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WELCOME FOR QUALITY UPGRADATION MEET
LET’S MAKE THE THING HAPPEN
VENDOR UPGRADATION MEET
Purpose of Vendor Up gradation Better understanding Customer specific requirements. Positive approach towards enhancing Quality management system. Surviving in Competitive market for better quality & Competitive Cost. LOYAL SUPPLIER- CUSTOMER RELATIONSHIP.
LET’S MAKE THE THING HAPPEN
VENDOR UPGRADATION MEET
Impacts of Vendor audit system rating Assessment audit score impact over all Vendor rating calculated by Supply chain Good vendors got more opportunities in Increasing in share & new business. Vendors can be given recognition for Best Vendor performance award. Reduction in Vendor rating may impact the Current share & new Business. Even may lead to exclusion based on performance. Re- audit will be done on chargable bases by MACE
LET’S MAKE THE THING HAPPEN
VENDOR UPGRADATION MEET Customer Voice LET’S MAKE THE THING HAPPEN .
Vendors to meet QCDD requirements as per the Customer requirement. On time delivery & Warranty returns as per the Customer needs & requirement LET’S MAKE THE THING HAPPEN . Defects (QPCR).VENDOR UPGRADATION MEET Voice of Customer MSIL Vendors to achieve minimum 70% of the score in system audit rating. Focus on processes. More Emphases on (Quality is produced not inspected) Vendor should comply the requirement of Customer complaints.. NPD & component revalidation. PPMS .
VENDOR UPGRADATION MEET Salient features of Vendor system audit. (Marks can be given either full or zero) LET’S MAKE THE THING HAPPEN . Suzuki started the new system in 2003 MARUTI started the same audit through MACE in 2004. System audit check sheet contains Total 22 main items & 115 Sub items. Total Marks – 209 & There is no partial marking allowed. The new vendor audit system is Benchmarked with Suzuki & our Auditors are trained by Suzuki Audit Experts.
LET’S MAKE THE THING HAPPEN .VENDOR UPGRADATION MEET Continued. Requirement check sheet sent in advance Two weeks before for Self assessment MSIL Target to score minimum 70% for each supplier as most of our suppliers are certified to ISO/TS 16949. Each item has either got 1 marks or 3 marks ( 3 for more important) Total 4 man days are involved in System Audit.
meeting requirements to be added in development plan.) Procedure: Production preparation addressing new part. new technology parts. factory transfer etc.VENDOR UPGRADATION MEET DETAILED DESCRIPTION OF CLAUSES. Review & main activity to be identified and monitored through Micro level Timing chart List of problems with countermeasures in PDCA format.01 Production Preparation (New parts. Guide line for FMEA. Clause :. APQP activities matrix to used to prepare development plan. Specs. Cut off for RPN. change part development from receipt inspection to mass production stage. LET’S MAKE THE THING HAPPEN . occurrence and detection. design change parts. Effectiveness of C/M to be checked. Review frequency and event.
g feed/ angle/ press.Prod. Preparation Phase (1) (1) Change Points 1) Process Parameter Change ( e./ temp etc) 2) Tool/ Die/ Machine/ Equipment change 4)Relocated Plant 5) Supplier Change 6) Operator Change Process Change 3) Layout change LET’S MAKE THE THING HAPPEN SOP of Process Change . Preparation Order receipt from customer SOP of customer Design Trial Prodn Trial Mass Prodn Trial VENDOR UPGRADATION MEET Process Change Initiation (1) ECN Receipt SOP of ECN APQP Prodn.
02.VENDOR UPGRADATION MEET Clause No. (Special control until the quality is stabilized after the start of mass prod's) Initial supplies after sample approval ( up to 03 Month’s for New Parts / lots /quantities) Additional (control) checking and preventive actions. (Follow up of Pre launch Control plan/PCS during Initial supply Control) Objective : To overcome teething problems (to stream line supplies in terms of quality and quantity) Display of process and sub vendors Initial supply control Tags LET’S MAKE THE THING HAPPEN .Initial Supply control.
of extra controls during I/C SOP Period of I/C (Usually 3 months) Increased inspection items Increased frequency A combination of above two Frequent Process capability (Cpk) evaluations Supplier Audits Reaffirmation of operator skills Added roles & responsibilities of managers & supervisors Reduced cycles times for problem solving No. Preparation Phase (1) I/C (2) I/C (2) Few e.g. of Defects Ist Extra Controls 3rd 2nd Time LET’S MAKE THE THING HAPPEN Process Change Initiation (1) .Initial Supply Control Design Trial Prodn Trial Order receipt from customer Mass Prodn Trial SOP of customer VENDOR UPGRADATION MEET ECN Receipt SOP of Process Change I/C (2) SOP of ECN (1) APQP Prodn.
67 2) All problems occurring before SOP are resolved & a recheck done to confirm that they remain solved 3) Any new problem arising in I/C is also resolved LET’S MAKE THE THING HAPPEN .Initial Supply Control VENDOR UPGRADATION MEET TERMINATION CONDITIONS 1) Cpk > 1.
Identification of I/P Inspection of I/P and retention Tolerance standard for non given tol. LET’S MAKE THE THING HAPPEN . NC dealing procedure for I/P. trial parts. Process change parts.Initial product control. Definition of Initial product.03. design change parts. Check sheet to ensure availability of inspection report.VENDOR UPGRADATION MEET Clause No. FPP card etc. Control of new parts.
Initial Product Control SOP of customer Order receipt from customer Design Trial Prodn Trial Mass Prodn Trial VENDOR UPGRADATION MEET Process Change Initiation ECN Receipt SOP of ECN SOP of Process Change (1) I/C (2) I/C (2) (3) (3) (3) (3) APQP (3) I/C (2) (1) Prodn.The first piece/ part or lot or samples from the first lot produced during prodn trial. after SOP of a new part or a change point. Preparation Phase (1) Initial Products Defn of Initial Product (I/P):. mass prodn trial. LET’S MAKE THE THING HAPPEN .
04. Effectiveness of counter measure is being monitored & relevant docs revise as per the counter action raised. In-house defects & Supplier defects. LET’S MAKE THE THING HAPPEN . Organization shall establish.Corrective & Preventive measure of defects. the procedure of Handling of Customer complaints &In-house rejects addresses the communication of same to the operator immediately. How the Serious problems & Customer complaints informed to the Top Management. maintain & Implement procedure for handling of the problem analysis & countermeasure reported during Customer Claims. Organization shall establish .VENDOR UPGRADATION MEET Clause No.
LET’S MAKE THE THING HAPPEN . Horizontal deployment of the same action on similar process & is documented into the Countermeasure reports. The Organization has maintained control register of Customer complaints . Organization shall establish & display of actual quality results & how they are reducing the Defects.Corrective & Preventive measure of defects.04. In-house Defect & supplier defects & effectiveness of the counter measure monitored Organization shall calculate Cost of poor quality ( Company wise as well as Department wise).VENDOR UPGRADATION MEET Clause No.
Training & Education Consider all level of people in organization (including the contractual workers.VENDOR UPGRADATION MEET Clause No. Actual ( Staff & Manager Level) Link in Skill Matrix & training plan Orientation / on the job training Maintain training history ( Individual) Training records (attendance.05.etc.) in training plan and monitor. Training Plan vs. F/back) LET’S MAKE THE THING HAPPEN .
Audit Schedule ) LET’S MAKE THE THING HAPPEN .VENDOR UPGRADATION MEET Clause No.) Documented evidence of Internal quality audit ( NCR Report.06.number of cases and defect rate etc. Audit Audit Report.Quality Audit Top management carry out the audit according to the procedure Perform the Internal audit based on the annual audit plan Quality policy and deploy it company wide Decide the yearly quality target of company and each department and follow up the actual results numerically (money loss for defect .
do you inform Maruti Supplier Evaluation based on the selection standard? Prepare and exchange the inspection standard with your sub-vendor ?. do you take action to reduce the supplies to achieve desired quality of parts LET’S MAKE THE THING HAPPEN . Incase of the sub vendors with chronic defects and where no improvement has been observed despite repeated instructions.07.Supplier Control Documented Procedures to instruct and educate the sub vendors Record the number of defect cases and contents etc. for every sub vendor. and functional parts/ processes are out source/ sub-vendor changed.VENDOR UPGRADATION MEET Clause No. Compile the defect information Sub vendor-wise and perform the audit & training for the worst ranking sub vendors Supplier audit check sheet decided for Supplier audit when A parts.
revised and old drawings clarified through a control register and do you control the latest one Control the revision of related standards based on the changes to drawings Collection of the old drawing copies or ensure that the old drawing copies is destroyed LET’S MAKE THE THING HAPPEN .08.VENDOR UPGRADATION MEET Clause No. Controlling section for control of drawings/ engineering changes clearly defined in the procedure Are the new.Control of Drawing & Stds.
ECN Change & Process Are their any boundary samples / Limit samples displayed o identification Supplier has approved MIS-P (For MARU'A' Parts) Control register for (Inspection standard & PCS) with revision num reason of change. Documented procedure for the the creations of Inspection std & defined check the records of any change in the process resulting in change (Evidence related to customer complaints. InspectionTHING HAPPEN with th .09 &10 -Control of Inspection standard & Process control standard & Operation Std.VENDOR UPGRADATION MEET Clause No. LET’S MAKE THE standards Establish Linkages between the PCS.
Control Plans LET’S MAKE THE THING HAPPEN .Observance (Implementation) of Operation Standards VENDOR UPGRADATION MEET ROUTE MAP OF QUALITY : Maintenance Machine Jig Fixtures Tool Quality of the Prod. Material Method/ Process Insp. Stds. Man/ Operator Health of Operator Morale of Operator Skill of Operator ??? Incoming / Receipt Insp.
by the supervisor . ( Similar activities has been carried out by MSIL named as MOS-K) LET’S MAKE THE THING HAPPEN .Observance ( Implementation) of operation standard Is the operation carried out as per the standard Audit of operator by supervisor as per plan using check sheet Is there any check on the operations/ activities carried out by the operator/ way of working etc.11.VENDOR UPGRADATION MEET Clause No. Is the quality check for the observance of operation standard carried out as decided and recorded.
Role of manager.VENDOR UPGRADATION MEET Clause No.12. Responsibilities & Authority of each Supervisor & manager to be defined for production preparation. DWM shall be carried out for each individual ( Level from Supervisor & Manager) LET’S MAKE THE THING HAPPEN . Initial supply control & Initial product control. supervisor Roles & responsibilities of each manager & supervisor defined in normal & abnormal situation.
Training Carrying out quality inspections of the product / process on a sampling basis Ensuring Operator is checking all the parameters While starting the work. Are there unwanted / suspect products lying on the ground Daily Plan vs. LET’S MAKE THE THING HAPPEN . Actual Roles during New Dev. check if the operator is checking machines. Briefings & making Plans * Participation in evaluation meetings/ trials/ chekkai * Making plans for Mass Prodn. Operator Change/ New Operator. / I/C * Participation in new comp. poka yoke etc. tools. supervisor VENDOR UPGRADATION MEET A few of the daily responsibilities of the supervisor : Holding morning meetings Red Bin Analysis.Role of manager.
Vendor CFT conduct the audit & check the imperfect setting. inverse assembly & missing parts can be discovered.Quality improvement of process System to develop the Projects for Process Improvement & Defect free parts e.g. Is there any scope of pokayoke / lay out change / material handling LET’S MAKE THE THING HAPPEN .VENDOR UPGRADATION MEET Clause No. wrong parts.13. Documented evidence of Projects initiated by CFT with Roadmap of improvement of Process imprecision.
Preventive& predictionmaintenancechecks heet of machine& records of repair his tory of the s ame. jig & die Supplierhas a s ys temin placeto ens urethat the Ins pectionitem.14.Control of manufacturing machine.VENDOR UPGRADATION MEET Clause No. check the record of the s ame.f each eq uipmentdefined & do the s upplier performdaily & pe M ach ine. Documentedprocedureto check & correct the jig/tools /equip defective part is produced during p roduction s tage. Jig & Die. redres s ingtools & ele defined. LET’S MAKE equip ment recorded Is the res ults & his tory of the machine & THE THING HAPPEN . Is the life of the cutting /regrindingtools .
15.Operation std & current situation) LET’S MAKE THE THING HAPPEN Documented procedure mentioning the responsible person of han . gauge Recording of daily & periodical inspection of instruments with freq criteria of inspection. Measuring equipment history sheet & records of repair in the same she Check all the equipment used during intial development are used at production ( Check the Intial inspection standards.VENDOR UPGRADATION MEET Clause No. Documented procedure to check & correct the jig/tools/equipmen defective part is produced during production stage. Daily Instrument & equipment results are recorded in the checksheet.Control of inspection equipment. jig.
VENDOR UPGRADATION MEET FOCUS AREA These are the AFI’S (Area for Improvements) to improve in the weak areas to achieve minimum requirement of 70% of Customer. of Suppliers submitted their Counter measure action plan which are present here) LET’S MAKE THE THING HAPPEN . We have not received the Countermeasure action plan re-audit from most of the supplier’s. ( Only 05/ 21 Nos. where a audit has been carried out.
VENDOR UPGRADATION MEET Clause no.16.Statistical method Organization shall establish SPC manual and application of SPC. Use SPC at the time of problem solving Decide inspection plan based on the Cp / Cpk (Review all the sampling plan Review control limit as per SPC study LET’S MAKE THE THING HAPPEN .
wrong assembly. Mix up possibilities (RM/WIP/FG) identification Temporary storage (Identification.Prevention of missing process.17. Work instruction) Fool proofing installation as per FMEA Functional checking of Fool proofing Horizontal deployment of Fool proofing LET’S MAKE THE THING HAPPEN .VENDOR UPGRADATION MEET Clause No.
Control of non conforming product C heck LET’S MAKE THE THING HAPPEN . 18.VENDOR UPGRADATION MEET Clause No.
19-Storage of product Check w LET’S MAKE THE THING HAPPEN .VENDOR UPGRADATION MEET Clause No.
WIP & Finished parts. qty. Identification tags comprising of Part Name. specified on Material.FIFO FIFO to be practice for Raw material storage. 20.VENDOR UPGRADATION MEET Clause No. Old stocks (Expired) at location LET’S MAKE THE THING HAPPEN . Manufacturing date etc. Number.
LET’S MAKE THE THING HAPPEN .History Management (MARU “A” parts) Establish & maintain a batch codification system for product traceability & display of daily Batch code near the process station Establish a system to trace & search the manufacturing date. 21. Maintain Repair history records of reworked items for future Reference. manufactured parts quantity during field failures.VENDOR UPGRADATION MEET Clause No.
22.Implementation of inspection Check t LET’S MAKE THE THING HAPPEN .VENDOR UPGRADATION MEET Clause No.
VENDOR UPGRADATION MEET THANKS LET’S MAKE THE THING HAPPEN .
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