validity.2 Monitoring and measurement 8. and products. 8.Mgr. Also includes objectives for manufacturing process capability. These measures include quality. The output of the manufacturing process design and development process is in the form of Operator Process Instructions. Control plans are reviewed and revised for additional control needed. including determination of applicable methods and statistical techniques. measuring. if any.3. Measurement. control (stability) process validity and over adjustment is a competency requirement throughout the organization. QC monitors weekly.3 Performance monitoring measures are decided for the quality management system processes.2.Mgr. Processes performance on each measure is measured by the concerned process owner. PPAP results are documented. Corrective actions are taken as appropriate when planned results are not achieved. 8.2. related to customer perceptive/performance measures. and other instructions to provide necessary information as means of production measurement. Specific checklists are developed for the audits. such as variation. analysis and improvement needed to demonstrate conformity of product. 8. frequencies. Sr. 8. ensure conformity of the quality management system.The information on perceptive measures are developed by the organization for additional customer feedback. Significant process events are noted on the control charts and inspection records maintained for controlling the manufacturing process. maintainability and availability as well as acceptance criteria. ANALYSIS. e-mail. standards. covering all quality management related process.MUSASHI SOUTH CAROLINA MEASUREMENT.1. Countermeasures are developed and monitored for any unsatisfactory areas identified from the customer ratings. during the audits. 0 .2. OPIs define inspection. and methods. Audit frequency is appropriately increased when internal / external non-conformances or customer complaints occur.1 Appropriate statistical techniques are determined during manufacturing process design and included in control plan. sales communications. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. Customer web site information is updated monthly for key scoring criteria. in meeting the planned results. The audits also aim at determining the effectiveness of the manufacturing process. such as phone calls. based on the PPAP results. IMPROVEMENT Page 29 of 45 DOC NO.2 Training on basic statistical concepts.2.1. analysis and improvement 8. activities and shifts. Information on customer performance measures are obtained from our customers’ electronic web site postings of supplier rating systems. expectations and applications of measures to enhance customer satisfaction.1. and continually improve the effectiveness of the quality management system.

Rework instructions are established. including appropriate lighting. necessary actions. acceptance without repair by waiver (through deviation from customer. products with visible nonconformances detected will not be reworked without prior approval of customers. When non-conforming product is detected after delivery or use has started. (Ref. control. Currently MSC does not have service. IMPROVEMENT Page 30 of 45 DOC NO. and at frequency defined for each product. and root cause analysis as appropriate. Records pertaining to control of nonconforming products are maintained as per relevant procedures. accessible and utilized by appropriate personnel in their work area. if and where necessary). documentation. Nonconforming products are quantified. unless approved otherwise by a relevant authority or via customer communications. segregation (where practicable). The system ensures that the product / process conforms to original or superceding specifications on expiration of this approval. defining a system for identification. and X bar & R charts have been established for monitoring and measuring the characteristics of the product to verify that product requirements have been met. 0 . According to this procedure nonconforming products are reviewed by authorized personnel for action required to eliminate cause. analyzed and a prioritized reduction plan instituted as necessary.s also includes product audit and layout inspections of products at appropriate stages of production and delivery. check sheets. Reworked parts are re-inspected prior to release. of the non-conformance is taken. or potential effect.1 Related Procedures QC SP 016 Control of Non Conforming Product Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev.P.MUSASHI SOUTH CAROLINA MEASUREMENT.:MSC-QM1 SECTION#: 8 Appropriate reaction plans in the Control of Non-Conforming Product. In the event this becomes a future requirement the necessary controls. determine rework. The reaction plans include containment.I. Products with unidentified or suspect status are classified as nonconforming. is different from that approved in Production Part Approval Process (PPAP). and the products in the bins containing then are visually identified. inspections and tests have been satisfactorily completed. and segregation of product.2.4 Operator Process Instructions. In the event service applications are required. evaluation. 8. containment. ANALYSIS. or aftermarket provisions required by customers. Material shipped after customer approval is appropriately identified. The plans are reviewed and approved by the customer. The O. Corrective actions plans are developed and implemented to assure that the process become stable and capable. if required. will be defined. that affects the final product. 8. Prior written customer approval is obtained whenever the product or process. disposition. rework / repair and prevention of unintended use of nonconforming / suspect products at various stages during manufacturing. Product releases for delivery to customer do not proceed until all the planned operations.3. including customer notification appropriate to the effect. Related procedures QC SP 023 APQP QC SP 017&026 Gage Control.3 Control of nonconforming product A procedure for control of nonconforming products has been established. 100% inspection. and Corrective Action Procedures have been developed and are followed for characteristics that are either unstable or non-capable. and Gage Calibration Scope QC SP 016 Control of Non Conforming Product QC SP 018 Internal Quality Auditing QC SP 011 Customer Satisfaction QC SP 001 Management Review PD SP 001 Process Control 8. Also SCR-Supplier Change Request) Quantity/time criteria for this approval is maintained. or for the rejection / scrap. Reworked / repaired products are re-inspected according to the original specified requirements. Currently MSC does not have any customer requirements for “appearance items”. Nonconforming / suspect material is placed in designated color-coded product bins at operations. master samples and qualifications of personnel.

Key customer related trends are determined and action plans prepared and prioritized for prompt solutions to customer related problems.4. This occurs once manufacturing processes are capable and stable and product characteristics are predictable and meet customer requirements. IMPROVEMENT Page 31 of 45 DOC NO.:MSC-QM1 SECTION#: 8 8. Trends in non-conformances observed in internal quality audits. customer complaint. are analyzed to determining potential non conformances and preventive action taken to prevent their occurrences.MUSASHI SOUTH CAROLINA MEASUREMENT. Non-conformances observed and reported by customer if any. delivery. All customer complaints. The data is used to evaluate / identify opportunities for continual improvement of the effectiveness / performance of the quality management system. or internal audits. conformance to product requirements. and for continually improving the effectiveness of the quality management system and the performance of the organization. 8. delivery performance. This demonstrates the suitability and effectiveness of the quality management system. 8. This includes data relating to customer satisfaction. incoming material. safety and other performance measures. productivity. The trends are presented in the Management Review Meeting. vendor delivery performance. Effectiveness of the preventive action is reviewed. Mistake proofing methods are used as part of corrective and preventive action process. The continual improvement process also focuses on control.5 Improvement A procedure has been established defining a method for controlling the process for continual improvement.4 Analysis of Data The organization prepares and maintains trends in quality. Changes in quality system / processes are documented and summary of the preventive action taken are submitted for Management Review. reduction of variation in product characteristics. causes relating to product. final inspection. ANALYSIS. Records of results of corrective and preventive actions including analysis of customer returned products are maintained. etc. customer returned products. production process. process capability. using disciplined problem solving methods. customer satisfaction index. 0 . and countermeasures are taken to eliminate the causes. process and quality systems are established. are responded to in manner prescribed by the customer. and appropriate benchmarks. characteristics and trends of processes and product and suppliers.1 Related procedures QC SP 019 Corrective Action QC SP 020 Preventive Action QC-SP 021 Continual Improvement Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 04/02/03 Rev. Documented procedures established for corrective and preventive action are as follows.1 Related procedure QC SP 001 Management Review 8. appropriate to the magnitude of the problem. where they are reviewed along with actions plans if necessary. cost. The effectiveness of the corrective action is verified from the quality of subsequent product processes. Wherever applicable the successfully implemented corrective actions and controls are applied to other similar processes and products to prevent possible non-conformances. and manufacturing parameters. The trends are compared with progress towards overall business objective. reports of product non-conformances identified during the process are analyzed.5.

Currently.:MSC-QM1 SECTION#: 9 Section 2: Customer Specific Requirements MSC will adhere to its customer specific requirements in relation to TS16949:2002. we do not have any other business with the companies who have requirements in Section 2. See Visteon Customer Specific requirements.MUSASHI SOUTH CAROLINA CUSTOMER SPECIFICS Page 32 of 45 DOC NO. should business with customers be realized that have these requirements. In the future. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition:01 Date: 04/02/03 Rev. or other standards as necessary. MSC will fulfill their specific requirements. 0 .

Control Plan. + X&R no --------------------------> Operator Process Instruction Broach/Champher/ Burnish During lathing operations: Broach. and route thru Heat Treat furnaces Operator Process Instruction yes Heat Treat Caborize. 2 8/15/03 Work Instruction Accept Receive Steel yes C. and dry Time & Temp.S.Q.A. FMEA.xls. burnish SORT REWORK REJECT/SCRAP yes Inspectchecksheet.MUSASHI SOUTH CAROLINA PROCESS INTERACTION VISTEON BEVEL GEARS Quallity Decisions Intructions/Methods OPERATIONS Start Bevel Gear Manufacturing INPUT APQP: Feasibility. no --------------------------> Inspect/Test checksheet.O. Process Validation(CPk) PPAP INPUT QC-Flow.O. champher. + X charts Route thru to shot peen/blast Removes heat treat resudue Operator Process Instruction Shot Blast/Peen Route to wash on roller conveyor Operator Process Instruction Final Wash Detergent wash. harden cycles Time & temp. DISPOSE BY QC Deliver to Heat Treat Dept. Delivered on time Customer Satisfaction & Perceptions of M. dimensions Non-Conforming HOLD Tag. Design Drawings Build Schedules Delivery Schedules --------------------------> Operator Process Instruction Cut Billets yes Inspectchecksheet Shear cut steel bars into billets no ---------------------------> Process Owners President Plant Manager Sr.C.Doc. + Deliver to Lathing staging area Operator Process Instruction yes Lathing CNC precision lathe. yes QCAudit SPCs checksheet. Log Book HOLD AREA Review for Disposition by QC Inspectchecksheet. Process Design. requirements (APQP) Design Process Product/Process Validation (PPAP) Mass Production Delivery Feedback Management Oriented Process Business Planning Resource Planning Management Review Continous improvement Analysis of Data Corrective/ Preventive actions Customer satisfaction feedback Product/process perfomance Internal audit Support Processes Marketing Sales Human Resources Training Quallity Control & Calibration Engineering Maintenance E/H/S Purchasing Material/Supplies Production Control Deliver to shot blast Operator Process Instruction Shot Blast Shot blast removes rust and scale Deliver to Hot Forging Forge billetts into gears Operator Process Instruction yes Hot Forge Inspectchecksheet no ---------------------------> Operator Process Instruction Normalizing / Annealing Gears enter directly inline Anneal forged gears yes Inspectchecksheet.F.. Sulser 5/4/2012 . + OUTPUT Stage/ Ship 78472242. Production Manager Managers: Forging/Sizing Lathing Heat Treat & FI Team Leaders Associates Customer Oriented Process (Key Processes) RFQ Process Customer P. Operator Process Instruction Final Inspection/Pack Final Inspection of dimensions Apply rust preventative QC selects samples for SPC measurements & documentation no ---------------------------> Output to Customer : Acceptable Finished Gears.ms_office Bevel Gears R. Steels bars from approved supplier no Non-conformance Customer Inputs R. Operator Process Instruction Degrease Degrease lathing lubricants Identify Lot #s. no ---------------------------> Deliver to shot blast Operator Process Instruction Shot Blast Shot blast cleans residue Deliver to Sizing Operator Process Instruction yes Sizing Trims & Sizes preliminary dimensions no --------------------------> Inspectchecksheet.-101 Rev.O. + Place gears on racks no --------------------------> ACCEPT ACCEPT RETURN TO MANUF. P.

I. Mgr. Detroit. QC Customer Contact Contracts Review Liaison RFQ Feasibility Review Inputs Order Info Delivery Reqmnts.Maintenance Machine Establish Data Analysis Customer Launch Mass Ship on Capability Review Approval Product Production Time Product PPAP Monitor Monitor . Mgr.Tooling Communicate Review . RFQ Info-Pass thru Sr.-102 Rev.) Material Parts/Pkg. or W. Parts \vboxsrv\conversion_tmp\scratch228658472242. Prod.External & Internal Process Inputs to Musashi South Carolina Process QC-Flow. Musashi South Carolina Customer Process Musashi Review Team North America President Sales Office Sr. 2 5/26/04 Material/Components Inputs Customer Designated Raw Steel /Supplied Honda(Assy.Doc.Engineering Facility & Equipment Controls .Refine controls CPks Analysis Analysis . Business decisions Feedback Planning Process Production Process Feedback . MI Sr. Continual Improvement Communicate Plan Process Defines Processes Outputs APQP FMEAs Control Plans Process Info Parts Musashi .Japan (MSI) Inputs of Information and Parts Develops preliminary draft plans input for each new product MSC takes ownership upon receipt and finalizes to conform to MSC processes May supply finished.xls.Training Meas.P. Equip.Instructions OPIs . PC/Sales/Proj. Mgr. Parts& Pkg./Maint./Engrg.ms_office 5/4/2012 External Inputs CUSTOMERS Customers .

7.3. requirements Accept Quote MGT-SP-001 Yes Customers' Product/Order Requirements QC SP 007.6. & Regular run rate capability 7.2Engineering HR-SP-001 HR-SP-002 MT-SP-001 Prev.4 Prev. skill.5.2 Corrective & 8.1 Product/process conformance QC-SP-011 PD-SP-001. specifications.1.3..docProcess QC-SP-016 8.2.5. Data Collection QC-SP-013 SPC/Cpk Insp.doc QC SP 013.doc QC-SP-006 QC-SP-007 Packaging & labeling requirement 7. delivery.xls QC-TM-41 Training Matrix. etc.2 Training HR-SP-001 HR-SP-002 Skilled workforce .4 Raw Mat'l P.doc Order/ Request Drawings.2.02\PD-HT-705SM.doc APQP Production 7.O.1.test & Final .1 Customer Satisaction/feedback 7. etc. quantity. 1 .xls Prepared by: Ralph Sulser Approved by: Keith Shepard \vboxsrv\conversion_tmp\scratch228658472242.2.4 Analysis of data MGT-SP-002 BOP 5.1 Continual improvement 8.2.5 Delivery ASN Transport Utilities No Dock Audits Specified carrier. legal requirements Company culture & mgmt objectives manpower needs Payroll 6.2 Design Process Control Plan FMEA (PPAP) QC-SP-009 PSW/PPAP Process. Mgr. 5.doc ..2 MSC President & Sr.doc QC-SP-015 OPIs Process Control ID & Trace 7.5 Packaging PC-SP-001 7.ms_office Doc No.doc Customer Specs. QC-SP-017 7.5.6 Production Control Delivery Support Oriented Processes Mat'l cost Mat'l req.1.4 Management Resp-planning-MSC..3 Preventive actions = Key processes Control Non-Conforming control QC-SP-019 QC-SP-020 8.PC/Sales Voice of customer Customer Oriented Processes Contract Review ..flo.2 Internal audit QC-SP-018 Planning Delivery QC-SP-023.2 Product / QC-SP-002 Cust Process Verification / Validation OK QC SP 010.7. QC SP 002.2.O. Raw Matls.6 Management Review QC-SP-021.doc 8.20.4 Business Planning/ 6. mat'l type tooling/equi pment 6.xls.doc Purch.2. QC SP 006. Results Scrap * Additional SOP Regulatory.5.5.3.xl. Gage Control Design/Order/Receive/ Validate Gaging requirements Manpower 7.\Heat Treat. addt'l training needs 6.xls 7.5 Tooling P.O.5.Process Map: Interaction and Sequence Musashi South Carolina Management Oriented Processes 5.5. education.1 Mass Production Stage FG./Components 7.3.\Procedures\QC SP 010.2.6 Calibration Process parameters 7.5. etc.2 HR comptetancy. Schedule Release Order IP inspection.2.5.5.5.2 HR 4.5.\Procedures\MGT-SP-001.doc Lab Scope OPIs Quanities. Maint.0 Resource Planning 5.\Procedures\QC SP 008.5. Label QC-SP-025 7. Price. Date: 5/28/04 Rev.xls QC-SP-001 8.: QC-PM-001 Rev.doc PD-SP-001.doc No Review Cause Receive P.

Calls.O. Sr.delivery. PC/Sales Sr.Date: 5/28/04 Rev. Ph.: 1 . Plan Contingencies MT-SP-001 QC-SP-024 Production operations Process PD-SP-001 Inspection Data Collection and analysis (SPC) for improvement and monitoring & prevention of possible errors. for Prototype build if reqd. availability Determine quality criteria. Review with RFQ team Submit quote to customer Determine materials & packaging Follow-up quote and review w/customer Receive prototype tooling if needed Planning & Prototype Build Receive P. 8D info--gathered & dispersed to appropriate function(s). Prod/Eng Production Control Mgmt. Gage calibrations QC-SP-017 Gage Control PH-SP-002 NG Handle per QC-SP-016 Control Inspections/each process QC-SP-010 OPIs QC-SP-004 Records Packing NG Stage/Store Handle per QC-SP-016 PC -SP-001 Delivery Ship to customer-ASN QC-SP-010. for mass production Production scheduled Equipment Preventive Maint. Review for costs/manufacturing/volumes/ lead times /feasibility Define material cost Calculate Plant Manufacturing cost Define total manufacturing & Determine timing & delivery Define tooling and Gage cost as required Determine cost of labor Determine machines & equipment Determine manufacturing feasibility. Source & Procure Raw Material Receive. Mgr. Mgr.b Rev. countermeas ures meeting to close all issues and concerns Customer Feedback Corrective Action Corrective Action QC-SP-019 Corrective/ Preventive Action Doc No. QC-SP-004 Payment Invoice Customer Customer feedback and communications -e-mails. inspect & store Resources Staffing Prototype Build Establish Quality Plans-APQP PH-SP-002 QC-SP-023 Determine & procure Gaging systems QC-SP-017 Gage Control Control Plans QC-SP-006 Source tooling and timing Order & receive Mass production tooling Tooling set up and production trials Source & Procure Raw Material Receive.: QC-PM-001.Process Map: Interaction Sequenced Management Oriented Processes Business Planning/ Resource Planning MGT-SP-002 Internal audit QC-SP-018 MSC QC-SP-021 QC-SP-011 QC-SP-019 & QC-SP-020 Prepared by: Ralph Sulser Approved by: Keith Shepard Management Review QC-SP-001 Continual improvement Customer Satisfaction/feedback Data analysis Corrective & preventive actions Support Oriented Processes Customer Oriented Processes President. customer requirements Develop price/cost. Engineering Process design Maintenance Production HR Quality Receive RFQ from customer Inquirey/R FQ Review all customer requirements with Contract review team-MSC MGT-SP-001 Establish major product/component and cost targets. inspect & store Establish training needs FMEAs 007 OPIs SP010 Cpk development PPAP/PSW QC-SP-009 Training HR-SP-001 + Department Skill Maps OK Mass Production Receive P.O. .

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0 . Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by:Ralph Sulser Approved by: Keith Shepard Edition :01 Date: 04/02/03 Rev.MUSASHI SOUTH CAROLINA ORGANIZATIONAL CHART Page 38 of 45 DOC NO.:MSC-QM1 APPENDIX ORGANIZATIONAL CHART The most recent organizational chart is maintainrd by the Human Resources department. and is on file.

MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 39 of 45 DOC. 1 . expectations and satisfactions are defined in the procedures MGT SP 001 QC SP 023 QC SP 023 Contract Review (Product Requirement Review) APQP (Planning for product realization) APQP (Planning for product realization) 5.MSC-QM1 SECTION #: 5 5. and management meetings.3 Quality Policy The Management of the company has defined the quality policy ensuring that the quality policy a) is appropriate to the purpose and organizational goals of the company. is periodically reviewed for continuing suitability.. a focus is made for communicating the customer requirements to all functions and ensuring product conformance.1 Management Commitment The MSC management is committed to the development and implementation of the quality management system and continually improve its effectiveness by: a) Communicating to all employees of the company: the importance of meeting customer as well as statutory and regulatory requirements through regular training programs. c) provides a framework for establishing and reviewing quality objectives. While reviewing the requirements. NO.0 Management Responsibility 5. f) Product realization process and support processes are reviewed for their effectiveness and efficiency 5. b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality management system. As a part of Management Review (Refer 5.2 Customer Focus The Top Management of MSC ensures that customer requirements are determined and fulfilled with the aim of enhancing customer satisfaction.6 below) . These are conveyed to the respective functions for ensuring that they are met. Methods of determining customer requirements. c) Ensuring that quality objectives are established. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. display of documents and departmental meetings. and e) Ensuring the availability of resources for improvements when required. b) Establishing the quality policy based on the improvement objectives. communication meetings. d) e) is communicated to all employees of the company and is understood at all levels in the company. the implied needs and expectation of the customer are also identified. d) Conducting regular management reviews.

The policy of Musashi South Carolina is to achieve total customer satisfaction by delivering products and providing services that meet or exceed customer quality requirements and expectations. 1 . NO. implemented and maintained by all personnel in their respective division / department / section. Department Managers. and timely deliveries – QCD (Quality.MSC-QM1 SECTION #: 5 The Policy of the company has been displayed at strategic locations and also distributed to all employees. Quality Policy distribution and display records are maintained. and gear assembly manufacturing.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 40 of 45 DOC.. and customer satisfaction. Cost. and area Team Leaders shall ensure that this policy is understood. Ultimate goal of working towards achieving zero defects. Periodic Training Programs are held for understanding by all the functions through out the organization. QUALITY POLICY “MSC will continually strive to produce quality products that meet or exceed customer expectations. Our mission is to make Musashi South Carolina a synonym for a world-class organization excelling in gear. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. It is implied that all people at all levels in our organization be committed to comply with requirements and continually improve the effectiveness of the Quality Management System and their performance. and inputs of the department management to focus on objectives. Okubo President Process interactions of achieving product realization are described below outlining typical duties. and subsequent end users. MSC Senior Management. Deliver on time. Assistant Managers. and at the most competitive prices in domestic and export market for our entire product range. and customer communication. cost competitiveness. Delivery) – through exercise of continual improvement. and environmental needs to minimize potential risks to employees. employee support.” Dated: 03/20/2003 S. Current plant organizational charts are on file in H. Necessary measures are also taken towards product safety.R.

Compressor. Environmental/Safety/Health. 2. and company activities.        Manager– Human Resources Responsible for coordinating with departmental heads to obtain staffing.  Authorized to “STOP PRODUCTION” in his area. Maint. the President creates an environment where people are fully involved. and Payroll Coordinator. NO. and other customers. for these activities.  Responsible for effective implementation of the quality management system. Reports to the Plant President. and stores.  Responsible for providing essential resources and personnel for implementation of the quality policy.  Developing facilities.MSC-QM1 SECTION #: 5 1.R. 3.  Preventive/Predictive Maintenance. finance.  Approves the MSC's quality policy and objectives. Assistant Manager of Accounting. and quality management system. Assisted by the Administrator of EHS. Accounting Manager  Overall responsibility for all accounting. Assistant. Heat Treat/Assembly. and Assistant Managers for Forging. Accounting Coordinator. Manufacturing Engineering. Mgr.Musashi South Carolina  The senior most executive at the plant and designated as President.  Approves the company's policies and gives directions for managing the objectives.  Reports to the Plant President. Manager. and has responsibility for the entire operation. . pump house and LPG and all utilities  Manages.  Authorized for taking corrective & preventive action in case of deviations in the operations. probationers. 4. and employee motivation needs. on their web sites  Chairman of the Management Review Committee. and supplies purchasing functions in the plant.H.. and the Assistant Manager Purchasing/Buyer. Senior Manager Production  Overall responsibility for planning. for the products. Determine the training needs related to managers. President . staff. tooling. Tool/Die. associates. Identifies. temporaries.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 41 of 45 DOC. coordinating & managing activities related to functions of Production. and trainees. on their web sites  Reports to the Plant President. 1 .  Assisted by the.  Authorized for approval of production processes in the plant.  Through leadership and actions. Projects.  Assists in guiding and supporting QMS related activities in those functions such as purchased supplies. and IT Administrator for these activities. and coordinates any modifications to be carried out in the existing operations or enhancing the efficiency of the plant.  Assisted by Manufacturing Engr.  Reviews customer scorecards for Visteon.  Reviews customer scorecards for Visteon. Mechanical. and other customers. and industrial relations to enhance productivity. and implements training. Electrical. Lathing. processes and equipments. and in which a QMS can operate effectively. if systems are not being implemented. Maintenance. Also in charge of public affairs..  Responsible for building the required competency level in the employees reporting to him.  Approves customer and supplier contract review actives.  Assisted by Managers.  Guiding and supporting QMS activities including regulatory requirement if any. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev.

QC Technicians.  Developing and implementation of plans for customer complaint resolution.  Preparing details for Production Part Approval Process.  Representing the needs of the customer in internal functions in addressing the ISO/TS 16949 requirements. and contact for quality issues. TS16949 Coordinator  Reviews and maintains scorecards for Visteon.. Mgr. and instructions for the plant  Monitoring the Process for outputs.  Authorized for dispositioning deviations on Non-conforming products for use at next stages.g. in process and final stages  Controlling the procedures for In-coming. NO.  Verifying the effectiveness of corrective and preventing actions. measuring and test equipment. and other customers. · Representing the needs of the customer in internal functions addressing the product realization planning (APQP) for ISO/TS 16949 requirements (e. process standards. and maintaining customer communication channels.  Production Part Approval Process (PPAP&PSW) and liaison with customers for same  Establishing.  Assessment of Preliminary (Ppk) and on going process capabilities (Cpk).MSC-QM1 SECTION #: 5 5. setting quality parameters. weekly on their web sites  Designated as Customer Representative to ensure customer requirement are met. and Inspection Standards. Senior Manager – Quality Control Responsible for quality systems.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 42 of 45 DOC.  Issuing and maintaining originals and withdrawal of obsolete APQP documents.  Monitoring and Measuring Customer Satisfaction metrics. In-process and Final Inspection Stages  Calibration of all identified inspection.  Identifying and implementing statistical technical techniques for process and product.  Providing Test Status on In-coming.  Obtaining waivers from customer on non-conforming finished products. FMEAs. selection of special characteristics.  Develops manufacturing process design quality controls including Process Flow Diagram. Control Plans and Process Standards. QC Associates. drawing and documents of external origin. 1 .  Assisted by Asst. procedures.  Authorized for providing inspection and test status on all products. In-process and Finished Products  Documenting trends in quality and current quality levels.  Controlling of non-conforming products. QC.  Authorized for release of finished product.  Reports to the Plant President Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev.  Inspection and testing at incoming.

storage and issue of products.     President .  Resolving any differences between the inquires and potential orders. and waste. and packaging. work in-process and dispatch to customer. preservation.  Reviews customer scorecards for Visteon.  Receipt of order / dispatch schedules from customer. and other customers. 1 .  Reviewing. MI Receipt of Inquiries from the customers and passes thyrough to Musashi South Carolina Coordinating with MSC President for planning future production Assists in assessments of customer satisfaction.  Inventory management of purchased products.  Supplier performance tracking  Supporting QMS requirements related to these functional areas. approving and maintaining effectiveness of the procedures for the above activities. Plant Facilities and Equipments Provisioning.  Communicating customer’s requirement to concerned personnel in the company.MSC-QM1 SECTION #: 5 6.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 43 of 45 DOC.  Production scheduling of all products  Control of customer-supplied products. Senior Manager Sales/Production Control/New Model Projects  Purchasing of manufacturing materials.  Checking adequacy of FIFO. and supplier monitoring.  Ensuring 100% on time delivery to customer. and packaging  Receiving.  Reviewing customer engineering specifications and standards. MSI Engineering.  Disposal of scrap. recommending and providing guideance for effectiveness of the procedures on Product requirement Review – Manufacturing Process Designing and Development.  Developing guidelines of new products planning. on their web sites  Preparing and submitting the quotation offer to customers.Japan  Reviewing.  Review of customer’s order for correctness.  Interaction with Customer for product development and all contract review activities  Reports to the Plant President 7. Detroit. and Coordinators..Sales and Marketing-Musashi North America. storage. Reports to President Musahi North America Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev.  Assisted by Production Control Manager. NO. 8.  Handling storage. WIP and finished product. identification and test status of all products during receipt.

5.4. implemented and maintained.1 Responsibility for quality Managers with responsibility and authority for corrective action are promptly informed of products or processes that do not conform to requirements.5. irrespective of other responsibilities. and summary of the Preventive Actions for Management Review. irrespective of other responsibilities.MSC-QM1 SECTION #: 5 9. 5. or delegated responsibility for. authority and communication 5. all Quality System Procedures. has the responsibility and authority that includes: a) ensuring that processes needed for the quality management system are established. 5.1.5. Management Representative ( 5.1 Quality objectives Top management ensures that quality objectives.1 Responsibility and authority Top management ensures that the responsibilities and authorities are defined and communicated within the organization. and c) ensuring the promotion of awareness of customer requirements throughout the organization.2 Quality management system planning Top management ensures that a) the planning of the quality management system is carried out in order to meet the requirements given in 4. Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. Personnel responsible for product quality have the authority to stop production to correct quality problems. and samples of all formats Identification of training needs for building a team of internal quality auditors 5. The quality objectives are measurable and consistent with the quality policy. 5. and b) the integrity of the quality management system is maintained when changes to the quality management system are planned and implemented.5 Responsibility.  Ensuring timely management review of the Quality System.5. Quality objectives address customer expectations and achievement goals within a defined time period.  Approving and ensuring effectiveness of procedures on Document Control. all work instructions..2 ) The Management of the company has appointed the Senior Manager-Quality Control.  Organizing Audit Summary Report. 5.2 Management representative Top management has appointed the Senior Manager-Quality Control who. assisted by the TS16949 Coordinator. b) reporting to top management on the performance of the quality management system and any need for improvement. Top management defines quality objectives and measurements that are included in the business plan and used to deploy the quality policy. has the responsibility and authority that includes: Management Representative (MR) and TS16949 Coordinator are responsible for  Establishing.4 Planning 5. including those needed to meet requirements for product [see 7.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 44 of 45 DOC. as well as the quality objectives.1 a)] are established at relevant functions and levels within the organization.  Preparation and issue of Quality System. Production operations across all shifts are staffed with personnel in charge of. who. ensuring product quality. 1 . and Procedures Manuals  Maintaining original documents and their master lists and issue of Quality System Manual. Quality Management System Auditing and Records Control. NO.1. as Management Representative. d) liaison with external parties on matters relating to the quality management system.4.  Liaison with internal and external parties on matters relating to Quality System. implementing and maintaining quantity system in accordance with ISO/TS 16949:2002 (E)  Reporting the performance of the Quality System for Management Review. which forms the basis for improvement of Quality System.

1 Review input The input to management review in the form of Agenda for Management Review in Steering Committee meeting includes information for the period under review on all elements of QMS STANDARDS.1 General Top Management of MSC reviews the company’s quality management system. (Customer perceptions & Complaints) d) Analysis of actual and potential field failures and their impact on quality. costs. Monitoring quality objectives Regular reporting and evaluation of cost of poor quality Evidence of achieving: quality objective specified in the business plan Evidence of customer satisfaction with products supplied 5. Visteron will be notified of any changes to customer rep.1 Quality Management System Performance-Input All requirements of the quality management system. 1 . f) Results of internal/external audits including the trends.MSC-QM1 SECTION #: 5 5. Items such as quality risks.5. 5. i) Planned changes that may affect the quality management system. adequacy and effectiveness. b) Improvement of product related to customer requirements.6. and j) Recommendations for improvement especially for product / process characteristics.. more focus is placed on the following: a) Business Plan/Quality objectives b) Cost of poor quality c) Customer satisfaction.2. l) Performance of Suppliers.6. analyzed. feedback.3 Review output The minutes of the management review meeting are recorded and maintained for a specified period. The review includes assessing opportunities for improvement and the need for changes to the quality management system. and others as appropriate. k) Status and results of Quality objectives and Quality Improvement Programs.3 Internal communication The Management of the MSC ensures that appropriate communication processes are established within the company and that communication takes place regarding the effectiveness of the quality management system. The output from the management review in the form of minutes of meeting and action plans include any decisions and actions related to: a) Improvement of the effectiveness of the quality management system and its processes. e. Manager-Quality Control has been designated as Customer Representative to assure customer requirements are addred within MSC. critical paths. 5.6.1. The Quality Management System of the company is reviewed by the Management Review Team that comprises all Managers of Departments under the Chairmanship of the President.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 45 of 45 DOC. and their impact on quality.5. safety. including the quality policy and quality objectives. performance. safety or the environment e) Follow-up actions from previous management reviews.2. and c) Resource needs support Procedure No. g) Process performance and product conformity. NO. and actions to be taken on non-conformances encountered in the activities including customer communication. 5. or senior mgmt.1 Additional Review Inputs a) Management analysis of actual and potential field failures. and reported with summary results.6. and delivery 5. QC SP 001 – Management Review Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev.6. h) Status of preventive and corrective actions..6 Management review 5.a. at planned intervals to ensure its continuing suitability.1 The Sr.. 5. and trends for continual improvement. Management Representative maintains records of management reviews. or the environment. However. b) Measurements at specified stages of design and development will be defined. lead times. monthly ratings for quality.

2.2 MSC President & Sr.5.2. 7.5.1 Mass Production OK Verification / Validation Utilities No IP inspection.5.6 Calibration Gage Control Process parameters 7.5.xlsQC-SP-001 QC-SP-019 QC-SP-020 8.5. etc.5.xls QC-TM-41 Training Matrix. Label QC-SP-025 7. Data Collection SPC/Cpk Insp. legal requirements Company culture & mgmt objectives manpower needs comptetancy.O.5. & Regular maint.5.20.5. Customer Specs.5.5.3. requirements Packaging & labeling requirement 7.5 Delivery Dock Audits Specified carrier..doc 8.1.2 Product / Process 7..2.2 Design Process Control Plan FMEA QC SP 010.2. req.doc QC SP 013.test & Final Inspections QC-SP-010 OPIs Process Control ID & Trace 7.. Results Scrap QC-SP-013 Regulatory.4 Raw Mat'l P.6 Production Control 7.2 Training HR-SP-001 HR-SP-002 Payroll 6.flo. Mgr.doc Quanities.PC/Sales Voice of customer Contract Review .1 Customer Satisaction/feedback 7.5.6 Management Review QC-SP-021.4 Analysis of data QC-SP-016 Process PD-SP-001.3.2. Design/Order/Receive/ Validate Gaging requirements Manpower 5.doc = Key processes Control Non-Conforming control MGT-SP-002 BOP 5.2 Corrective & 8.xls QC-SP-015 7.2 HR * Additional SOP Skilled workforce .5 Packaging PC-SP-001 Stage FG.5..4 Business Planning/ 6. education.xls Prepared by: Ralph Sulser Approved by: Keith Shepard file:///opt/scribd/conversion/tmp/scratch2839/78472242. ASN Transport Schedule Release Order . specs. etc. 1 .5 Tooling P.2.doc QC-SP-002 Cust Process. specifications.3.02\PD-HT-705SM. delivery./Components 7.doc Lab Scope OPIs QC SP 002.: QC-PM-001 Rev.xl.3 Preventive actions 8.doc QC-SP-006 QC-SP-007 Order/ Request Accept Quote MGT-SP-001 Yes Customer Oriented Processes Drawings.4 Prev.3.1. 7.2.xls Doc No. addt'l training needs 6. quantity. skill. Delivery Delivery Mat'l cost Mat'l req.doc .2 Internal audit QC-SP-018 Planning Support Oriented Processes QC-SP-023.2Engineering 4. 7.doc (PPAP) QC-SP-009 PSW/PPAP PD-SP-001. Price. tooling/equi run rate capability mat'l type pment 6.1.\Heat Treat.2. Maint.4 Management Resp-planning-MSC.\Procedures\QC SP 008. Date: 5/28/04 Rev.1 Product/process conformance QC-SP-011 8.O.6.Process Map: Interaction and Sequence Musashi South Carolina Management Oriented Processes 5. etc.doc No Review Cause Receive P.\Procedures\MGT-SP-001.doc APQP Production 7.0 Resource Planning 5.1 Continual improvement 8. Customers' Product/Order Requirements QC SP 006.7.\Procedures\QC SP 010.O.2 HR QC-SP-017 HR-SP-001 HR-SP-002 MT-SP-001 Prev.doc QC SP 007. Raw Matls.doc Purch.

inspect & store Training HR-SP-001 + Department Skill Maps OK Production scheduled Equipment Preventive Maint. countermeasures meeting to close all issues and concerns Customer Feedback Corrective Action Corrective Action QC-SP-019 Corrective/ Preventive Action Doc No. Calls. PC/Sales Sr. Plan Contingencies MT-SP-001 QC-SP-024 Production operations Process PD-SP-001 Inspection Data Collection and analysis (SPC) for improvement and monitoring & prevention of possible errors. Review for costs/manufacturing/volumes/ lead times /feasibility Define material cost Calculate Plant Manufacturing cost Define total manufacturing & tooling costs Develop price/cost. customer requirements Determine materials & packaging Follow-up quote and review w/customer Receive prototype tooling if needed Prototype Build Planning & Prototype Build Receive P. Sr. Source & Procure Raw Material PH-SP-002 Receive. QC-SP-010.: QC-PM-001. inspect & store Resources Staffing Establish Quality Plans-APQP QC-SP-023 Determine & procure Gaging systems QC-SP-017 Gage Control Control Plans QC-SP-006 Source tooling and timing Order & receive Mass production tooling Tooling set up and production trials Establish training needs FMEAs 007 OPIs SP010 Cpk development PPAP/PSW QC-SP-009 Mass Production Receive P. 8D info--gathered & dispersed to appropriate function(s). for mass production Source & Procure Raw Material PH-SP-002 Receive. Prod/Eng Production Control Mgmt.delivery. for Prototype build if reqd. Review with RFQ team Submit quote to customer Determine timing & delivery Define tooling and Gage cost as required Determine cost of labor r Oriented Processes Determine machines & equipment Determine manufacturing feasibility. Mgr.b Rev. Engineering -Process design Maintenance Production HR Quality Receive RFQ from customer Inquirey/R FQ Review all customer requirements with Contract review team-MSC MGT-SP-001 Establish major product/component and cost targets.O. Mgr.Process Map: Interaction Sequenced Management Oriented Processes Business Planning/ Resource Planning MGT-SP-002 Internal audit QC-SP-018 MSC QC-SP-021 QC-SP-011 QC-SP-019 & QC-SP-020 Prepared by: Ralph Sulser Approved by: Keith Shepard Management Review QC-SP-001 Continual improvement Customer Satisfaction/feedback Data analysis Corrective & preventive actions Support Oriented Processes President. Ph. QC-SP-004 Control Inspections/each process QC-SP-010 OPIs QC-SP-004 Records Packing Gage calibrations QC-SP-017 Gage Control NG Handle per QC-SP-016 NG Stage/Store PC -SP-001 Handle per QC-SP-016 Delivery Ship to customer-ASN Payment Invoice Customer Customer feedback and communications -e-mails.: 1 . availability Determine quality criteria.O.Date: 5/28/04 Rev. .

doc Storage .doc • ATV Gear Lathing • Production Tooling • Heat Treating ..doc • Internal Com unication m ---------------------------------------------------• Control of Docum ents .doc • Production Control .doc • Engineering • Receiving .\Production Control\PC-W I-003Visteon Shipping instruction..doc Realization Processes Support Processes C U S T O M E R S M easurement..doc • Purchasing .\Procedures\QC SP 016.\Procedures\QC SP 001.29.\Policies\QUALITY POLICY.5. Quality Managem ent System QC-QMS.doc • Tool & Die Training ... 0 5.doc• Tool Managem ent • • Inspections.doc Em ployee Motivation • Preventive Action • Control of NC Product .doc ....doc • ID/Traceability .\Procedures\QC SP 015.doc • Custom Issues er ..doc ork Instructions\PD-W .Process-100 Rev.\Procedures\QC SP 011.doc Product Realization C U S T O M E R S Satisfactio n Parts Input Output Musashi South Carolina..policy.\Procedures\QC SP 018..\Production Control\PC-W • I-002Prod.\Procedures\QC SP 019.\Policies.doc • Quality Control • Cold Forging • Calibration and MSA .doc • Control of Records .\Procedures\QC SP 020..\Procedures\QC SP 013.\W ork Instructions\PD-W I-L103. 630&800TP..6..03 .\Procedures\QC-SP-023.\Procedures\QC SP 004.doc • QMS Perform ance Analysis • Managem ent Review .\Procedures\MT-SP-001.doc an • Data Analysis ..doc • Shipping .Plan.doc • ATV Gear Assem bly .doc EHS EHS.doc • Im • Internal Auditing provem ent Projects . Inc.Business Planning . Improvement Hum Resources • Maintenance ....20...\Procedures\HR-SP-001..\W ork Instructions\PD-W I-A001. Analysis..\W ork Instructions\PD-W I-SH-101 Shear Oper • Inventory Control.\Procedures\PC-SP-001.doc • Hot Forging .0200.CONTINUAL IMPROVEMENT OF THE QMS Management Responsibility • Operational Managem ent • QMS Planning and Objectives • Quality Policy .\Procedures\QC SP 014..\Procedures\QC SP 017. Testing ..\Procedures\QC SP 008.doc Resource Management • • • • Requir em ents • Process Planning .doc •Shearing .\W ork Instructions\PD-W I-HF-102.\Procedures\QC SP 003.Gearing test and inspection.doc • Laboratory ...\Heat Treat.\W Corrective Action I-015...doc • Bevel Gear Lathing .

:MSC-QM1 APPENDIX ORGANIZATIONAL CHART The most recent organizational chart is maintainrd by the Human Resources department.MUSASHI SOUTH CAROLINA ORGANIZATIONAL CHART Page 49 of 70 DOC NO. and is on file. 0 . Issued by:Ralph Sulser Approved by: Keith Shepard Edition :01 Date: 04/02/03 Rev.

MUSASHI SOUTH CAROLINA ORGANIZATIONAL CHART Page 50 of 70 DOC NO.:MSC-QM1 APPENDIX Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by:Ralph Sulser Approved by: Keith Shepard Edition :01 Date: 04/02/03 Rev. 0 .

Methods of determining customer requirements. Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. While reviewing the requirements. c) Ensuring that quality objectives are established. These are conveyed to the respective functions for ensuring that they are met.6 below). and management meetings. and e) Ensuring the availability of resources for improvements when required. expectations and satisfactions are defined in the procedures MGT SP 001 QC SP 023 QC SP 023 Contract Review (Product Requirement Review) APQP (Planning for product realization) APQP (Planning for product realization) 5.3 Quality Policy The Management of the company has defined the quality policy ensuring that the quality policy a) is appropriate to the purpose and organizational goals of the company. d) Conducting regular management reviews.1 Management Commitment The MSC management is committed to the development and implementation of the quality management system and continually improve its effectiveness by: a) Communicating to all employees of the company: the importance of meeting customer as well as statutory and regulatory requirements through regular training programs. f) Product realization process and support processes are reviewed for their effectiveness and efficiency 5. communication meetings.2 Customer Focus The Top Management of MSC ensures that customer requirements are determined and fulfilled with the aim of enhancing customer satisfaction. As a part of Management Review (Refer 5.MSC-QM1 SECTION #: 5 5.0 Management Responsibility 5. is periodically reviewed for continuing suitability. b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality management system.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 51 of 70 DOC. display of documents and departmental meetings. b) Establishing the quality policy based on the improvement objectives. d) e) is communicated to all employees of the company and is understood at all levels in the company. 1 . a focus is made for communicating the customer requirements to all functions and ensuring product conformance. NO. c) provides a framework for establishing and reviewing quality objectives. the implied needs and expectation of the customer are also identified..

1 . NO. Department Managers. Assistant Managers. Delivery) – through exercise of continual improvement. and inputs of the department management to focus on objectives. MSC Senior Management. Ultimate goal of working towards achieving zero defects.MSC-QM1 SECTION #: 5 Note: Printed documents are not controlled copies-check master computer files for latest revisions The Policy of the company has been displayed at strategic locations and also distributed to all employees. and customer communication. Cost.” Dated: 03/20/2003 S. Necessary measures are also taken towards product safety. and subsequent end users. QUALITY POLICY “MSC will continually strive to produce quality products that meet or exceed customer expectations.. and area Team Leaders shall ensure that this policy is understood. Periodic Training Programs are held for understanding by all the functions through out the organization.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 52 of 70 DOC. and timely deliveries – QCD (Quality. Deliver on time. cost competitiveness. Quality Policy distribution and display records are maintained. and Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. and gear assembly manufacturing. and at the most competitive prices in domestic and export market for our entire product range. implemented and maintained by all personnel in their respective division / department / section. The policy of Musashi South Carolina is to achieve total customer satisfaction by delivering products and providing services that meet or exceed customer quality requirements and expectations. Okubo President Process interactions of achieving product realization are described below outlining typical duties. employee support. and environmental needs to minimize potential risks to employees. Our mission is to make Musashi South Carolina a synonym for a world-class organization excelling in gear. It is implied that all people at all levels in our organization be committed to comply with requirements and continually improve the effectiveness of the Quality Management System and their performance.

and company activities. • Authorized for taking corrective & preventive action in case of deviations in the operations. pump house and LPG and all utilities • Manages. Note: Printed documents are not controlled copies-check master computer files for latest revisions 1. and implements training. 2. and customer satisfaction. NO. Determine the training needs related to managers.MSC-QM1 SECTION #: 5 Process interactions of achieving product realization are described below outlining typical duties. • • • • • President . and Assistant Managers for Forging. Current plant organizational charts are on file in H.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 53 of 70 DOC. 3. Compressor. Electrical. for the products. • Reviews customer scorecards for Visteon. the President creates an environment where people are fully involved. Maint. and coordinates any modifications to be carried out in the existing operations or enhancing the efficiency of the plant. and has responsibility for the entire operation. and inputs of the department management to focus on objectives.Musashi South Carolina The senior most executive at the plant and designated as President. Responsible for providing essential resources and personnel for implementation of the quality policy. on their web sites • Chairman of the Management Review Committee. • Assisted by Manufacturing Engr. Manufacturing Engineering. • Assisted by Managers. • Through leadership and actions. • Reports to the Plant President. 1 Issued by: Ralph Sulser Approved by: Keith Shepard . temporaries. and quality management system. processes and equipments. • Authorized to “STOP PRODUCTION” in his area. and supplies purchasing functions in the plant. finance. Approves customer and supplier contract review actives. and IT Administrator for these activities. • Reviews customer scorecards for Visteon. Accounting Manager 4. Assistant Manager of Accounting. • Assists in guiding and supporting QMS related activities in those functions such as purchased supplies. and other customers. • Responsible for building the required competency level in the employees reporting to him. Heat Treat/Assembly. Senior Manager Production • Overall responsibility for planning. Maintenance.R. • Guiding and supporting QMS activities including regulatory requirement if any. • • • • Manager– Human Resources Responsible for coordinating with departmental heads to obtain staffing. Edition: 01 Date: 07/30/03 Rev. Identifies. and trainees. Approves the company's policies and gives directions for managing the objectives. and other customers. • Assisted by the. coordinating & managing activities related to functions of Production. Approves the MSC's quality policy and objectives. and employee motivation needs. Lathing. and in which a QMS can operate effectively. Manager. and the Assistant Manager Purchasing/Buyer. Mechanical. tooling. Accounting Coordinator. • Developing facilities. Mgr. on their web sites • Reports to the Plant President. • Preventive/Predictive Maintenance.. if systems are not being implemented. probationers. • Responsible for effective implementation of the quality management system.. • Overall responsibility for all accounting. for these activities. staff. Environmental/Safety/Health. Projects. and stores. associates. • Authorized for approval of production processes in the plant. Tool/Die.

Control Plans and Process Standards. QC Associates. • Verifying the effectiveness of corrective and preventing actions. QC Technicians. • Issuing and maintaining originals and withdrawal of obsolete APQP documents. selection of special characteristics. procedures. • Authorized for dispositioning deviations on Non-conforming products for use at next stages. • Production Part Approval Process (PPAP&PSW) and liaison with customers for same • Establishing. • Identifying and implementing statistical technical techniques for process and product. and instructions for the plant • Monitoring the Process for outputs. .g. Assisted by the Administrator of EHS. drawing and documents of external origin. NO.R. • Monitoring and Measuring Customer Satisfaction metrics. Assistant.H. • Develops manufacturing process design quality controls including Process Flow Diagram. in process and final stages • Controlling the procedures for In-coming. and Inspection Standards. • Assessment of Preliminary (Ppk) and on going process capabilities (Cpk). Mgr. Senior Manager – Quality Control Responsible for quality systems. TS16949 Coordinator • Reviews and maintains scorecards for Visteon. In-process and Final Inspection Stages • Calibration of all identified inspection. QC. setting quality parameters.. and contact for quality issues.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 54 of 70 DOC. • Preparing details for Production Part Approval Process. • Authorized for release of finished product. • Representing the needs of the customer in internal functions in addressing the ISO/TS 16949 requirements. weekly on their web sites • Designated as Customer Representative to ensure customer requirement are met. Note: Printed documents are not controlled copies-check master computer files for latest revisions 5. and other customers.MSC-QM1 SECTION #: 5 • • • Also in charge of public affairs. In-process and Finished Products • Documenting trends in quality and current quality levels. · Representing the needs of the customer in internal functions addressing the product realization planning (APQP) for ISO/TS 16949 requirements (e. Reports to the Plant President. and maintaining customer communication channels. • Reports to the Plant President Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. FMEAs. • Obtaining waivers from customer on non-conforming finished products. • Authorized for providing inspection and test status on all products. and Payroll Coordinator. process standards. measuring and test equipment. • Controlling of non-conforming products. • Developing and implementation of plans for customer complaint resolution. • Inspection and testing at incoming. and industrial relations to enhance productivity. • Providing Test Status on In-coming. • Assisted by Asst. 1 .

MI Receipt of Inquiries from the customers and passes thyrough to Musashi South Carolina Coordinating with MSC President for planning future production Assists in assessments of customer satisfaction.. • Developing guidelines of new products planning. recommending and providing guideance for effectiveness of the procedures on Product requirement Review – Manufacturing Process Designing and Development. Reviewing. • Supplier performance tracking • Supporting QMS requirements related to these functional areas. NO. • Receipt of order / dispatch schedules from customer. • Reviewing customer engineering specifications and standards. and packaging. MSI Engineering. • Reviews customer scorecards for Visteon. and waste. Senior Manager Sales/Production Control/New Model Projects • • • • • • • Purchasing of manufacturing materials.Sales and Marketing-Musashi North America. • Resolving any differences between the inquires and potential orders. • Assisted by Production Control Manager. preservation. work in-process and dispatch to customer. Detroit.MSC-QM1 SECTION #: 5 6.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 55 of 70 DOC. storage and issue of products. and other customers. • Ensuring 100% on time delivery to customer. 8. Production scheduling of all products Control of customer-supplied products. and packaging Receiving. • Inventory management of purchased products. approving and maintaining effectiveness of the procedures for the above activities.Japan • Reviewing. and supplier monitoring. Handlingof scrap. on their web sites • Preparing and submitting the quotation offer to customers. • Review of customer’s order for correctness. • Interaction with Customer for product development and all contract review activities • Reports to the Plant President 7. identification and test status of all products during receipt. and Coordinators. WIP and finished product. • Communicating customer’s requirement to concerned personnel in the company. storage. 1 . • • • • President . Disposal storage. • Checking adequacy of FIFO. Plant Facilities and Equipments Provisioning. Reports to President Musahi North America Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev.

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and Procedures Manuals • Maintaining original documents and their master lists and issue of Quality System Manual. as well as the quality objectives. irrespective of other responsibilities.5 Responsibility. Production operations across all shifts are staffed with personnel in charge of.1. The quality objectives are measurable and consistent with the quality policy. • Preparation and issue of Quality System. • Ensuring timely management review of the Quality System. Management Representative ( 5. 1 . 5. 5. authority and communication 5. or delegated responsibility for. and c) ensuring the promotion of awareness of customer requirements throughout the organization. all Quality System Procedures. Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev.5.1 Quality objectives Top management ensures that quality objectives. b) reporting to top management on the performance of the quality management system and any need for improvement..4. and b) the integrity of the quality management system is maintained when changes to the quality management system are planned and implemented. • Approving and ensuring effectiveness of procedures on Document Control. assisted by the TS16949 Coordinator.2 Quality management system planning Top management ensures that a) the planning of the quality management system is carried out in order to meet the requirements given in 4.5. • Organizing Audit Summary Report. ensuring product quality.1. irrespective of other responsibilities. Quality Management System Auditing and Records Control.1 a)] are established at relevant functions and levels within the organization. and samples of all formats Identification of training needs for building a team of internal quality auditors 5. implemented and maintained. all work instructions. Personnel responsible for product quality have the authority to stop production to correct quality problems.MSC-QM1 SECTION #: 5 9.1 Responsibility for quality Managers with responsibility and authority for corrective action are promptly informed of products or processes that do not conform to requirements. has the responsibility and authority that includes: Management Representative (MR) and TS16949 Coordinator are responsible for • Establishing. which forms the basis for improvement of Quality System.2 ) The Management of the company has appointed the Senior Manager-Quality Control. and summary of the Preventive Actions for Management Review.1 Responsibility and authority Top management ensures that the responsibilities and authorities are defined and communicated within the organization.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 57 of 70 DOC.2 Management representative Top management has appointed the Senior Manager-Quality Control who. including those needed to meet requirements for product [see 7. implementing and maintaining quantity system in accordance with ISO/TS 16949:2002 (E) • Reporting the performance of the Quality System for Management Review. • Liaison with internal and external parties on matters relating to Quality System.5. who.5. Quality objectives address customer expectations and achievement goals within a defined time period.4 Planning 5. as Management Representative. 5. has the responsibility and authority that includes: a) ensuring that processes needed for the quality management system are established. Top management defines quality objectives and measurements that are included in the business plan and used to deploy the quality policy.4. NO. 5.

1 . Note: Printed documents are not controlled copies-check master computer files for latest revisions Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. NO.MSC-QM1 SECTION #: 5 d) liaison with external parties on matters relating to the quality management system..MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 58 of 70 DOC.

and delivery 5. adequacy and effectiveness. Monitoring quality objectives Regular reporting and evaluation of cost of poor quality Evidence of achieving: quality objective specified in the business plan Evidence of customer satisfaction with products supplied 5. and their impact on quality. safety or the environment e) Follow-up actions from previous management reviews. 1 . g) Process performance and product conformity. analyzed. b) Improvement of product related to customer requirements. f) Results of internal/external audits including the trends. and trends for continual improvement. i) Planned changes that may affect the quality management system. Items such as quality risks. or the environment.MSC-QM1 SECTION #: 5 5. and j) Recommendations for improvement especially for product / process characteristics.5. 5.6.1 Additional Review Inputs a) Management analysis of actual and potential field failures. and actions to be taken on non-conformances encountered in the activities including customer communication. more focus is placed on the following: a) Business Plan/Quality objectives b) Cost of poor quality c) Customer satisfaction. 5.1 The Sr.5.6. (Customer perceptions & Complaints) d) Analysis of actual and potential field failures and their impact on quality. Manager-Quality Control has been designated as Customer Representative to assure customer requirements are addred within MSC. 5. The review includes assessing opportunities for improvement and the need for changes to the quality management system.6 Management review 5.. and others as appropriate.3 Internal communication The Management of the MSC ensures that appropriate communication processes are established within the company and that communication takes place regarding the effectiveness of the quality management system. Management Representative maintains records of management reviews. The output from the management review in the form of minutes of meeting and action plans include any decisions and actions related to: a) Improvement of the effectiveness of the quality management system and its processes.MUSASHI SOUTH CAROLINA MANAGEMENT RESPONSIBILITY Page 59 of 70 DOC.2. monthly ratings for quality.3 Review output The minutes of the management review meeting are recorded and maintained for a specified period. costs. Visteron will be notified of any changes to customer rep.6. feedback. safety.. NO.1 Quality Management System Performance-Input All requirements of the quality management system.a. e. performance. 5.1 General Top Management of MSC reviews the company’s quality management system. and c) Resource needs support Procedure No. h) Status of preventive and corrective actions. The Quality Management System of the company is reviewed by the Management Review Team that comprises all Managers of Departments under the Chairmanship of the President. or senior mgmt. QC SP 001 – Management Review Issued by: Ralph Sulser Approved by: Keith Shepard Edition: 01 Date: 07/30/03 Rev. at planned intervals to ensure its continuing suitability.2. critical paths. and reported with summary results.6. lead times.1. l) Performance of Suppliers. including the quality policy and quality objectives. b) Measurements at specified stages of design and development will be defined. k) Status and results of Quality objectives and Quality Improvement Programs. However..6.1 Review input The input to management review in the form of Agenda for Management Review in Steering Committee meeting includes information for the period under review on all elements of QMS STANDARDS.

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