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SUPPLIER QUALITY MANUAL

Version 2.1 (Revised on 1.10.2017)


©Copyright 2017 Tata Motors Ltd.
This material belongs to Tata Motors Ltd. and is of confidential nature. Reproduction, circulation or distribution of this
material in part or whole in any form without permission is prohibited.
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Owner:
Mr. Neeraj Gupta
Head (SQMS)

Guidance:
Mr. Gangadhar Nadgouda
Head (SRM & Purchase Policies)

Contributed By:
Mr. Ashok Havanurkar
Mr. Manish Deshmukh ,
Mr. Kuldeep Kanaujia

This book is property of Tata Motors. All rights


reserved. No part of this book may be reproduced in
any form or by any electronic or mechanical means,
including information storage and retrieval systems,
without permission in writing from the copyright
owners.
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TABLE OF CONTENTS
1. FOREWORD 3
2. TATA MOTORS POLICIES 3
2.1. MISSION, VISION AND VALUES 4
2.2. QUALITY POLICY 5
2.3. ENVIRONMENT POLICY & 6
2.4 ENVIRO PROCUREMENT POLICY 7
2.5. SAFETY AND HEALTH POLICY 8
3. HOW TO USE THIS MANUAL 9
3.1. DOCUMENT ACCESS 9
3.2. AIAG DOCUMENTS 9
3.3. SUPPLIER FEEDBACK 9
4. INTRODUCTION 10
4.1. PURPOSE 10
4.2. SCOPE 10
4.3. RESPONSIBILITY 10
4.4. RECORDS 10
4.5. GENERAL REQUIREMENTS 10
4.5.1. Quality Requirements 11
4.5.2. Applicable Statutory and Regulatory Requirements 11
4.5.3. Product Safety 11
4.5.4. Laboratory Requirements 11
4.5.5. Specific Requirements 11
4.5.6. Tata Code of Conduct 11
5. TATA MOTORS PROCESS OF SUPPLIER QUALITY 12
5.1. ADVANCE QUALITY 12
5.1.1. Potential Supplier Assessment (PSA) 14
5.1.2. Sourcing Decision 16
5.1.3. Advanced Product Quality Planning 18
5.1.4. Pre-Production Meeting 20
5.1.5. Quality Management System 22
5.1.6. Production Part Approval Process-PPAP 22
5.1.7. Run at Rate 34
5.1.8. Early Production Containment 37
5.2. CURRENT QUALITY 41
5.2.1. Continuous Improvement 41
5.2.2. Quality Workshop 44
5.2.3. SQ Process & Measures 44
5.2.4. Level I – Controlled Shipment (CS I) 53
5.2.5. Level II – Controlled Shipping (CS II) 56
5.2.6. Performance Monitoring 58
5.2.7. Improvement Meeting 59
5.2.8. Re-Sourcing 60
6. APPLICABLE DOCUMENTS 62
7. GLOSSARY OF TERMS 63
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1. FOREWORD

At Tata Motors, we believe that our strengths stem from an organization-wide culture, which
rests on our values – Integrity, Teamwork, Accountability, Customer Focus, Excellence and
Speed.
While our transformation journey started in to gain speed in 2017 we had shift gears to
turnaround with a single-minded focus on execution.
Turnaround is a sprint while we are running a marathon for sustainable, profitable growth of
company
We have a brand new identity to live for Connecting Aspirations. Speed Simplicity and Agility
are the key characteristics driving high performance culture.

In support of the strategy, our effort is directed towards selecting the best suppliers based on
capability and performance. Once selected, our goal is to work with these suppliers to develop
a strong, long-term, structured relationship with them.
We expect our suppliers to be committed to a ZERO DEFECT APPROACH and to
demonstrate this commitment through:
 Delivering fully conforming parts or products,
 On time delivery,
 Rigorous adherence to approved processes and requirements,
 Pro-active risk management.

Through focused efforts, we have started to build our future highly capable supplier base.

As a Tata Motors supplier, it is expected that the requirements in this manual will be passed
on to sub tier suppliers to ensure that quality is consistent through the entire supply chain.
Collaborating with our suppliers as business partners is essential, in order for us to develop
and produce attractive products and services for our customers. This document is intended to
serve as a reference to better understand our requirements and your role in the shared
responsibility to deliver the highest quality & safety. We are convinced you will support us in
making our objectives a reality.
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2. TATA MOTORS POLICIES

2.1. Mission, Vision and Values


5

2.2. Quality Policy


6
2.3. Environment Policy
7
2.4. Environmental procurement Policy
8
2.5. Safety and Health Policy
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3. HOW TO USE THIS MANUAL
The target of this document is to communicate to our suppliers the Tata Motors requirements
to ensure the quality of supplied parts.
The Tata Motors Supplier Quality Manual is organized into two sections:
 Advance Quality
 Current Quality
Each Section in the manual is divided into 8 Steps. Each step contains certain activities, which
include the following details:

Activity Flow
Description Output Methodology References
Name Chart

All our Supplier related transactions are through SAP, single server environment across all
the plants of Tata Motors in India.
Suppliers have been provided access through our intranet services called SRM. This is
compatible with SAP and suppliers can view Purchase Order details, schedules, status of their
quality acceptance of supplies, payments etc. along with other initiatives like quarterly
feedback on Supplier rating, rejection, warranty information and Tata Motors Standards
required by them at their premises.

3.1. Document Access


Tata Motors SQ Pro-X form references are available in this manual and can be obtained
from the Tata Motors SRM portal. The latest valid version of this Supplier Quality Manual is
posted on the Tata Motors SRM portal. (https://srm.inservices.tatamotors.com/irj/portal).

To access the manual, log on to the SRM portal using your Admin ID (Vendor code) and
password. After logging on, go to the “Supplier Manual” folder using the following path:
Home > Documents > Tatamotors > Message > SupplierQuality > Supplier Manual.

3.2. AIAG Documents


All AIAG specific documents referenced can be ordered from www.AIAG.org.

3.3. Supplier Feedback


Feedback concerning this document is welcomed. Should you have any improvement
suggestion about this document, please send an e-mail to the following address:
sqms@tatamotors.com
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4. INTRODUCTION
The Tata Motors Supplier Quality Manual has been developed for suppliers to understand the
requirements of Tata Motors regarding quality management systems and ensure quality of
supplied parts.

4.1. Purpose
The Tata Motors Supplier Quality Manual has been developed to assist suppliers understand
the expectations of Tata Motors regarding quality management systems and meet the terms
of Tata Motors purchase agreement, engineering drawings and specifications.
This Supplier Manual defines the processes and requirements for:
 Process Standardization across all Tata Motors locations for Supplier Quality
 Follow of Benchmark Best Practices
 Cultivation of World Class Quality in Supplier Outputs
 Supplier Performance Measurement Parameters
 New Business

4.2. Scope
This Process, under Pro-X, is an integral part of the Supplier Quality Improvement Process.
It applies equally to all suppliers and affiliated organizations that supply parts, materials,
equipment, for production, pre-production, and/or services to the customer.

4.3. Responsibility
Suppliers shall utilize the latest revision of this Quality Manual and seek clarification from their
Tata Motors contact when necessary for items that are not identified or completely clear in the
manual. Tata Motors will continually improve and revise the contents of this manual.

4.4. Records
Suppliers shall maintain records of all required documents of this manual and shall be made
available to Tata Motors Supplier Quality Engineer upon request.

4.5. General Requirements


Tata Motors quality requirements stated in this document are general in nature. Quality
requirements for specific parts are specified in product specifications and order documents.

4.5.1. Quality Requirements


Suppliers to Tata Motors supplying auto parts meant for OE and SPD requirements are
expected to be IATF 16949: 2016 QMS Certification. Second and third tier are expected to be
certified to minimum ISO 9001-2015 with an aim to comply with IATF 16949: 2016 QMS
requirements. Tata Motors will carry out periodic assessment / audit of supplier’s Quality
Systems and manufacturing processes. Supplier is expected to carry out improvements in
time bound manner as identified during such audits. Supplier is expected to proactively take
suitable actions to make systems robust enough to ensure that non-conforming parts are
prevented from escaping supplier’s premises.

Supplier shall inform Tata Motors about changes in their QMS registration status, such as new
certificate, suspension, revocation or switchover to another certification body. Tata Motors
expects its Tier 1 suppliers to manage the quality of their supplier base. Tier 1 suppliers should
also ensure that their supplier base meets Tata Motors requirements.
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4.5.2. Applicable Statutory and Regulatory Requirements
Tata Motors demands the supplier to be in compliance with all applicable statutory and
regulatory requirements.

4.5.3. Product Safety


Tata Motors manufactures products for performance and safety in vehicles. It is of utmost
importance that our products are reliable in their applications. Product safety must therefore
be the highest priority throughout the complete supply chain.

4.5.4. Laboratory Requirements


 Supplier's laboratory shall comply with the requirement of the IATF 16949: 2016 &
Capability to perform these services correctly, traceable to the relevant process
standard. Laboratory and measurements reports shall comply with the requirement of
the IATF 16949: 2016.
In particular, laboratory and measurement reports shall include:
 The identity and location of the laboratory used
 The reference to the test methods used
 Any deviation of the test method shall be noted
 Measurement results
 All necessary materials and process traceability information on the tested components
or samples

4.5.5. Specific Requirements


In many cases, this manual will not sufficiently describe all of the specific requirements of Tata
Motors. The Tata Motors specific requirements shall be identified during the Advanced Product
Quality Planning (APQP) activities. If there are any questions regarding these specific
requirements, the supplier shall contact the respective Purchasing / Supplier Quality
Department of Tata Motors.

Product-specific requirements may include but not be limited to the following:


 Special characteristics
 Testing
 Special handling

Customer-specific requirements may include but not be limited to the following:


 Quality management systems
 Process techniques and process controls
 Identification and processing of critical parts and features
 Certification
Please refer annexure “Customer specific requirement “ for details.

4.5.6. Tata Code of Conduct


The supplier shall implement Tata Code of Conduct (TCOC) requirements at supplier's
operations and is applicable to all his dealings relevant to his relationship with Tata Motors.
Supplier as a business partner of Tata Motors shall not only subscribe to Tata Motors policy
but also support, promote and propagate them in all possible manners.
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5. TATA MOTORS PROCESS OF SUPPLIER QUALITY

5.1 Advance Quality


The Advance Quality defines TML’s common product quality planning requirements that are
necessary to develop and implement a robust development process for a product.
It is intended as a standard to provide the Supplier Quality Engineer and the Supplier a
common platform from which to proceed with all steps of Product Development.

5.1.1. Potential Supplier Assessment (PSA)


Purpose
Potential Suppliers assessment is done for new suppliers based on the assessment criteria
and their technical proposals are assessed to ascertain that all information in RFQ package is
understood, and the supplier is capable of manufacturing parts as per Tata Motors
requirements.
Scope
This step is applicable to all Suppliers of production parts, raw materials, service parts, and
sourced products.
Activities
The PSA is part of Tata Motors supplier approval process and has the following tasks:
 Potential Supplier Assessment for all new potential suppliers
 Technical Review
Process
This step formally starts off APQP process with program review and identification of key
strategies in the Purchasing Process, A comprehensive RFQ package based on SOR (from
the concerned stakeholders) is prepared to ensure that all information necessary to receive
equivalent bids is present.

Potential Suppliers are identified and tabled into the Preliminary Bid List. The suppliers are
assessed either on the Past Performance or Initial Supplier Assessment.

Potential Supplier Assessment is carried out in following conditions:


 For a New Supplier / For a New location
 For a new process / technology with Existing Supplier

Suppliers who pass the PSA (Potential Supplier Assessment) or have approved Supplier
Performance in Integrated Supplier Rating (Source-able Category) are eligible to receive RFQ.
On submission of RFQ, the Technical Reviews are evaluated to ensure suppliers are
technically capable of producing parts as per parameters set by Tata Motors.
Suppliers who have passed the Technical review and who have cleared the risk assessment
(Step 2) are eligible to receive new business, depending on the acceptance of their bids by
the purchase officer.
The supplier is informed of the nomination upfront and responsibility of EVI. A non-disclosure
agreement is signed off by the supplier to safeguard the project and product details. The
supplier gets added in the list of Potential suppliers; however depending on the technical
review/past performance, he/she may or may not get business later.
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5.1.1.1. Process Flow ( 1.1) SOR (Released to


All in bid list)
INPUTS:
1. Indent for New Part.
2. ECN
3. Alternate Source RFQ Package
4. Project Details

Preliminary
bid list

New /
Existing
Scope
Change

Fail Poor
Potential(MSA) Supplier (ISR)
Not –Capable Supplier Rating Non –Source able
Assessm

Technical
Capable Source able
Review

Pass Fail

TRSO
Exit
Sign Off

Commercial Negotiation
& Supplier finalization

Purchase order release

New Part development


process starts

Supplier Performance
Monitoring
PRR : Problem Reporting
& Resolution
Improvement Meeting Resourcing
If No Response
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5.1.1.2. Potential Supplier Assessment
Description
Assessment of potential new suppliers, identified in the preliminary bid list, based on the
assessment criteria. Key focus in this activity is on evaluation of risks associated with:
 Company Management & Financials
 Technology
 Program Management.
 Purchasing & SCM
 Process Control & analysis
 Customer Support.

A risk assessment score from manufacturing site assessment shall be given to the supplier,
with more than 80 % score supplier is considered as capable, and between (60% ~ 80%)
score, supplier is considered as conditionally approved. Less than 60% is considered as not
capable supplier. For business decision, please refer the process flowchart (1.1) above.

Timeline
Prior to Sourcing Decision, before Technical Review

Output
Risk assessment Status – Pass or Fail

Inputs
Input Source
List of Potential Suppliers Buyer / ERC
Supplier Profiles Purchase / Buyer

Methodology
 The SQE receives the potential bid list from the buyer.
 The SQE evaluates if the supplier has active business with Tata Motors.
 In case, the Supplier has active business, the SQE reviews the Supplier Rating (ISR)
to verify that supplier meets the required criteria before proceeding towards Technical
Review.
 If the supplier is not engaged in active business, the SQE proceeds towards PSA.
 Audit of suppliers are being done as per ‘Manufacturing site assessment’ (MSA)
program and format. Please refer Manufacturing Site Assessment (MSA): Revised
Guidelines (version 4) on SRM portal.
 The supplier is evaluated on following 6 parameters:
Company Process
Program Purchasing Customer
Management & Technology Control &
Management. & SCM Support
Financialsn analysis

 The supplier supports the SQE in conducting the PSA by providing all
documents/necessary support in a timely manner.
 If the supplier has achieved satisfactory Score in each of the 6 parameters, the supplier
is qualified for technical review.
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5.1.1.3. Technical Review
Description
This activity reviews the technical proposal of the supplier to validate that all the requirements
mentioned in the RFQ package have been understood and the supplier has a plan and is
capable to produce parts meeting Tata Motors Standards. The Technical Review is a pre-
requisite for any commercial negotiation and approval at the Sourcing Table

Timing
Prior to Sourcing Decision

Output
Identification of capable suppliers

Inputs
Input Source
Technical Documents Design Engineer
Quality SOR (May Include Part Specific SOR) SQE
List of Directed Buys Buyer
Carryover Part List Design Engineer
Required Quality Information Supplier

Methodology
Supplier Responsibilities:
Suppliers must review information in the SOR and produce upon information as requested by
the Tata Motors SQE:
 Adherence to Tata Motors Quality Requirements, including but not limited to:
– Adherence to IATF 16949:2016 Systems.
– Adherence to requirements mentioned in AIAG documents
– WCSQ Requirements
– Production Support Requirements
– Continuous Quality Improvement
 Preliminary Timing Charts
– Highlight concerns related to tooling, gages & fixtures, and/or testing that may
impact PPAP.
– Detailed list of (proposed) changes to the manufacturing facility, including
Greenfield and brownfield plans.
– Optimized and dedicated resource deployment to successfully complete the
APQP project; including competency mapping and training requisite to
complete the tasks.
 Suppliers should have Preliminary process flow diagrams, PFMEA and Control Plan.
– The suppliers must specifically list down all information that is material,
including but not limited to special assembly techniques, test methods
(including EOL testing, functional and compliance testing), and containment
procedures deployed.
 Capability Studies on similar parts (Commodity) and tolerances:
– Error Proofing systems, MSA studies, SPC, EPS mechanisms and their record
keeping is included.
– Plan to meet warranty targets (Review open PRRs, existing warranty action
plans and data on similar parts/aggregates)
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 Present process and resource plan for evaluation and management of sub-
contracted/tiered suppliers.
 Respond to the assessment and observations and where applicable identifying
countermeasures to be taken.
 Provide evidence of product experience or technical expertise relevant to the new
product.

5.1.2. Sourcing Decision


Purpose:
Evaluate the sourcing eligibility of the supplier based on the TRSO and risk criteria. The score
band in the risk criteria serves as a guideline to determine if APQP is Supplier Monitored or
Customer Monitored.

Scope:
All parts under development

Activities:
Risk Assessment

Process
To receive new business, the supplier’s manufacturing location must either be:
 Approved on the Tata Motors Preliminary Bid List for Quality in the specific commodity
OR
 Have a supporting Quality Business Case (QBC) approved according to the criteria
outlined in this task.
Suppliers clearing the Technical Review and qualifying the risk evaluation criteria will be
eligible for consideration in the sourcing process.

5.1.2.1. Risk Assessment


Description
The overall risk assessment score decides if APQP project plans proceed with Customer
monitored (Tata Motors) or Supplier monitored APQP.
Note: Further Risk Assessment can be done during any stage of APQP Project Plan, and the
decision to change APQP Risk Assessment Status can be taken by SQE in consultation with
SQ Head.

Timing
Prior to Sourcing Decision (Sourcing Recommendation Table)

Output
Completed APQP Supplier Assessment
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Inputs:
Input Source
Supplier Plant Location List Buyer
Existing IATF 16949:2016 Certification SQE
Assessment required completion date Buyer
Current Bid List Quality Status (R/G) Buyer/ SQE

Methodology:
Supplier Responsibilities:
Provide necessary information and support audit requests.

APQP Activity Responsibility Matrix:


The following matrix describes the responsibility differences between “Customer-Monitored”
and “Supplier-Monitored” APQP. Suppliers are responsible for carrying out all the “R” activities
shown in the supplier column of the matrix, whether or not their parts are designated as
customer or supplier monitored APQP. If a part is designated as customer-monitored APQP,
Tata Motors SQE will monitor and approve the APQP activities.

APQP Activity Tata motors Supplier Monitored


Monitored APQP APQP
Supplier Tata Supplier Tata
Motors motors
1 Technical Reviews S R S R
2 Sourcing Decisions N/A R N/A R
3 Pre-Production Meeting
a) Kick Off Meeting S R S R
b) Remaining Gate Review R A R I
4 Quality Management system R A R A
5 PPAP R A R A
6 Run @ Rate R A R I
7 Lessons Learned R I R I
8 DFMEA
a) Supplier Responsible R S R I
b) Build To Print Parts S R A I
9 Tool & equipment review R A R I
10 Gage Review & Approval R A R A
11 PFMEA R I R I
12 Control Plan R I R I
13 PPAP R A R A
14 Run @ Rate R A R I
15 Lessons Learned R I R I

Note: Unless otherwise specified, APQP will be supplier monitored.


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5.1.3. Advanced Product Quality Planning
Purpose:
APQP is a structured method of defining and establishing the steps necessary to assure that
a product satisfies the customer (Tata Motors). The goal of APQP is to facilitate
communication with all stakeholders to assure that all required steps are completed on time.
Some of the benefits of APQP are:
 To direct resources to satisfy the customer requirements.
 To promote early identification of required changes
 To avoid late changes
 To provide a quality product on time

Scope:
All new parts under development

Activities:
APQP enlists 3 core activities within the step, namely:
 APQP Project Plan
 APQP Timing Chart
 APQP Kick Off Check sheet

Inputs:
Input Source
APQP Status SQE (APQP Risk
 Customer (Tata Motors) Monitored Assessment Score)
 Supplier Monitored
Detailed Timings for tooling, facilities, gages Supplier/SQE/
Project Timing Requirements LOB
Open Issues SQE/Supplier/Design
Engineer (COC)
Sub Contract Management (Supplier Tiers / Supplier/Buyer
Directed Buy)

Output
 APQP Open Issues List
 Updated APQP Timing Chart
 Customers for Deliverables

Process
The APQP project plan is developed in accordance with the recommendation of AIAG APQP
manual, listing the various activities in line with Tata Motors NPI DR Gates /Milestones. The
type of Product, complexity and project expectations are considered in selecting the timing
elements that are planned and charted. Each event has a “start” & “completion” date along
with the actual point of progress recorded. APQP process is then formally kicked off (APQP
Kick Off) for the various projects.
 The reviews are conducted by Tata Motors for all parts that are designated as
Customer monitored APQP during Step 2.
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 For supplier monitored APQP parts, the supplier reviews and updates the timing charts
and Open issue lists throughout the APQP Process. Supplier must update all
information pertaining to Product Quality and Timing to the concerned SQE.
Note:
 The timing chart is developed in accordance with principles of Critical Path Method
(CPM), Gantt chart, and is driven by the principles of simultaneous engineering
performed by product and manufacturing engineering activities working concurrently.
 Each project plan will be different depending on the project program and the part.
 The APQP Timing chart will be continually referenced and review throughout the
Product Development Cycle.
 APQP project planning facilitates communication between the supplier and customer
(Tata Motors) to clarify requirements that translate into more detailed specifications.
 Suppliers prepare component specific timing chart in line with the APQP Project Plan
(Master Timing Chart) considering development along the entire supply chain
(including Sub Contractor Development).

Supplier Responsibilities
 Create an APQP Timing Chart or equivalent and track tasks to completion in line with
chart.
 Suppliers should use APQP as a tool to support process development1:
– To develop and execute an APQP Plan for flawless product launch.
 Launch of new components intended for regular production.
 Development of new manufacturing processes
 Significant changes to existing products or process
– Regularly update the progress of product development based on their APQP
plan and share the same with customer (Tata Motors) teams.
 Suppliers are required to adhere to APQP Timing Chart.
– Create an APQP Open Issues and monitor the same throughout the program.
 Utilize APQP Open Issues list to capture all issues requiring action.
– Update timing chart as timing changes occur and communicate any changes,
concerns and issues to SQE.
 Develop recovery plans for issues impacting quality and timing and
drive the plan to maintain program timing
 Any timing changes by the customer (Tata Motors) have to be
adequately communicated downstream.
– Sub-component (tier II) milestones shall be pulled ahead of the Supplier’s
assembly milestones to protect Tata Motors program timings.

1 Refer AIAG APQP Manual


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5.1.4. Pre-Production Meeting
Purpose
Pre-Production Meeting is a review mechanism to track the progress of all APQP Tasks in the
APQP Project Plan2 and APQP Timing Chart.

Scope
All activities covered under the APQP process.

Activities
Pre-Production Meeting marks the start of activities which are conducted periodically
throughout the APQP cycle to evaluate progress of various activities in a structured manner.
Tata Motors SQE will be scheduling these Gate Reviews with Supplier.

Process
 SQ Gate Reviews are conducted prior, preferably 1-2 weeks, to Project DR Gate
Reviews.
 Pre-Production Meeting entails the first Gate Review (GR1) should be completed
within 4 weeks after the release of PO.
– Subsequent Gate Reviews are aligned with the vehicle built for each
component.
 Completion of all activities as mentioned in the APQP Gate Review Chart, ensures
qualification to next level, else the progress takes a step back to a prior level.

5.1.4.1. Gate Reviews


Description
Gate Reviews are done to ensure that all tasks in the APQP project plan due at a particular
Gate are completed.

Timeline
Completed prior, preferably 1-2 weeks, to Project DR Gate Reviews.

Output
 Updated APQP Open Issues List
 Progress of Project – Completed documents of all required activities
 Gate Clearance Status
 100 % Interim Saleable along with minimum 75 % Fully Approved PPAP Status at time
of pilot production.
 100% WCSQ compliance before PPAP approval.
– WCSQ compliance will be considered as a pre-requisite for fully approved
PSW.
 Minimum 90% Run @ Rate at SSF (Start of System Fill)

2 PSC-SQ APQP Project Plan


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Inputs:
Input Source
Program timing for key events Buyer/ Program Manager
Detailed Program Timing Supplier / SQE
APQP Open Issues List Supplier / SQE
APQP Timing Chart Supplier / SQE

Methodology
Supplier Responsibilities
 Ensure completion of required activities as per APQP plan at various gates.
 Supplier should ensure his readiness for audit by Tata Motors prior to any gate review.
 Review the completion status of actions required for compliance to SQ SOR and Part
Specific SOR, Lessons learned.
 Ensure lessons learned are captured adequately in the FMEAs or Control Plans.
 Validate capability studies and RPN reduction plans to satisfy Tata Motors design
specifications and quality requirements.
 Validate capacity/plan vs. capacity required by Tata Motors.
 Identify and communicate key issues in adhering to the APQP timing chart to Tata
Motors management.
 Co-ordinate the gate reviews after APQP kick-off. For Supplier monitored parts, the
supplier must conduct the APQP Gate reviews and periodically report the same to Tata
Motors SQE.
 Complete the gate reviews with sub-contractors (Tier II to Tata Motors), at least 6
weeks prior to Tata Motors gate reviews to protect Tata Motors project timing. Inform
Tata Motors SQE, in case of any discrepancy or non-conformation.

 Protect Tata Motors program timing and objectives by adhering to the APQP charts.
– In case of deviation, prepare comprehensive recovery plans and submit the
same to Tata Motors SQE.
– Track all open APQP issues and report any concerns to Tata Motors SQE,
immediately.
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5.1.5. Quality Management system.
Purpose
Quality Management system helps us to Achieve & Exceed the global benchmark levels to
manufacture and deliver the Highest Quality Products. By achieving compliance to the
process, it may help supplier to reach world-class Quality level.

Quality is built into the process


 Built-in-quality (BIQ) is made the DNA of the Organization
 People are involved and strive for Quality Excellence
 Prompt Actions are taken for all abnormalities

Scope
Quality Management system applies to all Suppliers collaborating and/or engaged in business
with Tata Motors. This is also evaluated during MSA audit at supplier.

Timeline
 During APQP & sustenance.

Output
 Quality management system helps us to Achieve & Exceed the global benchmark
levels to manufacture and deliver the Highest Quality Products
Activity
The activity has the following 10 key elements
1. Quick Response Teams
a. Quick Response Process
b. Problem Solving
c. Lessons Learned
2. Control of Non-Conforming Product
3. Quality Gate
4. Standardized Operations
5. Standardized Operator Training
6. Error Proofing
7. Layered Process Audits
8. RPN Risk Reduction (Reverse FMEA)
9. Contamination Control
10. Supply Chain Management

5.1.6. Production Part Approval Process-PPAP


Purpose
PPAP’s purpose is to provide the evidence that all Tata Motors engineering design record and
specification requirements are properly understood by the Supplier and that the manufacturing
process at the Supplier has the potential to produce the product meeting these requirements
consistently during an actual production run at the quoted production rate.
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Scope
 Applies to all supplier sites supplying Production parts, service parts, production
materials or bulk materials.
o For bulk materials, refer to the Bulk Materials Checklist3.
 Suppliers supplying standard catalogue parts (e.g. Bolts, nuts etc.) shall comply with
PPAP, unless otherwise specified by the authorized Tata Motors SQE.

PPAP Requirements4
 Design Record
 Authorized Engineering Changes
 Customer Engineering Approval
 Design FMEA
 Process Flow Diagrams
 Process FMEA
 Control Plan
 MSA Studies
 Dimensional Results
 Records of Material/Performance Test Results
 Initial Process Studies
 Qualified Laboratory Documentation
 Appearance Approval Report
 Sample Production Parts
 Master Sample
 Checking Aids
 Customer Specific Requirements
 Part Submission Warrant (PSW)

5.1.6.1.Process Flow Diagram


Description
Process Flow Diagram provides a logical pictorial representation of the process flow that can
be used as the foundation for PFMEA’s, control plans, work station layouts, etc.

Timeline
Initial chart–prior to sourcing, reviewed at Gate 2 and Gate 3, and completed in PPAP.

Output
Process Flow Chart (depicting Sub component system)
Inputs:
Necessary Inputs: Source:
Information on each step of Manufacturing Process Supplier
Part Specific Quality & Process SOR (If applicable) SQ

3 AIAG PPAP Manual, Appendix F


4 Refer AIAG PPAP Manual, Section 2 – PPAP Process Requirements
24
Methodology
Supplier Responsibility
 Create a preliminary process flow chart using a similar process as part of response to
RFQ package requirement.
 Define a production flow chart once product design is released.
 Document all items in the flow chart with the respective nomenclature (store, move,
inspect, correct, etc.)
 Ensure the process flow chart is linked to the PFMEA and control plan
 Update flow chart to reflect actual production process.
 Communicate any changes on an ongoing-basis to SQE.

5.1.6.2. Design Review


Description
The purpose of Design Review is to ensure that the Product Design is adequately defined to
enable construction of tools and gages. The Supplier shall have the design record for the part,
including design records for sub-components.

Timeline
As per APQP Project Plan

Output
 Defined and measurable Classification of Characteristics (CTQ)
 Appearance, performance and material testing specifications
 Geometric Dimensioning & Tolerancing (GD&T)

Inputs
Necessary Inputs: Source of Input:
SOR ERC
Appearance specifications PAT-PQ Engineer (ERC)
Performance and material specifications PAT Engineer (ERC)
Production Assembly Documents if available Simultaneous Engineer
Bill of Material (BOM) Bill of Material (BOM)

Methodology
Supplier Responsibility
 Confirm the manufacturing process can achieve the specified tolerances on a
sustained basis.
 Any recommendations / improvements to the design record are documented and
submitted to Tata Motors for approval.
 Communicate any concerns related to the CTQ cascade Designators or GD&T
scheme and the manufacturability of the part. Document any open issues on the
APQP Open Issues List
 Develop an understanding of the engineering change process with the Tata Motors
ERC Engineer. Refer Design Review Check sheet5 and address any open action
item.

5 PSC-SQ-06-13 Design Review Check Sheet


25
 Note: Where the design record is in electronic format, e.g., CAD/CAM, the Supplier
shall produce a hard copy.

5.1.6.3. Design Failure Mode and Effects Analysis (DFMEA)


Description
Design Failure Mode and Effects Analysis is an activity to assess and prioritize the risk of
failure of a product design component, subsystem, or system in achieving product
performance, reliability, or safety goals and to develop mitigation plans.
The purpose of DFMEA is to predict the potential failure of the product design, evaluate the
effects of those failures, and then identify actions to reduce the risk before the design is
released to manufacturing.

Timeline
Initiated before or at design concept

Output
DFMEA document and cascade DFMEA to sub-component level DFMEA.

Inputs:
Necessary Inputs: Source:
Requirements as stated in SOR ERC
Design intent COC
Vehicle Requirements Designer
Manufacturing/Assembly requirements Designer
Lessons Learned /Part-Specific Quality & Process SOR SQE
CTQ Cascade Templates (if already identified) FMQ

Methodology
Supplier Responsibilities:
 The supplier needs to create and submit the DFMEA if it is design responsible.
 The DFMEA document should be maintained throughout the life of the product and
updated and revised prior to any engineering changes. Changes in part level DFMEA
should be communicated to Tata Motors for updating system level DFMEA.
 Supplier must address and identify all Tata Motors special characteristics as given in
TS11413 standard.
 The DFMEA shall be ranked based on AIAG guidelines for Severity, Occurrence and
Detection Ratings.
26
5.1.6.4. Process Failure Mode and Effects Analysis (PFMEA)
Description
A PFMEA is used to identify potential weak areas in the manufacturing and assembling
process. Cross-functional teams should be organized to study each step of the process for
possible failure modes, effects of failures, and potential causes. Countermeasures must be
provided for failure modes as per requirements in AIAG FMEA Manual.

Timeline
Starting at APQP Kick-Off Meeting and complete by PPAP.

Outputs
 PFMEA
 RPN Reduction Summary

Inputs
Necessary Inputs: Source of Input:
DFMEA ERC/Supplier Design Engineer
Lessons Learned/ Parts Specific Quality/ Supplier/ SQE
Process SOR
Process Flow Chart Supplier
Warranty Data SQE
PRRs on Similar Parts Supplier/ SQE
Supplier Performance Report Supplier/ SQE
Supplier’s Manufacturing Process Capability on Supplier
similar parts
Error Proofing Techniques Supplier/ SQE

Methodology
Supplier Responsibilities:
 Review and update PFMEA each time a design change is made or a Process change
is implemented. All potential areas for failure are included in the PFMEA and
appropriate corrective actions are planned and implemented.
o Note: A PFMEA should not consider product design changes to compensate
the process deficiencies.
 Prepare PFMEA with inputs and participation from cross functional team.
 Adhere to PFMEA RPN Reduction Summary6, including the categorization of risk,
establishment of a top ten list, development of recommended actions, and update to
Tata Motors SQE on demand.
 Drive simple and inexpensive mistake / error proof devices into the process to help
prevent and detect errors.
 Ensure that all failure modes and related severity numbers from DFMEA are listed in
the corresponding PFMEA.
 Ensure that the current process controls and results of recommended actions on the
PFMEA are listed on the control plan.
 Ensure that the PFMEA has a link with the manufacturing process flow chart and the
control plan.

6 PSC-SQ-06-18 RPN Reduction Summary


27
 If the process, material or manufacturing location changes, revise the PFMEA and re-
evaluate the impact on severity, occurrence, and detection ratings.
 Ensure that subcontractors’ PFMEAs are developed and RPN reduction action plan
are implemented.

5.1.6.5.Tooling and Equipment Review


Description
The task ensures that the manufacturing process is designed to the latest engineering change
level (e.g. NR, A, B, C etc.) and certified to produce quality parts at rated production rates as
per Tata Motors specifications.

Timeline
Starting at Tooling Kick off Meeting till PPAP approval

Outputs
Process capable Tooling and Equipment delivered on time as per APQP Project Plan.

Inputs:
Necessary Inputs: Source of Input:
Approved GD&T, CTQ Cascade Design Engineer
Designators and CAD Data
Part-Specific Quality & Process SOR SQE
Quoted Tool Capacity Buyer
Process Capability Requirements SQE/Supplier
Timing Requirements Buyer/SQE/Supplier
Capacity Requirements Buyer
Error Proofing Supplier
Functional Test Requirements Tata Motors Validation Engineer
(IDT/ODT)/ Supplier

Methodology
Supplier Responsibilities:
 The supplier should review and inform Tata Motors about any changes in the original
project timing.
 The supplier must participate in Tata Motors design reviews to incorporate Tata Motors
requirements and special characteristics in the tooling or equipment.
 Design, build and obtain certification of and validation of tooling and equipment as per
latest CAD data.
 Participate in design reviews with Tata Motors and ensure GD&T, CTQ Cascade
requirements are included in the tooling, equipment and functional test design. Also
ensure tooling and equipment will produce parts consistently to meet process
capability requirements.
 The supplier should inform Tata Motors about any design and process changes
regarding any new or modified tools, rearrangement of existing tooling or equipment,
any product or process changes impacting fit, form, function, performance and
durability of saleable product, any test/inspection methods and any new facilities.
 Prior to tools being grained, dimensional verification is required by Tata Motors and
Grain Approval to be signed off.
28
 Ensure PFMEA has been comprehended and incorporated into tooling and equipment
design.

5.1.6.6. Gage Development and Approval


Description
To design, build and certify gages according to latest GD&T release.

Timeline
To be completed by PPAP Approval

Outputs
Approved Gage Prior to PPAP.

Inputs:
Necessary Inputs: Source of Input:
Part CAD Data Design Engineer
CTQ Cascade Designators Design Engineer
Gage Design & Build Approval Gage Engineer
Timing Requirements Buyer/SQE/Supplier

Methodology
Supplier Responsibility
 Identify gage requirement as per CTQ cascade mentioned on drawing.
 Review timing to ensure compliance and inform Tata Motors SQE about any changes
from original project timing, any design and process changes, any new part math data
and/or GD&T changes, any test/inspection methods that include gages, any new
facilities that would house the gages.
 Participate in design reviews, ensure GD&T scheme is released and relevant CTQ
cascade parameters are incorporated into final gage design.
 Design, build, certify gage dimensionally (including a third party certification), perform
complete AIAG MSA (GR&R and Bias study) and meet all requirements as per Tata
Motors fixture standards.
 The supplier shall conduct and document Gage R&R studies upon receipt of new or
repaired measuring equipment.
29
5.1.6.7. Control Plan
Description
 It defines the method to be used to control all CTQ Cascade for parts being built for
vehicle builds, power train, and service applications to ensure customer requirements.
 It is to be developed in line with the control plan format referenced in the AIAG APQP
Manual.
 For Product safety requirement refer IATF 16949: clause 4.4.1.2.

Timeline
Starts with Initial draft at APQP Kick Off, supplier shall update parallel PFMEA changes prior
to PPAP.

Output
 Control Plan
 Individual Process Control Charts for all CTQ cascades (FMASOW)

Inputs:
Necessary Inputs: Source of Input:
DFMEA/PFMEA Design Engineer/ Supplier
Lessons Learned, Part Specific Quality & Process SOR Supplier/ SQE
Process Flow Chart Supplier
Warranty Data SQE
PRR on similar parts SQE
Supplier Performance Report SQE
Supplier’s Manufacturing Process Capability on similar Supplier
parts
Error Proofing Techniques Supplier/ SQE

Methodology
Supplier Responsibilities:
 Supplier should maintain the control plan throughout the life of the product.
 The control plan must be approved by a cross functional team at supplier’s end. It may
be reviewed by Tata Motors depending upon the component.
 The supplier must identify and address all Tata Motors special characteristics on the
control plan.
 The supplier should communicate any changes in control plan to Tata Motors
 The supplier should conduct frequent audits to check the implementation of controls in
the control plan.
30
5.1.6.8. Production Part Approval Process
Description
The details of various PPAP activities as prescribed in the AIAG PPAP manual are mentioned.
Please refer to AIAG PPAP Manual, latest edition for further details.

Timeline
As per APQP timing Chart

Output
Completed PPAP documents, PSW

When PPAP is required?


 New Part
 Engineering Change(s)
 Tooling: Transfer, replacement, refurbishment or additional tooling
 Correction of discrepancy
 Tooling inactive > one year
 Change of optional construction or material
 Sub-supplier or material source change
 Change in part processing
 Parts produced at new or additional location

Submission Levels
The supplier shall submit the items and/or records specified in the level identified below:

•PSW only and AAR, if applicable submitted to Tata Motors.


Level 1

•PSW with product samples and dimension results submitted to Tata Motors.
Level 2

•PSW with product samples and complete supporting data.


Level 3

•PSW and other requirements as defined by the Tata Motors.


Level 4

•PSW with product samples and complete supporting data reviewed at the
Level 5 supplier’s location.
31
Submission to Tata Motors: - Levels of Evidence7
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
Design Record
- for proprietary parts R R R * R
- for all other parts R S S * R
Engineering Change Documents R S S * R
Customer Engineering approval R R S * R
DFMEA R R S * R
Process Flow Diagrams R R S * R
PFMEA R R S * R
Control Plan R R S * R
MSA Studies R R S * R
Dimensional Results R S S * R
Material, Performance and Test R S S * R
Initial Process Studies R R S * R
Qualified Lab Documentation R S S * R
Appearance Approval Report S S S * R
Sample Product R S S * R
Master Sample R R R * R
Checking aids R R R * R
Records of compliance R R S * R
Part submission warrant S S S S R
Bulk Materials Checklist S S S S R
Legend
S – Supplier shall submit to Tata Motors and retain a copy of records or documentation items
at appropriate location
R – Supplier shall retain at appropriate locations and make readily available to Tata Motors
upon request.
* – Supplier shall retain at appropriate locations, and submit to Tata Motors upon request. Tata
Motors will determine what is needed for submission.

PPAP Approval Status


Full Approval
 PSW signed off as approved and all open issues are closed8.
 For Bulk Materials, supplier shall use the Bulk Materials Approval Form, AIAG PPAP
Manual, Appendix F.
 For tires and Commercial Vehicles (truck industry), suppliers shall refer the AIAG
PPAP Manual, Appendix G and H respectively.

Interim Saleable
 Permits shipment of parts for a given time or quantity, whichever is less.
 Interim approval is granted when the supplier has prepared and submitted an approved
action plan to the Tata Motors SQE and is valid till POPP batch.
 If the PPAP is not re-submitted within the time frame of Interim Saleable status (unless
otherwise specified by the Tata Motors SQE), PPAP is rejected.

7 As per AIAG PPAP Manual


8 Refer APQP Open Issues List PSC-SQ-03-08
32
– If the PPAP submission date is extended beyond the time frame, approval from
SQ Head and Design Engineering Head shall be taken.

Interim Non Saleable


 PPAP submission does not account for all defined Tata Motors requirements.
– If the requirements are related to Product safety and/or statutory requirements
this status is invalid and PPAP stands rejected.
 Supplier must submit corrective action plans to meet Tata Motors requirements
 Interim Non Saleable PPAP is valid for only alpha and beta build.
– Note: - Parts should be dimensionally known parts

Reject
 PPAP submission does not meet Tata Motors defined requirements based on the
production lot and/or accompanying documentation.
 Document submission and/or process correction is required.
 Parts will not be shipped before submission of approved/Interim Saleable PPAP.

Methodology
PPAP activities (DFMEA, PFMEA, MSA studies etc.) are conducted concurrently, as per the
APQP timing charts. Evaluation of the significant production run is done after all issues
identified in EPC station (Step 8) are resolved.
 For Production parts, product for PPAP shall be taken from a significant Production
Run. A significant production run is of at least 8 hours of continuous production or a
production quantity of at least 300 consecutive parts, unless otherwise specified and
approved by Tata Motors SQE.
– For bulk materials, supplier shall refer to AIAG PPAP Manual, Appendix F.
– For tires, unless otherwise specified by Tata Motors SQE, size of significant
production run is 30 tires. PPAP is derived from 8 hours of tire curing from the
approved production process as specified in the control plan.
– For parts developed for commercial vehicles (Truck Industry), guidelines as
referenced in Appendix H of AIAG PPAP Manual, are applicable, unless
otherwise stated by Tata Motors SQE.
– This production is conducted at the production site, at the production rate, using
the production tooling, process, materials and operators. Parts from each
production line e.g., duplicate assembly line and/or work cell, each position of
a multiple cavity die, tool or pattern, shall be measured and representative parts
tested.
 The supplier is responsible for obtaining the latest revision of the AIAG Manuals and
forms. The supplier shall submit by default a “Level 3” PPAP package, unless
otherwise specified by Tata Motors SQE. All parts that are supplier designed require
“Level 5” PPAP package, unless otherwise specified.
 Any changes to the 4M’s shall be duly notified to the authorized Tata Motors
representative. After the change has been approved by Tata Motors SQE, the supplier
must re-submit the PPAP documents unless otherwise specified.
 Supplier shall maintain all records at his end regardless of submission levels for the
length of time that the part is active plus one calendar year.
33
5.1.6.9. Lessons Learned
Description
The purpose is to maximize the knowledge gained from previous programs and not revisit the
same quality or design issues.

Timeline
Throughout new part development

Output
 DFMEA & PFMEA and other PPAP Documents updated with Lessons Learned
 Part-Specific SOR for key commodities updated with Lessons Learned throughout the
APQP process.

Inputs:
Necessary Inputs: Source of Input:
Existing Lessons Learned for same commodity SQE
Engineering Knowledge for commodities Design Engineer
Process knowledge for same commodity SQE

Supplier Responsibility
 Lessons Learned Update
– Review solutions to issues identified in the Kick-off meeting and new items
added to the list in various builds till launch.
– As solutions are identified, DFMEA, PFMEA, Flow Chart, and Control Plan are
reviewed and updated.
 Contribute with additional lessons learned based on knowledge of the commodity.
 Adhere to the Part-Specific SOR.
 Place a formal process to update FMEA and control plans based on Lessons Learned.
34
5.1.7. Run at Rate
Purpose
Run at Rate (R@R) is an activity to verify that the supplier’s actual manufacturing process,
functioning under normal conditions, is able to produce components meeting Tata Motors
requirements and matching the Quoted Tool capacity as mentioned in Purchase order.

Scope
All Suppliers of production parts, service parts, and sourced products that have PPAP
submission status as “saleable” or “fully approved”.

Timeline
 Upon PPAP approved Status.
 8 weeks prior to start of production.

Output
• Completed R@R Capacity Workbook and R@R for each part
• Supplier meets Daily Contract Capacity

Inputs
Necessary Inputs: Source of Input:
PPAP documentation Supplier
Tata Motors daily requirement (Lean Capacity Rate) Buyer
Supplier’s Contracted Tool Capacity Supplier & Buyer
Planned & unplanned downtime record Supplier
Written confirmation of quality, capacity and delivery Supplier
for all sub-components

Process
R@R is carried out once the PPAP has been submitted as mentioned in scope above. The
SQE verifies that Tata Motors Lean Capacity Requirement9< = Quoted Tool Capacity10

9 Daily Production Requirement


10 QTC as mentioned in the Tata Motors Purchase Order
35
Process Flow
Escalate any
Missing PO
information

GR 3 Meeting and
Is Run @ Rate
Yes R@R Kick off Meeting escalate any missing
Required
supplier information

No Supplier completes
PFD, Shared
Capacity Sheets.
Exemption
from SQ Head

Status:-
Exempt Supplier
TML or Supplier Conducts
TML
monitored APQP Prior R@R

Supplier

Supplier conducts Fill the Hourly Supplier conducts


R@R in presence of Sheet R@R in presence of
SQE SQE

Supplier completes Supplier completes


Capacity Workbook Capacity Workbook
& sends it to SQE. & sends it to SQE.

R@R
R@R Status?? Pass
Complete

Fail

Supplier updates
APQP Open Issues
List.
36

Methodology
Supplier Responsibility
 Develop a R@R plan and provide to the SQE at the Gate 1 APQP Kick-Off meeting.
 Complete the Capacity Workbook (Manufacturing Flow Diagram, Shared Capacity
Sheet(s), and Manufacturing System Capacity Estimate) and submit to the SQE prior
to the Gate 3 APQP Review.
 The capacity analysis must show satisfactory results prior to ordering tooling and
equipment.
 Ensure understanding of the R@R “PASS” performance metrics.
 Conduct preliminary R@Rs and/or simulations prior to the planned R@R to confirm
readiness. The PPAP run of parts will be one of the trial runs.
 Complete verification for all subcontractors, and submit prior to the R@R.
 Completely fill the R@R Hourly Count Sheet during the R@R for both the final
operation and the constraint operation.
 Completely fill the Capacity Workbook for all R@Rs and forward to the SQE

References
 Run @ Rate Check Sheet – PSC-SQ-07-20
37
5.1.8. Early Production Containment
Purpose
The purpose of EPC is to:
 Validate the supplier’s production control plan
 Protect Tata Motors assembly and manufacturing centres and service part
warehouses from quality non-conformances
 Document the supplier's efforts to verify control of its processes during start-up,
acceleration and after revisions to the manufacturing process.
 Ensure that any quality issues that may arise are quickly identified, contained, and
corrected at the supplier's location
 Increase involvement and visibility of supplier’s top management

Scope
EPC station is to be established for all parts that require PPAP approval from Tata Motors.

Timeline
EPC is an activity conducted at supplier’s location:
 EPC will start from first off tool sample to meet Product and Process Validation Phase
 Containment until agreed exit criteria is achieved.

Output
 EPC Control Plan audit – PSC-SQ-08-21
 Defect free parts

Inputs
Necessary Inputs: Source of Input:
Production Control Plan Supplier
Order Requirement Tata Motors - SCM
38
Process Flow

New Part / Change


in Existing part

No EPC
Is PPAP Required No
Required

Yes

Verify Supplier has used


PFMEA to determine
necessary controls

Implement additional
Supplier develops EPC
checking provisions. Inform
plan
Tata Motors SQE

Timeline :- Minimum 3
Months

Correct any Non-


Conformances found by Tata
Motors manufacturing sites

No

Has the Supplier


achieved the Exit
Criteria ?

Yes

EPC Exit

Methodology
Supplier Responsibility
Supplier should demonstrate compliance to requirements mentioned in SQ-SOR for EPC but
not limited to the following:
A. Establish a validation process that contains the following elements:
i. Identify and train staff that ensures the development and implementation of the
verification process.
39
ii. Implement EPC with entry date, exit criteria, and exit date as defined by Tata
Motors SQE.
iii. Establish EPC containment stations, which must be off-line, separate, and
independent check from the normal manufacturing process and located at end of
process. Additional, or when increased effectiveness, in process containment
stations can be utilized, permission from approved Tata Motors SQE must be
sought and the same documented.
iv. Identify additional inspections, testing, and dimensional checks required at the
EPC station based on Critical Quality Characteristics (CTQs), critical measurement
points, high RPN and/or issues identified during product and process development.
v. Establish a reaction plan for each and every defect.
vi. Implement an audit process of the EPC station utilizing Layered Process Audit
Methodology11, including site leadership, to ensure conformance to the Pre-Launch
Control Plan.
vii. Include subcontractor (Tier 2) in the validation process.
viii. Submit data to Tata Motors for all CTQ, and critical measurement points.

B. Plan Development of a significantly enhanced Pre-Launch Control Plan, consisting of


additional controls, inspections, audits, and testing to ensure the conformance and
capability of the manufacturing process. The plan needs to consider:-
i. Increased frequency/sample size as stated in the Production Control Plan.
ii. Verification of packaging and label requirements – including service and accessory
part requirements.
iii. Verification of the effectiveness of error proofing.
iv. Immediate implementation of containment and irreversible corrective action when
non-conformances are discovered in the EPC containment area or at the receiving
location.

C. Documentation: Document the Pre-Launch Control Plan using the Control Plan format
referenced in the AIAG Advanced Product Quality Planning and Control Plan
Reference Manual. (Note:-The Pre-Launch Control Plan is not a substitute for the
Production Control Plan but, is an addition to the Production Control Plan and is used
to validate it.)
i. Document additional inspections, functional testing, and dimensional inspections
required at the EPC containment station or at process work stations on the Control
Plan Special Characteristics form referenced in the AIAG APQP Manual –
Supplement K and reference said document in the Pre-launch Control Plan as a
specific operation.
ii. Document inspection work instruction in a standardized format for the EPC
containment station to insure standardized work.12
iii. Document evidence of execution and validation of the control plan utilizing the I-
chart or other format agreed upon by Tata Motors. The data must be readily
available for review by the SQE.
iv. Document problem solving for both internal and Tata Motors quality concerns
utilizing customer acceptable format; including problem description, root cause,
irreversible corrective action with break points and update FMEAS and Control
Plans as appropriate.

D. Identification: To identify lots shipped with EPC gates, supplier must attach to each
shipping label a green circular, sticker, signed by the supplier’s staff person
accountable to insure proper implementation of EPC.

11 Refer AIAG CQI-8 Layered Process Audit


12 Refer WCSQ principles for further guidelines
40
Exit Criteria
Supplier will be eligible to exit EPC after validating the effectiveness of Process Control Plan
and meeting the criteria listed below. If the supplier is unable to meet the exit criteria or the
supplier’s EPC plan continues to identify non-conformances.
The supplier shall continue the necessary containment measures to insulate Tata Motors
manufacturing location until the quality concerns have been resolved to the satisfaction of both
the supplier and Tata Motors, and the supplier’s Production Control Plan is validated.
The exit criteria are as mentioned below:
 Ship required quantity as specified by the Tata Motors for the EPC period without any
issues identified at either the EPC gate or Tata Motors. For a Supplier to exit from the
EPC firewall, the manufacturing process should be error free for 21 consecutive days
after observation of the problem, subject to minimum 3 months of a firewall stationed
installed at the supplier end.
 If EPC plan continues to identify non-conformances, the EPC plan shall be kept in
place until process controls and capabilities have proven effective and the Production
Control Plan is validated.

Consequences of shipping non-conforming material


 Failure to execute EPC may result in Controlled Shipping Level 2 and other possible
consequences.
 Shipment of non-conforming material may result in Controlled Shipping Level 2.
41
5.2. Current Quality
The Current Quality defines the standardized work around common processes used across
all locations to protect Tata Motors manufacturing/assembly plants and to drive systemic
improvement to the supply base.

5.2.1. Continuous Improvement


Purpose
Continuous Improvement has been included in the Pro-X SQ Process to promote the culture
of PDCA at supplier manufacturing locations. Continuous improvement:-
 Defines the supplier’s responsibility in developing and sustaining a manufacturing (and
it’s allied) process that continuously improves the product and related manufacturing
processes throughout the product/part lifecycle.
 Reduces variation and ensures process stability and capability over time (after a part
has satisfactorily completed PPAP), with emphasis on zero defects.

Scope
Continuous Improvement applies to all suppliers of Tata Motors and is applicable even when
Tata Motors has not requested data and/or product characteristics have not been called out
in the design record.

Basic Requirements
All suppliers are required to have quality systems in place that ensures parts shipped to the
Tata Motors meet specification. Suppliers are also expected to have a system to:-
 Properly identify the root cause of non-conformities
 Capture and horizontally deploy lessons learned
 Prevent recurrence of non-conformances across their operations.
Additionally, all suppliers shall have processes in place to capture:
 Voice of the Customer (VOC):- (These measures reflect quality performance as seen
by the Tata Motors)
– Compliance with SQ Manual - Suppliers are required to have a process in place
that appropriately responds to PRRs on a timely basis.
– Defective parts shipped to Tata Motors - This measure represents the number
of non-conforming parts shipped to the Tata Motors and is expressed in parts
per million (PPM). Those suppliers that ship to our assembly and manufacturing
plants via a sub-assembler and/or sequencer must also monitor any defective
product found at either the sub-assembler and/or sequencer. Field and
warranty issues are also considered.
 Voice of the Process (These measures reflect quality performance as seen in the
supplier’s facility/process)
– Measure First Time Quality - First time quality (FTQ) is a measure of a process’
ability to make quality parts without scrap or rework. Reducing and controlling
the variation in the input variables presents an opportunity for continuous
improvement.
FTQ should be measured at the following locations:
o End of line FTQ (minimum requirement)
o Quality Gates
Quality Gates include the following elements:
o Alarm limits established (e.g. 1 defect/hour) to drive immediate
containment upstream in the process
o A Pareto of failure modes for a specific timeframe
42
o FTQ trend chart (I-Chart format recommended)
Further, suppliers must have adequate checks in the control plans to maintain
and improve the process capability of CTQs designated by Tata Motors.
– Process performance on CTQ’s - Variation on key product characteristics and
product quality characteristics (CTQs) reflects the variation in the process and
is a result of a supplier's ability to control the input variables of a process.
 Effective Problem Solving (EPS), Root Cause Analysis, and Corrective Action
Implementation with Verification –
– Suppliers are required to have an EPS13 process in place to identify the root
cause on a timely basis, and implement and validate the corrective actions. A
3*5 why analysis is required. Verification and validation of root cause and
corrective action should demonstrate the ability to turn the problem on and off.

Continuous Improvement Requirements


Suppliers must have an organized and integrated approach for continuous improvement that
drives reduction of risk and variation associated with manufacturing and supporting processes.
The continuous improvement process must be documented and institutionalized, actively
supported by the supplier’s leadership teams and include of the following elements:
 Variation reduction on CTQ. Suppliers are required to have an on-going process to
reduce variation on characteristics identified as CTQs.

 RPN reduction process. Suppliers are required to have a formal and documented
RPN reduction process which includes:
– A cross functional team that meets regularly and updates FMEA and Control
Plans
– Collection of external and internal data relative to rejects (scrap and rework)
– Incorporation of internal data (FTQ, scrap, etc.) and external data (PRR, etc.)
into the FMEA and validation that assigned RPN numbers are reasonable and
accurate
– A defined strategy for on-going efforts for RPN reduction
– Identification and implementation of action plans with timing and accountability

 Lessons Learned process. Suppliers are required to have a documented and


effective process in place to drive lessons learned into current and future application
of FMEAs and Control Plans.

 Focus on Prediction and Prevention of potential failures. The supplier’s efforts


must ultimately be focused on prediction and prevention of potential failures and failure
modes. Supplier’s quality system should:
– Validate and Evaluate Error-Proofing to ensure it is capable of preventing
defects.
– Ensure CTQs are audited/monitored and correlated.
– Maintain the process under statistical process control
– Remove special causes of variation.
– Reduce variation of common causes – improve the process.
– Following change requests ensure that existing process and engineering
controls are still effective and confirm process stability.

Update Documentation
The supplier must update and revise the FMEA, Control Plan, and Standardized Work.

13 Refer AIAG CQI 10 – Effective Problem Solving


43
 Internal data should drive at least quarterly updates.
 External data should drive at least monthly.

Verification of a suppliers' continuous improvement process by Tata Motors


Suppliers will maintain documentation supporting the continuous improvement activities
conducted on their facilities. Tata Motors may review a supplier's continuous improvement
efforts periodically. Suppliers are expected to document, maintain and display the following at
a minimum:
 First Time Quality Trend Chart ( I Charts)
 PRR Analysis Summary
 Horizontal Deployment
 Revised FMEA’s
 Revised Operator Standardized Work Instructions
 Revised Process Control Plan
 RPN Reduction Summary

References:
AIAG Manuals for Process Control Plans, Statistical Process Control, and Production Part
Approval
44
5.2.2. SQ Process & Measures
Purpose
To produce a product quality plan which will support development of a product or service that
will satisfy the customer. This section defines the process, roles, responsibilities and
requirements of:
 Problem Reporting and Resolution (PRR)
 Controlled Shipping
 New Business Hold
 Supplier Measurements
– PRRs
– Parts Per Million (PPM)
– Incidents of Controlled Shipping
– Major Disruptions
– New Business Hold
 Process control plan audit
 Shutdown/Startup Activity

Scope
This process is to be used for all pre-production, production, service and accessory part
requirements.

5.2.2.1. Problem Reporting and Resolution (PRR)


Description
A “Problem Resolution Report” (or “PRR”) is a record issued in a Tata Motors standard format
to:
 Quantify and describe the problems encountered by the Customer
 Define the magnitude of the problem
 Identify the Supplier Code
 Identify the part number, if applicable
 Identify key Customer contacts’ name and phone numbers
 Identify the phase of vehicle build (production, development)
 Quantify and request reimbursement for costs incurred due to problems encountered
 Define status and material disposition
 Record corrective action plan
 Record timing of updates to FMEAs and control plans
 Identify how the solution will be institutionalized across the Supplier’s facility
 Identify where the defect was found
 Identify tier 2 suppliers, if applicable

PRR’s may be issued to address the following:


 Part or material nonconformance through the life of the part or material
 Packaging nonconformance (i.e. labelling issues)
 Issues and concerns with the shipping of production parts or material to the customer
 Issues and concerns related to the quality of service as described in the service
contract
 Supplier responsible warranty
 Supplier responsible engineering design issues
 Procedural or process non-conformity i.e., failure to communicate in a timely fashion,
failure to comply to procedures, failure to meet deadlines
45
 New Business Hold

Inputs:
Input Source
Specific Non-Conformance Details SQE/Manufacturing/Tata Motors
Quality teams/ Program
Management Teams/ Supplier
Corrective and Containment action plans Supplier
Lessons Learned SQE / Supplier

Methodology
Types of PRR are listed below:
Supplier-Initiated PRR
 The issuing location may categorize a PRR as “Supplier-Initiated” if the supplier
notified the customer of a possible nonconformance prior to customers identifying the
problem on their own.
 If the part has not entered or affected the customer’s production process, and the part
has not impacted the workstation, no PRR is required.
 If the suspect material has entered the customer’s normal material flow to the
production operator, the PRR should be classified as “Supplier Initiated”.
Implications of Supplier-Initiated PRR’s
Costs incurred by the customer (e.g. segregating, rework) may be charged to the supplier.

Customer-Initiated PRR
Types of Customer-Initiated PRR’s
1) Quality
A Quality PRR should be issued when the customer has verified that a nonconformance was
caused by the supplier. Non-conformances that may result in a Quality PRR include, but are
not limited to, discrepancies or problems with:
 Appearance
 Dimensions
 Welds
 Finish, i.e. burrs or flash
 Contamination
 Coating
 Part or Container labeling issues affecting the part identification
 Laboratory and metallurgy specifications
 Machining
 Functions

2) Customer Satisfaction
A Customer Satisfaction PRR is issued when Tata Motors has verified that nonconformity,
excluding pricing and/or other commercial issues, was the result of a supplier’s action or
inaction.

NOTE: A Customer Satisfaction PRR can be issued to a supplying location with or without
reference to a part number
46
Nonconformance’s that can result in a Customer Satisfaction PRR include, but are not limited
to failures regarding:
 Communication requirements for data or information
 Lack of responsiveness, timeliness, or deadline issues (e.g. APQP Program
Management)
 Procedural requirements
 Failure to honor promised corrective action

3) Engineering
Engineering PRR’s may be issued to design responsible suppliers to document design related
concerns.

4) Indirect
An Indirect PRR may be issued to document a supplier responsible problem caused by a non-
production supplier (tooling, equipment repair parts, capital equipment, etc.) at the customer
plant. This would include scheduled work activities that cannot be completed due to the
supplier’s failure to meet prior delivery commitments.

5) Packaging
A Packaging PRR is issued when Tata Motors has verified that the supplier caused a
packaging non-conformance, which could result in part damage or affect the salability of the
part.

Non-conformances that may result in a Packaging PRR include, but are not limited to:
 Part or material was inadequately secured in the container
 Container was inadequately secured in the transport vehicle
 Container design, ergonomic interface, and/or fabrication was inadequate
 Container that has been damaged by improper handling
 Mixed pallets built incorrectly
 Labeling issues that do not affect part identification

The different types of packaging PRR are:


 Container Design/function
 Part Damage
 Design

a. Container Function
A Container Function PRR may be issued when the container does not function
properly. These types of issues do not result in part damage.

b. Part Damage:
A Part Damage PRR may be issued when there are part quality concerns resulting
from the container. These types of issues will ultimately result in part damage. Non-
conformances in this category that may result in a PRR include, but are not limited to:
 Jumbled parts
 Scratches on parts
 Warped / Deformed parts / Broken parts
47
c. Ergonomics:
An Ergonomic PRR may be issued when it has been verified that ergonomic stressors
exist on a container. Examples of non-conformances in this category that may result
in a PRR include, but are not limited to:
 Excessive reach required to load/unload the container
 Excessive forces required to open/close the container
 Sharp edges

d. Fabrication:
A Fabrication PRR may be written if it has been verified that the supplied item was not
produced properly. These types of issues may or may not result in part damage.
Examples of non-conformances in this category that may result in a PRR include, but
are not limited to:
 Container not fit for use
 Swing arms not closing properly
 Part interference issues (dunnage locations)
 Sharp edges
 Non-compliance to specifications

e. Design:
A Design PRR is issued if the container was not designed properly. These types of
issues may or may not result in part damage. Examples of non-conformances in this
category that may result in a PRR include, but are not limited to:
 Issues with build prints
 Insufficient container close offs.

f. Container Delivery
Delivery/ Logistics Failure:
 A delivery / logistics failure PRR should be issued when a fabricator or dunnage
supplier misses a milestone and delivers late or when they cause excess
transportation costs (dry run).

6) New Business Hold


The customer will issue a New Business Hold PRR to document the supplier being placed on
New Business Hold.

7) Shipping
A Shipping PRR should be issued when the customer has verified that a shipping or
scheduling-related nonconformity was caused by the supplier.

Non conformances that may result in a Shipping PRR include, but are not limited to:
 Noncompliance to schedule requirements
 Documentation noncompliance, i.e. missing or inaccurate shipping documents
 Nonconformity, or nonconformance caused by transportation carrier
 Nonconformity, or nonconformance caused by Logistical Service Provider
 Electronic communication issues or problems
 Premium shipment issues, i.e. prepayment, coordination, excessive use
48
8) Program Management
A Program Management PRR may be issued by Tata Motors P&SC only, for nonconformance
during launch phase that does not result in part damage or does not affect the salability of the
part. Non-conformances that may result in a Program Management PRR include, but are not
limited to the following:
 Failure to meet program timing
 Repeated engineering issues
 Data submission issues
 Non-responsiveness or lack of cooperation

Supplier Responsibilities
Acknowledgement
The supplier shall acknowledge the PRR by an email reply and initiate initial response
(containment) within 24 hours.

Initial Response (Time – 24 Working Hours)


Supplier response must contain the following:
 Immediate containment actions to prevent further shipments of nonconforming parts
or material. Containment shall include data collection and analysis.
 Initiate rework or segregation as an immediate containment at the Tata Motors plant
location.
 Disposition of the nonconforming parts at all Tata Motors locations, warehouses and
Stocks-in-transit.

Problem Solving
The supplier shall promptly complete appropriate problem solving activities as per PRR
process explained in the SRM portal.

Final Response
The supplier shall provide a final response within 15 days of issuance of the PRR. The final
response shall include at a minimum:
 Containment and preventive actions taken and evaluations/success of the results
thereof
 Root cause of the problem, including methods used to identify the root cause.
 How the solution is to be institutionalized with respect to other similar processes and
products. ”Horizontal Deployment” shall be used to document and implement
corrective action across similar processes.
 Dates when revised process Failure Mode and Effects Analysis (FMEA) and Control
Plan (PCP), will be available for customer review.
 Identification of the responsible tier 2 supplier, if applicable. This does not absolve the
tier 1 supplier of any responsibility
Note: Suppliers will be measured on the timeliness of their final response. If an adequate
response cannot be completed within 15 days, the supplier must notify the customer issuing
location of the situation. Failure to respond, without prior notification, may result in a Customer
Satisfaction PRR.
49
5.2.2.2. Controlled Shipping
For details refer to the section on CS1 and CS2.

5.2.2.3. New Business Hold


Placing a supplier on New Business Hold
Suppliers with ongoing quality problems or suppliers without IATF 16949:2016 certification
may be placed on New Business Hold (NBH). The process to place a supplier on NBH is as
follows:
 SQE sends a notification to Commodity Purchase Buyer informing them that a New
Business Hold request is being initiated and their support is requested.
 SQE submits NBH report to Commodity Purchase Buyer to schedule a review with
supplier
 Buyer and SQE review the improvement expectations with the supplier.

Removing a supplier from New Business Hold


Once a supplier has met the defined exit criteria, the process to remove a supplier from NBH
is as follows:
 SQE monitors supplier’s progress to ensure exit criteria are being met.
 SQ Manager sends a notification to Commodity Purchase Buyer to advise them that a
New Business Hold removal is being initiated.
 SQE will close the NBH PRR in the SRM portal.

5.2.2.4.Supplier Measurements
This section defines the supplier measurements used by Tata Motors to monitor supplier
quality performance. These measures are used in Quality Performance Reports to help guide
future business decisions, and help direct resources to the appropriate areas that require
additional focus.

Major Disruption
Major Disruptions are tracked by the issuance of PRR’s. Major Disruption categories include:
Premium Transportation, Downtime, Plant Disruption, Stockout and Field Action. Premium
Transportation disruptions relate to transportation failures, while Field Action disruptions relate
to significant Warranty issues. Plant Disruption, Stockout and Downtime PRR’s are produced
for quality related issues.
 A problem that affects multiple plants is considered one Major Disruption.
 A problem that could be classified as more than one type of Major Disruption shall be
issued under one PRR with one type of Major Disruption.

Parts Per Million (PPM)


PPM is impacted when both of the following conditions exist:
 Quality PRR is written with quantity discrepant and
 There are receipts for referenced part and supplier code within the previous twelve
months.

PPM for a supplier code is calculated monthly using the following formula:
1. Total all the “actual quantity nonconforming” for all part numbers for that location
2. Divide by total receipts for that location
3. Multiply by 1,000,000.
50

Incidents of Controlled Shipping


On a weekly basis, the customer tracks and reports the number of incidents of Controlled
Shipping Levels 1 and 2 for each supplier manufacturing location.

PRR Measures
On a weekly basis, the customer tracks the number of PRR’s for each supplier manufacturing
location to determine which suppliers require additional focus.

On a monthly basis, the customer tracks the PRR “Time to Implementation.” This measure
represents the time from PRR origination to the time when the supplier completes the PRR
response.

On a monthly basis, the customer tracks the PRR “Time to Closure.” This measure represents
the time from when the supplier completes the PRR response to the time when the customer
approves the PRR response.

New Business Hold


On a weekly basis, the customer tracks and reports all supplier manufacturing locations unable
to quote new business due to quality performance and/or lack of IATF16949:2016
certification.

5.2.2.5. Process Control Plan Audits


Purpose
The purpose of the Process Control Plan Audit is to ensure that the supplier is following,
updating, and maintaining the PPAP required documents (PFA, FMEAs, and Control Plans)
and, executing the PCP, while executing continuous improvement.

Timeline
Throughout the line of the product

Output
PCPA Audit Summary

Inputs
Input Source
PRR Analysis Summary IT Systems
Supplier’s Internal Data Analysis Supplier Supplier
Process Flow Diagram (PFD) Supplier
FMEAs Supplier / SQE

Methodology
Criteria for Application:
 Review the supplier’s manufacturing process during any onsite visit
 Investigate a potential nonconformance
51
 Understand the supplier’s process
 Verify corrective action implementation and updated documentation for a quality issue

Supplier Responsibility
 Extend full support for the PCPA audit.
 Implement any immediate containment/addition process controls as directed.
 Develop, document, and provide action plan with appropriate detail, timing, ownership,
etc.
 Implements action plan on a timely basis.

5.2.2.6. Shutdown / Startup Activity


Purpose
This activity is specifically focused around standardized set of activities to be enacted during
extended shut down periods and subsequent startups to ensure zero major disruptions caused
by a supplier’s shut down and subsequent restart of operations.
E.g. includes elimination and/or restart of a production shift or an extended weekend.

Timeline
Throughout the line of the product

Output
Shutdown / Startup Activity Audit form: P&SC-SQ-11-26

Inputs
Input Source
Shutdown/Startup Audit Form IT Systems
High Risk Supplier Supplier Performance Reports/SQE

Methodology
Criteria for Application:
 Extended shutdown periods
 Selected high-risk suppliers
Planning Phase
SQE Activity
 Identify key criteria for selecting targeted suppliers for the SD/SU Audit activity.
Suggested criteria may include:
– Spills, downtime, and emerging issues during a specified period
– CS2 activity for a specified period
– Number of CS2’s over 90 days
– High PPM or discrepant parts for a specified period
– Warranty or Customer Satisfaction spikes for a specified period
– Previous evidence of poor startup
 Identify the suppliers to be targeted based on the criteria mentioned above
52
Do:
Supplier Activity
 Performs a self-assessment of their shutdown/startup readiness using the SD/SU audit
 Completes the SD/SU audit form and return to the assigned SQE with appropriate
supporting documentation/evidence
 Develop an action plan to resolve any issues identified in the self-assessment and
implement containment and/or corrective actions. Sends the action plan to the
assigned SQE.
SQE Activity
 Reviews the supplier’s self-assessment on the shutdown/startup audit form
 Evaluate and update the supplier’s status on a master tracking list
o In case of lack of satisfactory response, the SQE does an onsite review at the
supplier location to resolve any issues and review the supplier’s action plans.
o Places the supplier into EPC or CS2 until all open issues are resolved.

Check/Act
SQE Activity
Review the supplier’s progress in resolving open issues and in implementing the action plan
53
5.2.3. Level I – Controlled Shipment (CS I)
Purpose
Level 1 - Controlled Shipment is a demand by Tata Motors that a supplier put in place an
inspection process at the supplying location to sort parts/products for a specific issue. CS 1
helps to:-
Implement a root-cause and effective problem solving process (EPS), while isolating Tata
Motors manufacturing plant from the receipt of nonconforming parts/material.
Note: - This inspection, enforced by Tata Motors SQE, is in addition to normal controls.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products with
below listed issues may fall under the purview of CS 1.
 Repeat and/or non-conforming PRRs
 Delayed closure of PRRs
 Severity of the problem
 Internal/External Supplier Data
 Major Disruptions
 Field Issues (Warranty, JD Power etc.)
Note: The above mentioned reasons are not exhaustive and the final say rests with the Tata
Motors SQE.

Inputs:
Input Source
Problem Reporting & Resolution (PRR) Mfg./QA/SQE
Request for entry into CS 1 Mfg./QA/SQE

Timeline
Suppliers may be placed in CS1, as per several criteria defined in the scope of the step. An
exit criterion for the supplier is mentioned in the methodology section of this activity.

Output
 Certified Material to the Customer facility.
 I-Chart to demonstrate product quality conformance. (Nonconforming vs. quantity
checked)
 Additional process controls to prevent future occurrences.
 Documented and verified Corrective Action.
 Revised PCPs, PFMEA, Standardized work instructions as required.
 Controlled Shipping Level I entry letter
 Controlled Shipping Confirmation Reply form
 Corrective Action Report from Supplier
 Controlled Shipping Level 1 Exit Letter

Methodology
Supplier Responsibilities:
Assessment
 Tata Motors manufacturing or Tata Motors Quality makes a request for CS1,
referencing the details as mentioned in the scope of the step.
54
 SQE reviews the request documentation to ensure it complies with the criteria for
application of CS1, and if applicable places the supplier in CS1.

Entry and Implementation


 Understand the nonconformance and revert with necessary escalation/action plan.
 Establish a separate CS 1 area at the manufacturing location
 Notify additional Tata Motors facilities that use the same part, inform them of the
nonconformance, and provide containment activities as necessary.
 Track breakpoints of nonconforming material. (Purge the supply chain of suspect
material, i.e. at Tata Motors facility, Stock in transit and all storage locations /
warehouses.)
 Mark individual parts, material, and containers, with CS 1 tags, to identify parts CS1
certified to be used in Tata Motors assembly/operations
 Provide a proper layout and instruction documents, space and tooling to perform
Controlled Shipping - Level 1.
 Commence segregation activities and display the results in a public and visible
location.
 The supplier, simultaneously, implements an Effective Problem Solving Process
(EPS), and isolates Tata Motors from the receipt of nonconforming parts/material.
 Review the results obtained at the additional, redundant station to measure the efficacy
of the additional process and corrective actions taken to eliminate the specific non-
conformance.

Performance Measurement
 Perform a redundant inspection of all suspected non-conforming products as per the
agreed upon process, and ensure defect free parts/material are delivered.
 Determine and demonstrate the root cause to the SQE
 PRR report to be filled and submitted to the SQE for validation.
 Develop, implement and validate the permanent corrective and/or preventive actions,
along with improved process controls
 Conduct a daily management meeting at the segregation location to review the results,
ensure the corrective actions taken are effective, and plan required changes.
 Update all applicable documentation, (i.e. Control Plan, PFMEA, Process Flow
Diagram, and Standardized work Instruction Sheets etc.)
 Document containment data in I-chart format.
 Communicate the action plan, inspection status, and results of problem resolution
activities to Tata Motors SQE.
Note: - If the PRR raised is for dimensional issue involving a CTQ characteristic, the supplier
shall revert to the inspection frequency defined in the EPC plan for a period of 30 production
days or until capability is re-established, as directed by Tata Motors SQE.

Exit
 Meet the defined exit criteria.
 Provide supporting documentation on performance and corrective actions to the
appropriate Tata Motors SQE.

CS Established Zone Guidelines (Common for CS 1 and CS 2)


CS Established Zone must follow a basic rigorous process that insulates the customer
assembly plant from the receipt of nonconforming parts and material:
55
 CS established inspection zone must be highly visible and properly lighted, equipped,
etc.
 CS established inspection zone must have well defined efficient material flow including
clearly identified areas for incoming and outgoing parts/material.
 Repairs will not be done in the CS established inspection zone.
 CS established inspection zones must be independent of the supplier production
process, unless not feasible.
o Approval of the Tata Motors SQE must be sought for the same.
 CS visual display bulletins must prominently display non-conformances, measures,
action plan and status, and results of the containment activity.
 Charts must be updated on a daily basis and reviewed by Supplier’s Quality Head.
 Inspection officers/operators must have standardized job instructions, quality
standards, boundary samples, tools, and equipment, etc. in a visible location.
o Operators must be properly trained.
 Preventive maintenance must be employed if required.

CS Visual Bulletins (Common for both CS 1 and CS 2)


CS Visual Bulletin boards should display the following:
 Boundary samples, technical specifications, drawings, etc.
 Nonconformance descriptions and resolution action plans (including the CS entry
letter, PRR etc.)
– PFD, Process Control Plan elucidating the location of the non-conformance.
– Trend charts and SPC charts, if applicable (I-Chart)
 Operator instructions, inspector instructions and training records.
 Inspection Control Plan, Inspection Flow Diagram, and Inspection FMEA (CS2 only).

Exit criteria (Applicable to CS 1 and CS 2)


The following details are a pre-requisite in any exit criteria:
 Measurable elements specific and relevant to the non-conformance issues
 Documentation demonstrating effectiveness of corrective actions taken
 Exit criteria must remain constant for each nonconformance
Default exit criteria
Default criteria will be used in absence of any exit criteria, as defined below:
 20 working days from date of implementation of corrective action, of data from the CS
Established zones
 The data should that the normal production controls are effective to contain and
prevent the non-conformances
 Documentation validating the root cause
 Documentation validating the implemented corrective action
 Copies of all documentation revised and updated as required (control plan, FMEAs,
process flow diagram, operator’s instructions, etc.)

References
 CS Entry and Exit Letter
56
5.2.4. Level II – Controlled Shipping (CS II)
Purpose
Level II - Controlled Shipment is a demand by Tata Motors that supplier put in place a 3rd
party redundant inspection process to sort for a specific non-conformance, while maintaining
Level 1 Controlled Shipment and implementing a root-cause problem solving process.
 The third party is selected by the supplier, approved by the Tata Motors, and paid for
by the supplier. Suppliers may select the third party from an approved listing of Third
Party Suppliers maintained by the Tata Motors.

Scope
A CS2 may be raised due to any of the following parameters:
 Repeat PRRs
 Severity of the problem
 Internal / external Supplier data
 Major Disruptions
 Ineffective Level 1 Controlled Shipment
 Field issues (Warranty, JD Power etc...)

Timeline
Suppliers may be placed in CS 2, as per several criteria defined in the scope of the step. An
exit criterion for the supplier is mentioned in the methodology section of this activity.

Activities
 Certified Material (with CS 1 tag) to the Tata Motors facility.
 Problem solving capability to establish root cause.
– I-Chart to demonstrate product quality conformance. (nonconforming vs.
quantity checked)
– Documented and verified Corrective Action.
– Additional process controls to prevent future occurrences.
– Revised PCPs, PFMEA, Standardized work instructions as required.

Description
Controlled Shipping Level II (CS 2) is a Tata Motors mandate to the supplier to put in place a
3rd party, redundant, inspection process to segregate a specific non-conformance, while
maintaining Controlled Shipping Level 1,and implementing a root-cause problem solving
process.
The 3rd party or a Tata Motors representative may perform assessment audits.
Note: - The 3rd party is selected by the supplier, approved by the Tata Motors, and paid by
the supplier.

Methodology
Supplier Responsibility
Assessment
Refer the CS 1 phase for the same.
57
Entry and Implementation
 Supplier contacts a Controlled Shipping 3rd party provider and issues a purchase order
for Controlled Shipping Level 2 activities within 24 hours of receiving the CS2 letter.
o SQE should receive a copy of the same when appropriate.
 Supplier performs a redundant inspection of all suspect nonconforming products per
the agreed upon process to ensure defect free parts (CS1). CS1 is a separate and
independent inspection process from CS2
 Supplier notifies additional Tata Motors facilities that use the same part of the
nonconformance, and provides containment activities as necessary.
 The 3rd Party Provider performs an additional redundant inspection of all suspect non-
conforming products per the agreed upon process to ensure defect free parts are
delivered to Tata Motors.
 Supplier submits irreversible corrective action plans to the IATF 16949:2016 registrar
for review and/or assessment and authorizes IATF 16949:2016 registrar to submit the
review and/or assessment findings to Tata Motors.

Performance Measurement
Refer to CS1 Activity for the same.

Exit
Refer to CS1 Activity for the same
58
5.2.5. Performance Monitoring
Purpose
 Enable suppliers to assess their performance.
 Award suppliers with best-in-class performance.
 Identify suppliers with poor performance for re-sourcing decisions.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products.

Timeline
Every quarter for all suppliers (Individual Supplier Location and Cumulative Supplier
Performance) supplying to Tata Motors Manufacturing Locations.

Inputs:
Input Source
PRR Analysis Summary IT System
PPM Report IT System
Program Mgmt. Issues Program Manager (PPM)
Plant Disruptions IT-Systems, PPC/ Supply Chain Manager/
SQE
Discrepant Part Systems – IT/ Production Manager/ SQE

Output
 Timely release of Supplier Performance rating (6 Panel Charts-Quarterly)
o PPM; PRR; Discrepant Parts; Major Disruptions
 PRR Measures – Weekly/Monthly
o Time To Close; No. of PRR; Time to Implement
 New Business Hold Cases - Weekly

Process
The supplier is rated on certain parameters14 and his Quality Performance Reports (6 Panel
Charts) are generated. Similarly the sourcing metrics are generated classifying the supplier
as approved or low performing supplier. These reports will be available to the supplier via the
SRM portal and updated every quarter.
These measures are used to:
 Report the sourcing metrics and Quality Performance Reports
 Direct future business decisions15
 Direct resources to the appropriate areas that requires additional focus.

14 Reference the Quality Performance Reports for further details


15 Step 1 : Potential Supplier Assessment
59
5.2.6. Improvement Meeting
Purpose
This step describes the formal meetings between Supplier’s Leadership Teams and Tata
Motors Leadership teams to review the Supplier’s quality performance and actions for driving
improvement.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products.

Activities
 This task describes 3 types of meetings, each with specific drivers, which engages
leadership involvement to improve supplier performance.
– Supplier Performance Review.
– Supplier Quality Improvement Meeting.
– Plant Disruption Review Meetings.
 Top Focus is used to improve the quality performance of the supplier by utilizing audits,
analysing data and driving systemic changes in manufacturing and quality systems at
supplier’s manufacturing locations.

5.2.6.1.Top Focus
Description
Top Focus is a process engaging the leadership teams to improve the quality performance of
the supplier via systemic changes (audits, data mining etc…) in the supplier’s manufacturing
and quality systems. Supplier’s Management is accountable for each action plan and impact
of failure of each target is identified in a step down chart.

Criteria for Application:


 Poor performing suppliers
 Negative impact on multiple Tata Motors Assembly due to either of the following:
o Major disruptions
o High PPM
o High PRRs
o Impact on DRR/DRL
 Continuous improvement activity for strategic suppliers

Timeline
Complete Product Life-cycle

Output
 Process Control Plan Audit (PCPA)
 Step Down Chart
 Quality Workshops (Optional)
60
Inputs
Input Source
Supplier Performance Reports (6 Panel IT Systems
Charts)
PRR Summary IT Systems
Data Analysis Supplier

Methodology
Phase 0: Plan / Assess
SQE Activities
 Identifies potential systemic issues and present the same to the supplier’s quality
manager/director.
 Conducts a Process Control Plan Audit (preferred in the assessment phase.)

Phase 1: Do
Supplier Activities
 Commit resources and participates in Quality Workshop (as requested).
 Performs a detailed analysis of the Supplier Performance Reports, including but not
limited to analysis of the defect sources (manufacturing process or product line), the
failure modes, the failure systemic root causes.
 Develop a Quality Improvement Plan, which includes specific quality action plans and
initiatives to address the issues identified in the Pareto analyses performed above.
 Track implementation of the initiatives and resulting quality improvements.

Phase 2: Check
SQE Activities
 SQE tracks the supplier’s progress with regular on site shop floor reviews, as required.
 Supplier provides an update of the action plans a minimum of once a month.
o Frequency may change as determined by the Tata Motors SQE.
 Update the Step-Down Chart and recent monthly audits.
 Escalate the consequences as stated on the Step-Down Chart if targets are not met.

Phase 3: Exit
 Supplier has met all exit requirements as stated: -
o 50% improvement in PRRs, PPM
o No spills within the last 6-month period
o Improvement is the result of specific identifiable improvements and sustained
over a period of time.
 SQE verifies effectiveness of corrective actions.
 Once the exit request has been approved, SQE notifies the supplier and issues the
exit notification letter.

5.2.7. Re-Sourcing
Purpose
Re-Sourcing step is included in Pro-X SQ Process to protect and mitigate risk to Tata Motors
from engaging in business with poorly performing suppliers.
61

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products with poor
performance in parameters including, but not limited to, Quality, Quantity and Business Quotes
of the part shipped. Supplier’s prior performance will not be considered in case of continuous
non-conformance with Tata Motors expected standards.

Input
Input Source
APQP Open Issues List SQE
Bid List Purchase Buyer
Supplier Performance Report SQE
PRR Summary SQE
Step-Down Chart SQE
Warranty Data SQE
Supplier Action Plan Supplier

Process Flow

Resourcing /
Exit

No
New
Business
D/E Supplier Quality PRR Improvements
Hold
Yes

Eligible for Good Parts Performance


Supply Award! Supplied Monitoring

Methodology
Suppliers with continuous quality problems may be placed on New Business Hold (NBH) or
Tata Motors may proceed to resourcing if the following criteria are met:
 Repeat of major disruptions: downtime, part shortage, tool/process change etc.
 Lack of IATF 16949:2016 certification (unless waived by buyer)
 Continuous Poor performance (In the bottom 5% of poor rated Suppliers)
 Continuous Customer Satisfaction PRR’s
62

6. APPLICABLE DOCUMENTS

Document Internet URL


Supplier Quality Statement of
Requirements
APQP Project Plan (Illustrative)
APQP Kick Off Meeting Checklist
APQP Open Issues list tracking
Tier II Supplier Management
Process Flow Diagram
DFMEA Format
DFMEA Check Sheet
Design review Check Sheet
Tooling/Equipment Review Check Sheet
Checking Fixture Design Check List
PFMEA Format
PFMEA Check Sheet
RPN Reduction Summary
Control Plan
I Charts
63
7. GLOSSARY OF TERMS

4M Material, Machine, Man, Method


AAR Appearance Approval Report
AIAG Automotive Industries Action Group, an organization formed by
General Motors, Ford and Daimler-Chrysler to develop common
standards and expectations for automotive suppliers.
APQP Advanced Product Quality Planning
BOM Bill of Materials
Cpk Capability Index for a stabile process
CSCS Classification of Special characteristics and symbols
DFMEA Design Failure Modes and Effects Analysis. It is used to identify the
potential failure modes of a part, associated with the design, and
establish a priority system for design improvements.
DVP Design Validation Plan
FMASOW Failure Mode Avoidance Statement of Work
FMQ Forward Model Quality
Gage R&R Gage Repeatability and Reproducibility
GD&T Geometric Dimensioning & Tolerance
IPTV Incidents per Thousand Vehicles
KCC Key Control Characteristics. It is a process characteristic where
variation can affect the final part and/or the performance of the part.
Kick-Off Meeting The first APQP supplier program review.
MSA Measurement Systems Analysis
NBH New Business Hold
NPI New Product Introduction
OEM Original Equipment Manufacturer
PFMEA Process Failure Modes and Effects Analysis. It is used to identify
potential failure modes associated with the manufacturing and
assembly process.
PO Purchase Order
PPAP Production Part Approval Process
Ppk Performance index for a stable process
PPM Parts per Million
PRR Problem Reporting & Resolution
PSA Potential Supplier Assessment
R@R Run at Rate
RFQ Request for Quotation
RPN Risk Priority Number related to FMEA development
SOR Statement of Requirements
SPC Statistical Process Control
SQ Supplier Quality
SQE Supplier Quality Engineer

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