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BRAKES INDIA LIMITED

SUPPLIER QUALITY ASSURANCE


MANUAL (SQAM)

Revision 2 – November 2009

Supplier Quality Assurance


Brakes India Limited
Padi, Chennai – 50.

http://www.brakesindia.com/brakesdivision/sqamanual.pdf
Brakes India SQA Manual

Brakes India Limited


Corporate Office & Factory
Brakes India Limited,
Padi,
Chennai – 600050
Telephone : (044) 26526000
Fax : (044) 26526960
Website : www.brakesindia.com

Other Plant Addresses:


Brakes India Limited, Brakes India Limited,
Brakes division, Cheyyaru - Vandavasi Road,
Sholingur – 631102. Polambakkam – 631309.
Tamil Nadu. Tamil Nadu.
Telephone : (04172) 262276 Telephone : (044) 27544107
Fax : (04172) 262210 Fax : (044) 27544103

Brakes India Limited, Brakes India Limited


Seals Division 834, Udyog Vihar,
3A, KIADB Industrial Area, Phase V,
Nanjangud – 571302 Gurgaon – 122016.
Karnataka. Haryana.
Telephone : (08221) 228222 / 228787 Telephone : (0124) 2347810 / 2340571
Fax : (08221) 228333 / 228777 Fax : (0124) 2342584

Brakes India Limited, Brakes India Limited


110, GIDC Estate Dhunia VIII, Plot No.3, Gar No.105,
Panchmahal Dist., Krishna Industrial Park,
Halol – 389351. Waki Budruk, Tal. Khed,
Gujarat. Pune – 410 501
Telephone : (02676) 226144 Telephone : (02135) 308031 / 308059
Fax : (04172) 262210

Brakes India Limited, Brakes India Limited


B-9, ESIT,Baruabagh Plot No. AA2, 6th Avenue
Udhamsingh nagar Dt..– 262405 Auto Ancillary SEZ, Mahindra World City
Uttaranchal. Natham Sub PO, Chengalpet - 603 002

Rolltec Engineering
(A 100% EOU of Brakes India Limited)
No.9, Avadi Main Road, Veeraraghavapuram,
Poonamallee, Chennai - 600 077
Telephone : (044) 64541920, 64541921
Fax : (044) 26800522

© Copyright notice.

All rights reserved. No part of the manual should be copied (or) published without prior written
permission of Brakes India Limited.

Initial release Nov 03


Revision 1 Sep 07
Revision 2 Nov 09

Page No: 2 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Message
As a key part of our supply chain, our suppliers play a very significant role to ensure that our
products perform consistently well in the field. Today, with the changes in regulations the entire
world has become a market place for every one. This has resulted in a highly competitive scenario,
wherein to sustain and emerge as a leader, our performance on quality has to be on par with the best
supplier in the world. Our customers expect defect free supplies on time every time. We need our
suppliers to certify their parts for Direct On Line (DOL). This translates into zero line rejections and
warranty rejections. Needless to say this should be achieved at competitive cost.

In order to achieve the above target along with you, we formulated a methodology, which has been
time tested and successful to compete globally. This was communicated to you through our supplier
quality assurance manual. Now, we are releasing this manual in line with our changed requirements.
We expect you to strengthen our hands in adopting the methodology followed by us.

S.VIJI
Managing Director

Page No: 3 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Acronyms
ANOVA Analysis of Variance
BI, BIL Brakes India Ltd & its satellite assembly units.
CAR Corrective Action Report
CC Critical Characteristic
CP Control Plan
Cp Process performance Index (Long term)
Cpk Process capability Index (Long term)
CRA Cost Recovery Advice
DOE Design Of Experiments
DOL Direct On Line
E, R&D Engineering Research & Development
ESQS Evaluation of Supplier Quality System
FFF Fit, Form, Function
FIFO First In First Out
FTC First Time Capability
ISLR Initial Sample Laboratory Report
LC Least Count
LSL Lower Specification Limit
MSA Measurement System Analysis
MSE Manufacturing Systems Engineering
NC Non conformance
OEM Original Equipment Manufacturers
PPM Parts Per Million
PFMEA Process Failure Mode and Effects Analysis
PPAP Production Part Approval Process
Pp Process Performance index (Short term)
Ppk Process Capability index (Short term)
PSW Part Submission Warrant
PTR Production Trial Run
QC Quality Control
R Range
RI Receiving inspection
SOP Start Of Production
SC Significant Characteristic
SDI Supplier Development and Integration
SDS Supplier Data Sheet
SIR Sample Inspection Report
SQA Supplier Quality Assurance
TPM Total Productive Maintenance
UD Usage Decision (used in SAP)
USL Upper Specification Limit
VMI Vendor Managed Inventory
WI Work Instruction
X bar Arithmetic average of data

Page No: 4 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Foreword to Brakes India Ltd SQA Manual, Revision 2

Effective 1st October 2009 the revision 2.0 replaces earlier version of BI, Supplier Quality Assurance
Manual.

Production part suppliers are to adhere to the BI requirements elaborated in the SQA Manual to
achieve & sustain best quality practices at all levels.

List of major modifications.


1) Introduction to SQA Activities: Interaction structure modified based on the revised scope.

2) Pre-PPAP Audit: Guidelines & acceptance criteria modified.

3) PPAP: Approved supplier list reference given. PPAP categorization details & document
requirements specified.

4) APQP & Safe launch plan: Safe launch plan details were elaborated.

5) FMEA : This section revised in line with FMEA manual rev. 4

6) Quality plan & Document retention: Document retention details of various suppliers
specified. PPM expectation from suppliers specified. Quality plan format modified to include
details about inspection during safe launch period & during customer complaints.

7) PSW approval: Conditional approval details must be informed to respective units & double
sampling to be done till the deviations are corrected.

8) Skip lot & DOL implementation. Skip lot procedure revised. DOL implementation
procedure specified.

9) Change management: Details about change management / Re-PPAP guidelines added. In


case of known violations by suppliers, BI’s action added.

10) Identification & traceability: DOL tag details specified & tag samples shown.

11) Quality rating & PPM calculation: Quality rating calculation procedure revised with the
modified practice of capturing rework, inspection reports receipt status, process scrap details
elimination, etc. Minimum PPM requirement details & action on high PPM suppliers
specified.

12) Control of non conforming products: Tips on Do’s & Don’ts added. CoPQ monitoring
requirements added.

13) Process & Product audit: Audit frequency calculation formulae & methodology specified.
Audit questionnaire modified.

14) Corrective & Preventive action: CAR flow chart modified. In line with the modifications,
revised CAR format included.

15) Cost recovery: This section added. Details regarding cost recovery details specified. Format
included.

Apart from this, salient points / caution points are given in boxes for each chapter.

Page No: 5 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Index
Sl. No Section # Click on the Description to go to the respective chapters Page No.

1) Introduction: This section provides the overview of the manual and list of interacting functions of Brakes India
with supplier.
1.1 Introduction to SQA activities 7

2) Supplier selection & Approval process: This section outlines the procedure for new supplier selection and
development of new family of parts with existing supplier.
2.1 New supplier selection 9
2.2 Pre PPAP audit & approval process 10

3) New product Development : This section explains in detail the procedure to be followed for new part
development & key elements from APQP till completion of safe launch period.
3.1 APQP & Safe launch plan 15
3.2 Production Part Approval Process - Overview 16
3.3 Design, Process, Tooling & Gauge Review 20
3.4 Process Flow Diagram 21
3.5 Process Failure Mode & Effects Analysis 22
3.6 Control Plan 25
3.7 Submission of sample parts 27
3.8 Measurement System Analysis 28
3.9 Process capability monitoring 29
3.10 Special process qualification 32
3.11 Capacity verification 33
3.12 Quality plan & document retention 34
3.13 PSW approval 36
4) Regular production & measurement of performance: This section gives details of controls required on sub
suppliers, traceability, etc. It also provides procedure for measurement of supplier performance, supplier audit &
DOL procedure.
4.1 Sub supplier quality assurance 37
4.2 Identification & traceability 38
4.3 Control charts 40
4.4 Receiving inspection at BIL 42
4.5 Quality rating & PPM calculation 43
4.6 Control of non conforming parts 44
4.7 Skip lot & DOL implementation 46
4.8 Change management 48
4.9 Process & product audit 50
4.10 Corrective & preventive actions 53
4.11 Tool management 55
4.12 Cost recovery process 56

5) Formats: Gives details of Brakes India specific formats as referred in the manual.
---- List of formats 57

Page No: 6 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Section 1.1 – Introduction to SQA activities


Purpose:
The purpose of this section is to
• Provide an overview of this manual
• Define the document control method followed
• Interaction structure of Brakes India with the Supplier
Scope:
This manual applies to all suppliers providing production parts to Brakes India Limited
and its subsidiaries.

Explanation:
Overview of the manual
1 All direct material suppliers to B.I. production plants shall be certified for ISO 9001
or TS 16949. ISO 9001 Suppliers shall have a definite time target for TS 16949 certification.
2 Supplier selection and approval method is to ensure supplier with demonstrated abilities of
sustaining required quality levels are selected.
3 Production part approval process with specific emphasis on defect prevention and also to
ensure consistent delivery capability.
4 The process to be followed for re-qualification of parts that are already under supply.
5 The Change management system to be followed in the event of a change in design / process /
location / material etc.,
6 System to be followed to ensure quality sustenance, quality rating and the non-conformance
reporting, corrective and preventive action process.

Document control
Brakes India Quality Assurance department will provide a soft copy of the manual to the supplier
and also intimate to all suppliers, in case of revision.

Supplier shall ensure that the entire operating team is conversant with this manual.

Should you have any improvement suggestion about this manual, please send an e-mail to
the following address. qacorp@brakesindia.co.in

Page No: 7 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Interaction structure of Brakes India with the supplier


The following table describes the interacting functions of Brakes India with the suppliers

Function Interaction for


- Design review (through SQA)
E, R&D - Concession / Deviation approvals (through unit)
- Supplier selection
Supplier Development & Integration - Business relationships
(SDI) - Commercials
- Sample development (Timeline related)
- Issuing & updation of drawings/standard - upto BIR (BI Release)
- New Supplier Approval
- Production Part Approval
- CAR adequacy closure
Supplier Quality Assurance (SQA) - Quality improvement activities
- Process & Product audits
- Sample development (Quality related)
- Supporting units in implementation of DOL activities.
- Delivery schedules
- Receiving Inspection
- CAR closure based on effectiveness of CAR.
Manufacturing Unit - Delivery issues.
- Payments
- Implementation of skip / DOL / VMI
- Issuing latest drawings (Released through alteration notes)

Finance / Accounts - Bill payments (through SDI / unit supply module)

Supplier shall use the documentation / format specified in this manual. However, the supplier
may substitute any other forms, provided it contains all the information specified in the
Brakes India format. This must be agreed with the supplier quality assurance representative
prior to use.

Each & every supplier has been assigned a SQA Engineer as a single
window contact. Please feel free to contact him for all your quality related
issues and queries.

Page No: 8 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Section 2.1 – New supplier selection


Purpose
To outline new supplier identification and selection procedure.
Scope:
Applies to all production parts.

Procedure
Flow Chart – Supplier Selection Process

Supplier Identification

Supplier Data Sheet despatch to supplier

Data receipt
`

Evaluation of data sheet

Feasibility Study Audit as per ESQS Commercials


(Evaluation of Supplier Quality system)

Not OK
Judgment

OK
Gap analysis & closure at supplier end.

For more details on ESQS, please refer the format.

Note: A Minimum ESQS score of 70 % is required for supplier selection.

Supplier should have minimum valid ISO 9001 certification to be a supplier of BI.

Page No: 9 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Section 2.2 – Pre-PPAP audit & approval process


Scope
This approval is required for an existing supplier who develops a different part family
than existing.
Procedure
1. BI shall notify the supplier about the exact date of audit in advance. Audit can be
planned based upon mutual consent of supplier and BI.
2. Audit will be based (focused) on audit checklist and following will be covered.
a. Part / material receiving
b. Equipments / gauges
c. Machine condition / Machine Layout
d. In-process quality control
e. Inspection
f. Parts shipping area.
g. Internal audit by the supplier
h. Line rejections & customer complaints
i. Corrective & preventive action (problem solving)
j. Continuous improvements
3. Evaluation criteria are given in the subsequent pages
4. Supplier selection is normally based on a minimum score of 3 out of 5. A minimum
score of 3.0 is expected in critical areas such as inprocess, inspection & past track
record of supplier.
5. If score is < 3.0, the gaps / observation shall be intimated to supplier by the
concerned SQA engineer.
6. Supplier has to give proper corrective action to close the gaps/observations made
during audit with time plan if selected & a re-audit will be done if required.
7. Selected supplier should follow the procedure for new product development.

8. The above audit can be waived if the supplier has been already audited / approved for
that part family.

Page No: 10 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual
Pre-PPAP audit sample format is given below.
Brakes India Limited
PRE PPAP AUDIT
Unit : Unit 12, Part Nos.: XXXX
Product : Wheel. Cyl. assy Supplier : XX
Location : Chennai Audit date : 14.07.09
Present part family supplied : Input rods Proposed part family : Alu. Plungers
Description Rating Comments
1. PART / MATERIAL RECEIVING
a) Receiving Inspection 5 Incoming parts control from sub-supplier traceability
b) Raw Material Control 4 FIFO to be followed.
c) Sub-Supplier Control 5 Sub-supplier rejection monitoring required.
Average 4.66

2. EQUIPMENT / GAUGES 5
a) Calibration 4 Calibration done
b) Availability & maintenance
Average 4.5

3. MACHINE CONDITION / MACHINE


LAYOUT 5 TPM activities initiated.
a) Maintenance 4
b) Process flow sequence & Shop layout
Average 4.5

4. IN-PROCESS QUALITY CONTROL W1 Available


a) Work Instructions 4 To be implemented for prevention.
b) Prevention of Defect (Poke Yoke) 5
c) Non-Conforming Parts Handling 5 Route cards to be initiated.
d) Monitoring process 4 Preventive maintenance to be carried out.
e) Tool / Fixture Maintenance 5
f) Training for operator 5 Process capability carried out
g) Process capability / process qualification 5 PFMEA to be prepared for all parts.
h) Process flow / Process FMEA / Control plan 5

Average 4.75
5. INSPECTION
a) Availability & Adherence to Inspection Standards. 4 Pre-control charts available.
(In-process & Delivery) Sampling plan available
b) Sampling Plan availability & adherence. 4
Average 4.0

6. PARTS SHIPPING AREA


a) Handling of the Parts 3 Fixed quantity packed in boxes
b) Packing of the Parts 4 Packing instructions available
3.5
Average
7. PAST TRACK RECORD
a) PPM / Quality rating – Last 3 months 4
b) Response to BI on complaints. 5
Average 4.5

Minimum overall rating required


Rating : 5 Excellent Overall rating 4.34 for approval = 3.0
0 Not satisfactory
Minimum 3.0 Reqd. for Sections 4, 5 & 7
Conclusion: Accepted for proposed part family.
Page No: 11 BI - SQAM Rev: 2 – Nov 09
Brakes India SQA Manual

Guidelines for Pre-PPAP scoring

RATING 5 Excellent 4 Good 3 Satisfactory 2 Needs Not


improvement satisfactory 0
or 1
Receiving RI Quality plan and RI Quality plan and RI Quality plan RI Quality plan RI Quality plan,
/ incoming sampling plan are sampling plan are and sampling plan available, but sampling plan &
controls clear. NC parts clear. NC parts are clear. NC parts not adhered. NC handling
handling procedure is handling procedure handling procedure NC parts procedure not
established with 100 % is followed with is not very handling satisfactory.
adherence. minor lapses. effective. procedure not
available.
Raw 100% identification for 100% identification 100% System is No
material receipts with 100 % for receipts with identification for established but identification
control FIFO & traceability 100 % FIFO & receipts with 100 FIFO & system for FIFO
adherence. traceability % FIFO & traceability not & Traceability.
adherence with traceability followed
minor lapses adherence not very
effective
Sub supplier Sub-suppliers QC Sub-suppliers QC Sub-supplier’s QC Sub-supplier’s No proper
control activities have been activities have been activities have QC activities system for sub
reviewed in detail and reviewed & been reviewed in are not effective supplier controls
every concern have concerns are detail but concerns
been solved. Periodical solved. But no are not solved
audit and development periodical systematically
with 100% adherence review/Audit plan

EQUIPMENT & GAUGES

Calibration All necessary gauges / All necessary All necessary All necessary Calibration
equipment are gauges / gauges / gauges / system not
available Calibration equipments equipments equipments not effective
frequency and available available available
identification are clear Calibration Calibration
and controlled well frequency and frequency and
with full compliance identification is identification are
clear & followed clear with partial
with minor lapses compliance
Maintenance Preventive Preventive All necessary All necessary Gauges &
availability maintenance check list maintenance check gauges / gauge & equipments are
for daily, weekly, list for weekly and equipments equipments are not available.
monthly and annually daily basis for all available and plan not available. No gauge
are clear and complied necessary gauges & for required gauge Gauge plan is planning system
with. equipments. Gap in & equipments is not available
disposal of rejected available
items & spare
availability

Page No: 12 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Guidelines for Pre-PPAP scoring


RATING 5 Excellent 4 Good 3 Satisfactory 2 Needs Not
improvement satisfactory
0 or 1
MACHINE
Maintenance Preventive maintenance Maintenance plan Preventive Periodical Repair only
check list for daily, based. maintenance maintenance is when
weekly, monthly and check list for not there breakdown
annually are clear and daily and weekly
complied with. Dynamic basis are
plan for zero PPM. available but not
adhered
IN PROCESS QUALITY CONTROL
Process flow / Process flow / Process flow / Process flow / Process flow/ Process flow
PFMEA / PFMEA/control plan are PFMEA/control plan PFMEA/ control PFMEA/ control / PFMA/
Control plan updated based on any are updated based on plan are plan are control plan
changes with periodical any changes but no available and up- available but not not available
review periodical review dated based on updated based on
Eg. Corrective action design change design change
given to customers on etc but it doesn’t etc
failures. The above link to other
should be linked to work documents
instructions and other
relevant documents
Process Cp greater than 1.67 and 1.33≤ Cp≤ 1.67 1.00≤CP < Cp < 1.00
capability / trend analysis for 1.33 Not
qualification improvement monitored
Work In addition to W.I are available in the Work Work No work
instructions requirements for rating 4, worksite and critical instructions are instructions are instructions
signs of updating and points are highlighted available in the available but are available
standardized job is with picture or diagram worksite but inadequate
incorporated points are not
highlighted
Prevention of Poka Yoke works Poka Yoke works Jigs and fixtures Detection Poke – No adequate
defects (Poka properly throughout the properly. But not (Prevention) are Yoke available detection
Yoke) process and are checked checked periodically having Poka but improvement
for effectiveness Yoke but required
periodically. improvement is
required
Monitoring At specified intervals Route card usage Daily check with Daily check but Non
process daily and action review no review existence
procedure is clear
Non In addition to NC parts container Process by Final inspection No adequate
conforming requirements for Rating 4, identified and process check only detection.
parts handing proper action for NC parts segregated in each containers Good and
and Counter measure plan process and daily identified for NC parts
is established rejection review defects. NC mixed
parts stop in
process

Page No: 13 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Guidelines for Pre-PPAP scoring

RATING 5 Excellent 4 Good 3 Satisfactory 2 Needs Not


improvement satisfactory
0 or 1
Training for In addition to NC parts container Process by Final inspection No adequate
operator requirements for identified and process check only detection.
rating 4, proper segregated in each containers Good and NC
action for NC parts process and daily identified for parts mixed
and counter measure rejection review defects. NC
plan is established parts stop in
process
Training for Skill level identified Instruction available & Instruction On job training On job
operator & clear instructions Skill level identification available but not with instruction training and
and monitoring is not there monitored by no instruction
progress by supervisor
supervisor
Tool / Fixture All check point for All equipments check All equipments All equipment Repair when
maintenance daily, weekly, sheet for weekly and check sheet for lists are breakdown
monthly and annually daily basis are weekly and daily available. No
are clear and available. Handling of basis are periodical
controlled. Worn out rejected items not clear available maintenance
& rejected
tools/Fixtures
handling is clear
INSPECTION
Quality check Standards are Standards are displayed Standards exist Standards exist No standard
availability and displayed in the work but not updated & but not but not displayed available
control area and updated reviewed maintained well & monitored
adequately / but no review
periodically &
reviewed
Gauges / Fixtures are Gauges and fixtures are Gauges and Gauges and Gauges /
available and available & maintained fixtures are fixtures are Fixtures are
sufficient to meet the well available but not available but not not available
product quality. maintained well identified
They are maintained properly
very well.
Sampling plan Frequency is Sampling plan is Sampling plan is Sampling plan is Non existence
sufficient. NC followed. But no NC available but available with
procedure is clear and handling procedure & frequency is not partial
countermeasure No zero defect plan sufficient compliance
activity carried out.
Zero defect policy
evidenced.
Handling of parts Adequate and Handling procedure & Operation Handling Handling
followed as per Operation Instruction is instruction is procedure is procedure is
operation instruction. adequate & followed available but clear followed not clear. (No
Trays usage inadequate with partial clear
exclusively for compliance instruction or
specified parts caution)
Packing of parts Packing work Packing procedure & Packing work Packing work Non existence
instructions are Operation Instruction is instructions are instructions are
available, clear, adequate & followed available but available with
adequate and inadequate partial
properly adhered compliance

Page No: 14 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Section 3.1 APQP & Safe launch plan


Purpose
To explain key points and submission procedure for the PPAP schedule and initial
supply controls.
Scope
This applies to domestic suppliers of production part and has to be submitted to BI on
demand.
Explanation
The goal of APQP – PPAP timing chart is to provide a schedule of the manufacturing and
control activities necessary to assure the quality of parts during mass production.
Suppliers are required to prepare the timing chart for each part. The schedule should span the
time between the issuance of the production drawing and PPAP approval.
Supplier responsibility
• The supplier should create and maintain an APQP – PPAP timing plan before start of the part
development plan.
• The timing of the various activities of the timing chart at supplier end must meet Brakes
India’s requirement.
• All the related departments within the supplier must have consensus on the timing chart
before submission to BI. In addition, the supplier’s top management is responsible for
monitoring this plan to achieve milestones as scheduled.
• Brakes India SDI & SQA will review and confirm the supplier’s activity to master schedule.
Request for any adjustments will be negotiated between the supplier and B.I.
• The supplier must review the timing plan status periodically and any revision must be
intimated to BI. The supplier must re-submit the updated timing plan in consultation with
Brakes India SDI & SQA.

Safe launch plan


• Safe launch plan will be applied to new products & existing product with major
design change. This is to overcome teething problems during the launch & ramping
up period. The supplier’s development incharge will be responsible for this.
• Safe Launch Plan shall be filed for each part and displayed at the final inspection
stage at supplier end.
• By default, the exit criteria is 3 months after the part’s SOP. However, the same will
be extended by BI’s discretion, based on the problems noticed in the 3 months.
• Precautionary activities & preventive activities to be carried out.
Typical precautionary activities include increased inspection/ increased frequency/
increased parameters.
Typical preventive actions include installing poka-yokes, deploying certified
operators, frequent audits in shop floor, reduced cycle time for problem solving.
• Identify the part with the necessary pilot batch identification tag (discussed in
coming pages) & ensure adequate special care is taken to eliminate mixup, damages,
rust.
A sample safe launch plan is shown in the annexure.

Page No: 15 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Section 3.2 – Production Part Approval Process - Overview


The Production Part Approval Process (PPAP) defines generic requirements for production
part approval. The purpose of PPAP is to determine if all customer engineering design records and
specification requirements are properly understood by the supplier and the process has the potential
to produce parts consistently to meet these requirements during an actual production run at the
quoted production rate.
Scope:
PPAP shall apply to all suppliers during the period from release of mass production drawings
to start of production. PPAP is optional for lubricants, carton protection sleeves, stickers, bars, tubes,
assembly fluids, sheets, packing containers, ingots & indirect materials.
Procedure
Flow chart – Production Part Approval Process
Decision to buy

New supplier Existing supplier

ESQS audit Same part family New part family

Pre-PPAP audit

Not Approved Approved


Capable Not capable

Design / Feasibility review / Timing plan - Discussion

Select another supplier


Sample submission / inspection

OK Not OK Process correction

Production trial run by supplier / BI-SQA based on part categorization

Quality plan documentation & agreement

PSW Sign off

Straight approval Conditional approval Review

Inform unit with details Action plan

Upload in database &


inform unit

Page No: 16 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

1. For a new project a routing sheet will be prepared which details out whether the parts are to
be produced in house or to be sourced out.
2. Once this is done, SDI will identify the source for the same. ESQS audit approval is required
for any new supplier. Details are given in new supplier selection section.
3. In case of new part family with existing source, supplier has to score 3 min in the pre-PPAP
audit sheet.
4. Supplier will be called for design review, feasibility review & process review.
5. Supplier shall have a timing plan and have periodic reviews with Brakes India during
development period.
6. Samples, inspection report & process flow chart to be submitted to SDI who in turn will
forward the same to manufacturing unit for inspection. The procedure is further detailed out
in sample submission section.
7. Manufacturing unit will clear the samples after obtaining comments from E,R&D and
approve the initial samples inspection report.
8. PPAPs are categorized based on part criticality / supplier’s capability, etc. Documentation
requirements are specified in the guidelines in the following pages.
9. List of PPAP documents to be submitted, the format to be used and methodology to be
followed are explained in the subsequent sections.
10. Supplier to ensure compliance in the production line as per the documents submitted. Upon
confirmation, SQA representative will visit the supplier and will witness a production run for
300 nos. or one shift quantity (whichever is minimum) as per the documents and fill in
compliance audit report. Yield of OK parts should be minimum 90 % for approval.
11. If the production run is satisfactory and there are no concerns, the PSW will be approved by
SQA. Otherwise, a re-run will be required or the PSW will be conditionally approved. In the
event of conditional approval the supplier has to submit a firm action plan. Further details are
given in PSW approval section.
12. Supplier has to inform SQA upon implementation of action plan and then it will be verified
by SQA and the conditional status will be removed provided the implementations are
satisfactory.
13. PPAP level is based on BI’s discretion.

• Supplier is responsible for the quality of their parts supplied to BI, irrespective of
any operating conditons.

• For both sample submission & for regular mass production, supplier must buy
rawmaterial or do special processes in BI approved sources only as specified in
TD 1-30-07. Violations if any will be looked into seriously by BI including cost debits.

Page No: 17 BI - SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Guidelines for categorization of parts

Commodity Group 1 Commodity Group 2 Commodity Group 3

Machining ,Casting, Forging, Sintering Pressed parts, Special process, Friction, Spring, Plastic, Rubber
Proprietary assembly parts

Critical Parts – A Category

Heat treated parts Chamber brackets All coil springs


Hard chrome & trivalent plated Tolerance 0.1mm or less Welded reservoirs
parts Anti rattle clips Pin boots
Surface finish 0.8 Ra or less Pad backing plate Piston boots
Tolerance 50 Microns or less Reaction disc
NRV, Linings

Major parts – B Category

Part from new sources Part from new sources Part from new sources
Special Fasteners Pad wear warning indicators Spacer for ‘S’ Cam
Castings Push rods Non welded reservoirs
Lever pawls Adaptors
Filler caps
Filter mesh

Others – C Category

Rivets, Standard fasteners Proprietary parts from TRW Protective plugs


Proprietary parts from TRW Customer specified sources Spacers for calipers
Customer specified sources TRW supplier parts. Bleed screw caps
TRW suppliers parts Gaskets
Proprietary parts from TRW
Customer specified sources
TRW suppliers parts

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Document requirements of PPAP


A Category parts: (PTR by BI compulsory)
All 18 requirements as in AIAG manual PPAP rev. 4 which includes SIR/ISLR and Brakes India
specific requirements as given below.
1) Design review minutes (or) supplier’s letter that he will meet all drawing + Cp, Cpk
requirements identified in drawing as well as identified during PPAP.
2) Quality plan.
3) Capacity verification based on run at rate, shared capacity & machine utilization.
4) PPAP checklist (To be filled by SQA Engineer)
5) Packaging specification sheet
6) Compliance audit (Conducted at supplier end by SQA Engineer)
7) Conditional approval sheet (If required)
8) Fit, Form & Function check sheet
B Category parts: (PTR by BI optional)
All 18 requirements as in AIAG manual PPAP rev. 4 which includes SIR/ISLR and Brakes India
specific requirement as given below.
1) Design review minutes (or) supplier’s letter that he will meet all drawing + Cp, Cpk
requirements identified in drawing as well as identified during PPAP.
2) Quality plan.
3) Capacity verification by supplier.
4) PPAP checklist (To be filled by SQA Engineer)
5) Packaging specification sheet
6) Compliance audit (Conducted by supplier)
7) Conditional approval sheet (If required)
8) Fit, Form & Function check sheet
C Category parts: (PTR by BI optional)

C Category (Import) C Category – Domestic


TRW / MAN / Hitachi / Meritor PSW – level 2 ticked (Supplier to retain all other documents
& other customer approved PSW at his end – Auditable by BI)
(Level 1) PPAP Check list - C category
Accepted SIR / ISLR Quality plan for particular part
or Supplier’s insp. reports
PPAP Check list – C category Control plan (Generic)
Approved SIR and ISLR by B.I
Capacity verification (mail confirmation is also acceptable)
Fit, Form & Function matrix (If applicable)

For all the above categories, if OEM customer asks for further documents, the same needs to be
submitted on case to case basis.

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Section 3.3 – Design, Process, Tooling and Gauges review


Purpose
To explain procedure for the design, process, checking fixture, tooling and
gauges review with supplier and agreement with B.I. SQA representative.
Scope
This applies to domestic suppliers of production part.
Explanation
The goal of these reviews by BI SQA representatives with supplier is to
1. Appraise the supplier of the functional requirements of the components.
2. Discuss parameter by parameter about achieving the dimensional requirements,
process capability requirements & metallurgical requirements packing requirement in
production.
3. Identify and agree the significant & critical characteristics based on drawing / based
on functional requirements.

Design review format is given in annexure.

Design review
- Once the drawing is received, supplier has to study the drawing in detail.
- In case the drawing refers TS / TD / other standards, please get & understand
the related requirements.
- Wherever SC/CC characteristics are mentioned, ensure that there is no issue
in meeting process capability.
- In case the drawing requirements / process capability requirement meeting is
doubtful, discuss this in design review.
- Understand all the Fit, Form & Function characteristics during design review.
- A properly conducted design review will solve design related issues & help
deliver “First time right”

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Section 3.4 –Process Flow diagram


Purpose
To explain process flow diagram and submission procedure.
Scope
This applies to all parts and components
Explanation
The process flow chart is a schematic representation of current or proposed process flow. It
can be used to analyze the sources of variation of machines, materials, methods and manpower from
the beginning to the end of a manufacturing or assembly process. It should be used to emphasize the
impact of sources of variation on the process. The flow chart helps to analyze the total process rather
than individual steps in the process. The flow chart assists the Product Quality Planning team to
focus on the process when conducting the PFMEA and designing the control plan.
Supplier responsibility
1. Raw material, Sub supplier name and Location specific to supplier own manufacturing unit
should be clearly addressed in process flow.
2. Any changes in sub supplier activity to be informed to B.I. immediately and process flow
should be updated. All critical and significant stages to be identified.
3. All critical and significant stages to be identified.

Sample Process Flow Diagram

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Section 3.5 – Process Failure Mode & Effects Analysis (PFMEA)


Purpose
To explain PFMEA creation and submission procedure

Explanation
A PFMEA is an analytical technique used to identify potential problem areas associated with
all stages of manufacturing i.e. right from receipt to dispatch. Efforts shall be taken to improve the
process to achieve defect prevention rather than defect detection.

Procedure
1. The starting point for a PFMEA is process flow diagram and data on things gone wrong.
2. A Cross-Functional Team should study each step of the process for process failure modes,
effects of failure and potential causes. Existing conditions should then be reviewed and rates
for the likelihood of severity (S), occurrence (O) and detection (D).
3. The product of these ratings is the risk priority number (RPN) for each possible cause of
failure. The RPN establishes priorities for investigating counter measures for each potential
cause of failure. As countermeasures are implemented, the results are recorded and RPN is
recalculated.
4. Do not use words like “Operator error” as a potential failure. The failure is rooted to the
process or system.
5. All critical and significant characteristics must be addressed in PFMEA.
6. The PFMEA is a living document that should be utilized / updated for the life of the part.
7. The table below gives the rating number to be given for each failure mode.

8. For further reference supplier to possess AIAG’s FMEA manual. 4th edition, release June
2008.

The outcome of a PFMEA will be the control plan; Poka Yoke and work instructions.

• PFMEA is a live document and has to be updated by the supplier during design
change / process change, customer complaint elimination, reduction of internal
rejection, etc.
• Wherever the severity rating of the defect exceeds 8, supplier shall plan and
implement poka-yoke in process.
• RPN should not exceed 100. Wherever RPN is more than 100, suitable actions
required to reduce RPN.
• When severity rank is 9 or 10 its corresponding occurrence and detection should not
go beyond 2 & 4 respectively.
• In case the above is not adhered, a firm action plan is mandatory.

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Severity rankings
Criteria: Severity of
Criteria: Effect on Product
Effect Severity of Effect on Product Rank Effect (Manufacturing/Assembly
(Customer Effect) Effect)
Failure to Potential failure mode affects safe 10 Failure to May endanger operator
Meet Safety vehicle operation and/or involves Meet Safety (machine or assembly)
and/or noncompliance with government and/or without warning.
Regulatory regulation without warning. Regulatory
Requirements Potential failure mode affects safe 9 Requirements May endanger operator
vehicle operation and/or involves (machine or assembly) with
noncompliance with government warning.
regulation with warning.
Loss or Loss of primary function (vehicle 8 Major 100% of product may have
Degradation inoperable, does not affect safe Disruption to be scrapped. Line
of Primary vehicle operation). shutdown or stop ship.
Function Degradation of primary function 7 Significant A portion of the production
(vehicle operable, but at reduced Disruption run may have to be
level of performance) scrapped. Deviation from
primary process including
decreased line speed to
added manpower.
Loss of secondary function 6 100% of production run
Loss or (vehicle operable, but comfort / may have to be reworked
Degradation convenience functions inoperable) Moderate off line and accepted
of Secondary Degradation of secondary function A portion of the production
Function (vehicle operable, but comfort / run may have to be
convenience functions at reduced reworked off line and
level of performance) accepted.
Appearance or Audible Noise, 4 100% of production run
vehicle operable, item does not Moderate may have to be reworked in
Annoyance conform and noticed by most Disruption station before it is
customers (> 75%). processed.
Appearance or Audible Noise, 3 A portion of the production
vehicle operable, item does not run may have to be
conform and noticed by many reworked in-station before
customers (50%). it is processed.
Appearance or Audible Noise, 2 Minor Slight inconvenience to
vehicle operable, item does not Disruption process, operation, or
conform and noticed by operator.
discriminating customers (<25%).
No effect No discernible effect. 1 No effect No discernible effect.

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Occurrence rankings
Likelihood of Failure Criteria: Occurrence of Cause – PFMEA (Incidents per items/vehicles) Rank
Very High > 100 per thousand 10
> 1 in 10
50 per thousand 9
1 in 20
High 20 per thousand 8
1 in 50
10 per thousand 7
1 in 100
2 per thousand 6
1 in 500
.5 per thousand 5
Moderate 1 in 2,000
.1 per thousand 4
1 in 10,000
.01 per thousand 3
1 in 100,000
Low <.001 per thousand 2
1 in 1,000,000
Very Low Failure is eliminated through preventive control. 1

Detection rankings
Opportunity for Detection Criteria: Rank Likelihood of
Likelihood of Detection by Process Control Detection
No detection opportunity No current process control; Cannot detect or is not 10 Almost Impossible
analyzed.
Not likely to detect at any Failure Mode and/or Error (Cause) is not easily detected 9 Very Remote
stage (e.g., random audits)
Problem Detection Post Failure Mode detection post-processing by operator 8 Remote
Processing through visual/tactile/audible means
Problem Detection at Failure Mode detection in-station by operator through 7 Very Low
Source visual/tactile/audible means or post-processing through
use of attribute gauging (go/no-go. Manual torque
check/clicker wrench, etc).
Problem Detection Post Failure Mode detection post-processing by operator 6 Low
Processing through variable gauging or in-station by operator
through use of attribute gauging (go/no-go, manual torque
check/clicker wrench, etc).
Problem Detection at Failure Mode or Error (Cause) detection in-station by 5 Moderate
Source operator through use of variable gauging or by automated
controls in-station that will detect discrepant part and
notify operator (light, buzzer, etc.) Gauging performed on
setup and first-piece check (for set-up causes only)
Problem Detection Post Failure Mode detection post-processing by automated 4 Moderately High
Processing controls that will detect discrepant part and lock part to
prevent further processing.
Problem Detection at Failure Mode detection in-station by automated controls 3 High
Source that will detect discrepant part and automatically lock part
in station to prevent further processing.
Error Detection and/or Error (Cause) detection in-station by automated controls 2 Very High
Problem Prevention that will detect error and prevent discrepant part from
being made.
Detection not applicable; Error (Cause) prevention as a result of fixture design, 1 Almost Certain
Error Prevention machine design or part design. Discrepant parts cannot be
made because item has been error-proofed by process /
product design.

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Section 3.6 – Control plan
Purpose
To explain Control plan creation and submission procedure.
Scope
This applies to all parts and components
Explanation
This is used to define all key part and process control points from raw material receipt to
shipment of finished goods. Since it applies to many areas of manufacturing, a multidiscipline team
should be established to develop an effective control plan.
The control plan is an integral part of an overall quality process and it is to be utilized as a living
document. Therefore control plan shall be used in conjunction with other related documents like
PFMEA, process flow and inspection standards.
The following available information should be utilized while developing control plan
• Process flow diagrams
• System / design / process failure mode and effects analysis
• Special characteristics including FFF characteristics.
• Lessons learnt from similar parts
• Team’s knowledge of the process
• Design reviews
• Optimization methods (e.g., DOE, etc.)
Besides Production control plan supplier may have to submit control plan for prototype and pre-
launch phase, which will be intimated by SQA.

1. Part / process number: This item number is usually referenced from the process flow chart. If
multiple part numbers exist (assembly), list the individual part numbers and their processes
accordingly.
2. Process name / operation description: All steps in the manufacturing of a system, subsystem, or
component are described in a process flow diagram. Process / operation from the flow diagram
should be identified by a name that best describes the activity being addressed.
3. Machine, Device, Jig, Tools for manufacturing: For each operation that is described, identify the
<
processing equipment, e.g., machine, device, jig, or other tools for manufacturing, as appropriate.
4. Characteristics: A distinguished feature, dimension or property of a process or its output (product)
on which variable or attribute data can be collected. Use visual aids where applicable.
4a. Number: Enter a cross reference number from all applicable documents such as, but not limited
to, process flow diagram, numbered blue print, FMEAs, and sketches (computer generated or
otherwise), if required.
4b. Product characteristics: These are the features or properties of a part, component or assembly that
are described on drawings or other primary engineering information.
Process controls must be established for controlling all the product characteristics. All special
characteristics must be included in the control plan.
4c. Process characteristics: This column will identify the characteristics of the process that, when
controlled will reduce variation in product characteristics. This must be specified. These
characteristics have a cause and effect relationship with the identified product characteristics.
5. Special Characteristic classification: Use the appropriate classification as required by OEM as
“critical”, “key”, safety or “significant” accordingly.

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6. Check method: This column identifies the measurement system required to measure product and
process characteristics. E.g., Vernier, gages etc. along with their L.C. (as applicable) Gauging
issues that should be considered include:
• A reasonable GRR must be attained before a characteristic can be controlled. Refer MSA
section for details.
• The selection of variable versus attribute gages.
• At most, special characteristics must be checked using variable gauges.
7. Sample size / Frequency: Arrive a required sample size and the frequency of checking to ensure
product conformance and control.
The general guidelines for frequency of inspection are evolved based on the following
assumptions.
• The process is under control.
• Occurrence is evolved based on internal rejections, Customer complaints and level of process
capability.
• Quantum of output per hour.

> 70 100 % Inspection


Occurrence 30 – 70 Once in 1 Hr. Once in ½ Hr. Once in ¼ Hr.
X 10 – 30 Once in 2 Hr. Once in 1 Hr. Once in ½ Hr.
Detection <10 Once in 4 Hr. Once in 2 Hr. Once in 4 Hr.
<50 per Hr. 50-100 / Hr. > 100 / Hr
Output
8. Control method: This describes the method of controlling the operation. When selecting
the method of control, focus on.
• Meeting all customer requirements
• Process control rather than Product control
• Prevention rather than detection
• Targeting nominal rather than specification limits.
• Error proofing rather than inspection This can be controlled but are not limited by the
following means,
o Statistical process control
o Inspection
o Attribute data
o Mistake-Proofing
9 Sampling plans It can reference procedures / documents for controlling. When choosing a control
method sources of variation must be considered. The most important common sources of
variation or dominating factors determining the quality of products are setup, machine, tooling,
operator, maintenance and environment.
10. Reaction plan: This refers to the actions that are to be taken to correct any potential non-
conformances.(Segregation of defectives, rework if applicable, and corrections necessitated in
machine to achieve a particular part characteristic etc.)

• Wherever, process dimensions are required like before plating / before heat treatment, etc
supplier to arrive process dimensions thru’ scientific methods with the help of past data &
studies in present part no.
• All poka-yoke to be verified for effectiveness before start of each production shift and
recorded.

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Section 3.7 – Submission of sample parts
Purpose
To explain the procedure for submitting sample parts and evaluation of results.
Scope
Applies to all pilot and production sample parts.
Procedure
Samples Development

Sample submission to Unit


Along with necessary reports

Sample evaluation (SIR & ISLR) by Unit

Not Ok
Clear Approval by E, R&D Improvements

OK

Initiate bulk production

Sample approval process


Wherever BI requires the part should be made in off tool – off process, that is the part should be
made in production intended tooling & process.
Supplier to consult SQA / manufacturing unit on details of sample size and submission of test piece,
stage samples, wire rods, R/M sample etc.
Along with the samples, submission of the following documents is mandatory.
• Self-inspection report – covering all dimensions / specifications in the drawing.
• Material check reports including surface protection details/ wherever applicable
salt spry test. & process flow.
Supplier responsibilities
1. If parts are produced from more than one cavity, mould, tool, die, pattern, or production process,
the supplier shall complete a dimensional evaluation on a minimum of one part from each unique
process/ variation. The specific cavities, molds, line, etc. shall then be indicated in the PSW &
the dimensional results report.
2. B.I. will cross verify the Dimensional, Material and Performance characteristics. The judgement
on the samples will be finally approved by BI. E, R&D.

• Suppliers to have adequate inspection facilities for measuring all requirements specified in
the drawing. In case facilities are not available, arrangements to be made by the supplier to
do it at third party inspection agency & to be certified OK before submission of samples /
regular lots.
• Samples should confirm to drawing requirements. Any rejection of SIR at BI, will be
reviewed seriously.
• Samples must accompany dimensional / material / performance test report.
• Supplies should commence only after clear SIR / ISLR approval.

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Section 3.8 – Measurement System Analysis (MSA)
Purpose
To explain procedure to carry out Measurement System Analysis and submission
procedure.
Scope
Applies to all measuring instruments and gauges.
Explanation
1. The objective of MSA study is to obtain information on amount of measurement variation
associated with measurement system when it interests with environment.
3. “Repeatability” is the variation in measurements obtained with one measuring instrument when
used several times by one appraiser while measuring the identical characteristic on the same part.
4. Is there a common cause (Random error) variation from the successive trials under defined
conditions of measurements? This is commonly referred as Equipment Variation.
5. Variation that occurs when repeated measurements are made of the same item under absolutely
identical conditions – Same operator, same setup, same units, same environmental conditions &
short term.
6. “Reproducibility” refers to the difference in the average of the measurements made by different
persons using the same instrument, or the same person using different instruments, when
measuring the identical characteristic.
7. The term “Reproducibility” refers to the variation that results when different conditions are used
to make measurements ie. different operators, different setups, different units, different
environmental conditions & different measurement systems.
8. Gage R&R is an estimate of combined variation of repeatability and reproducibility. GRR is the
variance equal to the sum of within system and between system variance.
σ2GRR = σ2repeatability +σ2reproducibility
Acceptability criteria:
Under 10% Error - Generally considered to be acceptable for measurement system.
10 – 30% Error - May be acceptable based upon importance of application, cost of
measurement device cost of repair, etc.
Over 30% - Considered to be not acceptable – Every effort should be made to
improve the measurement system.
In case the R&R is more than 10 %, prior approval from BI is mandatory.

9. Interpretation of GRR% with product tolerance: A variable gauge used to check a key product
characteristic of 125 ± 3 mm has an R & R result of 22% of product tolerance. That means the
gage error can be up to 1.32mm (± 0.66 mm) for any given measurement. To ensure that non-
conforming product is not accepted the acceptance limits must be reduced by 22% to 125 ± 2.34
mm.
Supplier responsibility:
Supplier must provide a means to verify all quality characteristics specified on the drawing and
inspection standard. The measurement method is to be mutually agreed with Brakes India
Limited. In the case of checking fixture and gauge the concept must be cleared with Brakes India.
Supplier responsible for performing appropriate analysis of the measurement system to ensure its
performance is acceptable for its intended purpose.

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Section 3.9 – Process Capability monitoring
Purpose
To define the requirements for process capability studies of designated control
characteristic.
Scope
Applies to all part characteristics denoted by symbol – Significant characteristics & -
Critical characteristics and for other parameters agreed as major characteristics in quality plan
during PPAP.
Explanation
1. Critical and significant characteristics are part characteristics that significantly affect
performance, fit, function or workability of system or subsystem and therefore require application
of statistical measures for capability assessment and control.
2. As used in this manual, “Process capability” refers to a comparison between the inherent
variability of a process and the specified tolerance. It is important to note that acceptable process
capability is achieved through the study and the control of key process parameters (e.g.
temperature, pressure, shot weight, speed, feed etc.)
Supplier Responsibility
1. Prior to mass production the supplier must analyze the stability and capability of the processes,
which contribute to variation in the critical / significant characteristics.
2. The supplier must carry out a detailed Machine capability study as per the procedure explained
later and submit to BI – SQA for review.
3. The supplier must conduct long term process capability studies for continuous process
improvement. The results of these studies should be made available to the B.I. as agreed in
quality plan.
4. Process capability studies should be performed during the high volume production trial. (See
section).
5. Capability studies can be affected by dimensional, specification changes etc and therefore must
be re-submitted for characteristics affected by change.
Additional Information
Definition of Process measures
- Process performance – The 6 σ range of a process total variation, where σ is usually estimated through
sample s, the sample standard deviation.
- Process capability – The 6 σ range of a process inherent variation, for statistically stable processes only,
where σ is usually estimated by R/d2

σ = Σ (Xi - X )2
(n- 1) X

Pp -This is the process potential index, (short term) which is defined as the tolerance width divided by
the process performance, irrespective of centering.
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Pp = USL – LSL
6σs
Ppk - This is the process performance index (short term), which accounts for process centering and is

P pk = Minimum of USL - X , X - LSL


3σs 3 σs
given by

Cp – Process potential index (Long term): Is defined as the tolerance width divided by the process
capability, irrespective of process centering.

Cp = USL – LSL

Where σ is estimated using R / d2
Cpk – Process performance index (Long term) : Specifically this index is the distance from the center of the
distribution of production output to the closest specification limit, measured in units of three standard deviations of
production output. It relates specifically to the scaled distance between process mean and the closest specification
limit to half the total process spread. Cpk - index should only be calculated after verifying that the process is in a
state of statistical control.

Cpk = Min USL – X , X – LSL


3σ 3σ

X = Process Average
USL – Upper Specification Limit
LSL – Lower Specification Limit
σ is standard deviation and is estimated using R / d2
Cpk
Cp Vs Cpk Low High
Cp Low Reduce process variability Impossible
High Move process towards mean. Maintain
Process Capability Index study requirements
Item Short term Long term (Min. one month data)
Samples 25 to 50 nos 25 Sub groups of 5 per sub-group
Pp > 1.67 -
Ppk > 1.67
Cp - > 1.33
Cpk - > 1.33

- For SC/CC & major characteristics if the process capability is not met, it is
mandatory to do 100% inspection before dispatch.
- In the case of one sided specification, Only Ppk / Cpk need to be computed using
the formula indicated above and not Pp / Cp.

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Ppk value and level of PPM
Sl. No Ppk PPM
1 < 0.55 > 100000
2 > 0.55 50000
3 > 0.78 20000
4 > 0.86 10000
5 > 0.94 5000
6 > 1.00 2000
7 > 1.10 1000
8 > 1.20 500
9 > 1.30 100
<
10 > 1.67 < 10
Process Capability Judgment and Action
<

Cpk Judgment Action


Greater than 1.33 The process capability is Maintain and control process capability. (need not have to
sufficient take special action)
1.00-1.33 Process needs improvement. Control the process carefully through 4Ms standardization
and control chart utilization Also try to improve the
process capability. i.e.
1. Enhancement of process control and machine
maintenance
2. Review of jigs / tools maintenance period
3. If there is a tendency of value change, create and
allowance for adjustment.

Less than 1.00 The process capability is If the cause is unknown and immediate action cannot be
insufficient. Need to improve implemented, inspection must be made more stringent
immediately. through 100% screening.
Clarify whether process capability in sufficiency is caused
by bias or variance. Survey the cause and take proper
action i.e
1. Reviewing 4M
2. Machine capability

Guidelines for conducting short term process capability study


• Identify the product characteristics to be studied and its specification.
• Data must be precise, complete and clearly recorded. Incomplete and/or incorrect data will lead to wrong
conclusion in case of corrective action.
• Tool change or tool resetting must not be done during study, since theses are external adjustments,
observations may not follow normal distribution.
• Inspection equipment must be calibrated and the lease count of measuring instrument must be 1 / 10th of
the tolerance. This is because accuracy of observations will directly influence Pp value.
• Minimum 50 consecutive samples to be taken for the study.
• Measurement to be carried out by a single skilled inspector.
• Other variations like material, method (tooling) should be kept at minimum. (use same operator) and same
batch of raw material)
• Pre-set the machine at nominal and do the set up approval before data collection.
For multi spindle / multi head machines treat each spindle / heard as individual machine. Samples have to
be retained till the completion of the report.

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Section 3.10 – Special process qualification
Special processes are that process whose output cannot be verified immediately after production.
The quality of the item will be known only by destructive testing. E.g. Weld Strength (Welding Process),
case depth, Tensile strength (Heat Treatment).

Since the output characteristic is difficult to observe, such processes need to be validated i.e. the
process parameters affecting the quality characteristic need to be identified, established through DOE and
their operating ranges are to be determined. By maintaining these process parameters we get the desired
output. This is known as process validation. Conducting trials in a organized manner using Design of
experiments techniques does this.
Steps in validating a special process using Design of Experiments.
1. Identify the Process.
2. Identify the Quality Characteristic
3. Qualify the measurement system and standardize the measurement process.
4. Identify all the variables, which are likely to have influence on the quality characteristic.
5. Identify the controllable variables. (Variables which are controllable by us.)
6. Choose the experimental variables and constant variables.
7. Decide the ranges for the experimental variables.
8. Keeping the endpoint of the ranges as levels design an experiment. (Full factorial or orthogonal
arrays).
9. During the experimental trials all the constant factors must be maintained at the same level.
10. Subject the experimental data to statistical analysis. (ANOVA)
11. If a variable is significant and the end result is satisfactory the range of the variable is to be
reduced to get more consistent result.
12. If a variable is not significant and the end result is satisfactory, then the current range is validated.
13. If a variable is significant or not significant but the end result is not satisfactory then new range is
to be explored.
In this manner the ranges for the process variables are established. Once the operating ranges are
established, the process variables are monitored for control. Actual quality characteristic is
verified on audit basis to confirm the suitability of ranges.

Design Of Experiments (DOE)


DOE is a tool to help us in arriving a optimum process parameter for a given process.
Contact your SQA engineer if there is a requirement to do DOE & understanding the
steps in doing DOE.

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Section 3.11 – Capacity Verification
Purpose
The purpose of capacity verification is to
• Determine if there are capacity constraints
• Identify process bottlenecks
• Be capable to meet full production volume at PPAP time
Scope
Capacity verification shall be performed on all the appropriate supplied components
and must be completed as part of all new or major modification PPAP submissions.

Procedure
The supplier shall fill up the form for each individual part number with the following
guidelines.
A. Supplier to give details about parts which follow similar production sequence occupying the same
production capacity to meet the annual monthly demand of each part.
B. Cycle time (C.T.) required for one component at each stage is provided and based on which hours
required at each stage is calculated. In case of multi cavity operations. Cycle time is the ratio of
processing time to the no of cavities.
C. Available hours per month are to be provided for a working standard of 2 shifts of 18 hours max
for 25 days.
D. Machine down time to be provided considering all setting, breakdown, planned maintenance
down times etc.
E. Hours lost due to operator effectiveness like operator change, untrained operators are recorded
here.
F. Out of total available hours, the hours allocated to BI is denoted in percentage. Percentage
utilization for BI and other customers is also to be provided along with the spare capacity.
G. Supplier needs to submit an action plan, if there were any capacity constraints at any of the
manufacturing stage.

A minimum 20 % free capacity is preferable for each process. It helps in meeting


sudden increase in requirement.

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Section 3.12 – Quality plan & Document retention
Purpose
To explain the requirements of Quality plan sign off which includes process
capability report, metallurgical inspection report & layout inspection report submission
procedure.
Scope
Applies to all parts and components in regular production.
Explanation
Quality plan will be signed between supplier and B.I’s supplier quality representative and
B.I. Mfg. Unit before PSW approval, listing all the major characteristics that are to be
incorporated in supplier’s final inspection report. It also includes the frequency of submission of
metallurgical inspection report, process capability study reports and layout inspection report as
given in the format enclosed.
Supplier Responsibility
1. Supplier to furnish self-certification for mutually agreed part characteristics under the
following headings.
• Dimensional inspection parameters.
• Visual inspection parameters.
• Metallurgical parameters, performance parameters.
• The revision number of B.I drawing to which the part is supplied to be mentioned
in final inspection report, submitted to BI.
2. Dimensions should be listed in the order indicated in the drawing, which are to be
measured on the actual part.
3. The method of checking column defines the measurement equipment to be used. The
least count of the instrument is to be mentioned. The inspection criteria should include
the actual dimensions and acceptance tolerance of the inspection items.
4. Visual inspection should define judgment for the acceptable limit of the inspection item.
If a representative sample is used to define this inspection item, this should be noted in
this section.
5. Metallurgical inspection describes the material control requirements including raw
material of the part. The inspection item should give the reference standards.
6. Performance describes any functional or reliability characteristic of the part like.
• Part corrosion performance
• Related durability cycle testing etc.
7. For layout inspection the supplier have to include all the dimensional, visual, material and
performance characteristics as per drawing and submit to B.I. every year.
9. For the characteristics identified in drawing as SC/CC, the process capability reports
should be maintained as per the frequencies agreed in the quality plan.
10. For other characteristics identified as SC/CC during PPAP process, the necessary process
capability reports to be retained at supplier end and should be made available during BI’s
visit to supplier end.
11 Quality documents retention period at supplier end should be as per the details given
below & it should be agreed in the quality plan. & adhered.

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Record retention period for various customers
Sl. No Customer Minimum Retention period (as per customer specific requirement)

1 Hitachi, Volkswagen 15 years

2 Nissan 12 Years
3 Maruti Suzuki, 5 Years (as per pre contract review agreement)
Volvo, Mahindra
renault
4 Ford PPAP, PO, Tooling records - 1 year after length of time the part is
in production
Inspection and test records – 1 year after which it was created
5 Arvin Meritor Internal quality system review & management review – 3 years
6 TRW Documents and product samples for the time the part is active (a
part is active as long as it is being supplied to the customer for
original or service applications) in production plus a minimum
period of 15 years.
7 All Other customers 2 years min.

• In case of a outsourced operation, the supplier and sub-supplier representative


should agree a quality plan.
• The final inspection report submitted with every lot should contain the
parameters as agreed in quality plan.
• It is mandatory to adhere to the parameters & submitting frequencies agreed in
the quality plan during regular supplies. Failure in submitting inspection reports
as agreed will be taken seriously by BI, and inspection costs shall be recovered
from supplier.
• The revision no. of BI drawing to which the part is supplied must be mentioned in
final inspection report, submitted to BI.

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Section 3.13 – PSW Approval
Purpose
To define the minimum requirements for obtaining the final approval of PSW and
conditions for conditional approval.
Scope
Applies to all suppliers of production parts.
Supplier Responsibility
1. Develop and implement an internal quality assurance system at their manufacturing location in
accordance with this SQA manual.
2. Supply sample parts, which meet all applicable requirements that were produced under regular
production processing conditions, using regular production materials. Also B.I. SQA
representative will verify the process as per compliance audit checklist.
3. Meet all SQAM documentation requirements. The documents should reflect current processes.
4. B.I. SQA will review the supplier’s documents and process as per checklist and if acceptable will
approve the PSW.
Situations of Conditional Approval
1. Pp and Ppk not meeting the specification in full (firm action plan like new machine or new
technology introduction).
2. Inadequate sub supplier control & core process outsourcing.
3. Delay in action on gap analysis
a. Process requirement b. Availability of gauges / instruments.
c. System requirements. d. Similar part rejection reduction.
4. Delay in corrective action plan submitted for RPN improvement
1. Control improvement 2. Introduction of Poke-yoke.
5. Delay in conducting process qualification for special process.
6. Lack of infrastructure in machines, gauges, equipments. etc.

In case of conditional approval, the deviations will be informed to respective unit’s


receiving inspection persons. Units will do double sampling inspection on these parameters.
Suppliers are expected to take necessary corrective action & convert the PSW to straight
approval within a period of 3 months from the date the conditional approval is given.

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Section 4.1 Sub-Supplier Quality Assurance
Purpose
To define the supplier responsibilities on their sub-suppliers controls.

Scope
Applies to all suppliers.

Explanation
The role of supplier in co-coordinating and guiding the sub suppliers Quality assurance activities
must be similar to the B.I. requirements stated in the SQA Manual. The suppler is responsible for sub
supplier’s part quality and production preparedness & also for evaluation of sub supplier’s part quality
and production preparedness and also for evaluation of sub suppliers parts and materials.

Supplier responsibility
B.I. suppliers are responsible for any quality concerns arising out
of their sub suppliers, including surface protection sub suppliers.
1. The supplier of B.I. should have a system in place for evaluating and selecting the sub suppliers.
2. The supplier shall ensure correct data (Specification, drawings, standards etc) has been
communicated to the sub suppliers.
3. The supplier shall ensure and assess the production and process control capability of their
suppliers including inspection and testing facilities.
4. The supplier should intimate B.I about the sub suppliers and any changes or addition of sub
suppliers should be authorized by B.I. SDI / SQA.
5. Suppliers are expected to involve their suppliers in the communication, planning, and problem-
solving activities, as required, to assure that quality is built in at each stage of the preparation and
production process.

6. The supplier and sub-supplier representative should agree quality plan.


7. Supplier should conduct periodic sub-supplier audits.
8. Core competent process should not be carried out at sub-supplier location.

It is the responsibility of suppliers to evaluate & approve their sub supplier’s


process. Sub supplier’s PPAP approval by suppliers is a must & approved PSW to
be attached with main PPAP, wherever there is an out sourced operation.

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Section 4.2 – Identification & Traceability
Purpose
To define the identification and traceability requirements to the suppliers of production
parts.
1. Identification
This refers to the method a supplier uses to identify a part so that if a problem occurs, necessary
information can be discerned quickly. This typically includes Rubber parts, plastic parts, castings and
forgings.
ƒ Cavity or mould number(s)
ƒ Special identification marks (Material type, inspection item etc)
ƒ Heat code
With the above information the supplier should be able to accurately determine the lot size, in process
stock, final inventory at the supplier and in transit quantity of parts with the same dates. If the supplier is
notified by BI. of non-conformance, the supplier will be able to use this information to control like
material at their facility.
2. Traceability
This refers to the ability of tracking a part back through all stages of manufacturing to the raw
materials. Process parameters set during production should be traceable, with applicable inspection and
test results. Traceability is mandatory for all parts supplied to BI.
Supplier shall indicate the date of manufacture in the dispatch tag and limit dispatches of a lot
from the same raw material batch.
The supplier must ensure that documented systems are in place at all sub-suppliers and in-house
to control tractability of all components from raw material to date of manufacture.
For effective implementation, the supplier is needed to practice FIFO with material history card
(Issue register) for both R/M and sub-supplier supplies, where this card reference number is to be
recorded. Bar coding system of lots is encouraged.
In case of polymers, rubber, lining base products, the supplier is required to keep a master batch
sample of each lot and its record of composition and process parameters.
Identification of materials supplied to BI.
Suppliers are to provide proper identification tags for their supplies to Brakes India. Every package is
to be tagged and the tags to clearly indicate the following details.
ƒ Part no; Part description, Rev. No. of BI drawing to which part is supplied
ƒ Supplier code; Supplier name, Date of Manufacture, Quantities.
ƒ Delivery Challan no, Raw material batch no.
ƒ Route Card No. and other part specific information.
Samples and New product parts supplied to BIL are to be separately identified from the regular
supplies. Color-coded tags are recommended for clear and easy identification. In case of more than one
supplier for a part, identification mark on the part is required for traceability.

TAG Color for identification


Sample Parts - Pink Color tag.
New Products (Pilot batches) - Orange Color tag. (i.e. for first 10 shipments)Also called
FPP tag.
Regular Parts Non DOL - White Color Tags.
Regular DOL parts - White color tag with “DOL” stamp affixed diagonally on
the tag

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TAG SAMPLE
Pink color tag - Sample inspection part Orange color tag - New products

SAMPLES NEW PRODUCTS


Supplier Name: XXXXXXXXX XXXXX Ltd. Supplier Name: XXXXXXXXX XXXXX Ltd.
Plant name :Vanagaram plant Plant name :Vanagaram plant
Part no. Part no.

Part name : Part name :

Quantity Quantity

No. of bins / pallets No. of bins / pallets

DC No/ date DC No/ date

Signature Signature

REGULAR PART DIRECT ON LINE


Supplier Name: XXXXXXXXX XXXXX Ltd. Supplier Name: XXXXXXXXX XXXXX Ltd.
Plant name :Vanagaram plant Plant name :Vanagaram plant

Part no. Part no.

Part name : Part name :

Quantity Quantity

No. of bins / pallets No. of bins / pallets

DC No/ date DC No/ date

Signature Signature

Revision 1

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Section 4.3 – Control chart


Purpose
Control charts are effective tools to understand process variation and help achieve
statistical control. They often lend themselves to being maintained at the job station by the
operator. They give the people closest to the operation reliable information on when action should
be taken and when action need not be taken.

Explanation
Properly used control charts can:
1. Help / aid operators & supervisors for ongoing control of a process
2. Help the process perform consistently, predictably, for quality and cost
3. Allow the process to achieve
• Higher quality
• Lower unit cost
• Better utilization / Increased productivity
4. Provide a common language for discussing the performance of the process
5. Distinguish special from common causes of variation as a guide to local action or action on the
system.

X bar - R Chart
A X bar and R chart, as a pair are developed from measurements of a particular characteristic of
the process output. These data are reported in small subgroups of constant size, usually 3 to 5 consecutive
pieces with subgroups taken periodically. (e.g., once every 15 minutes, twice per shift, etc.). A data-
gathering plan must be developed and used as the basis for collecting, recording and plotting the data on
a chart.
Before control charts can be used throughout an organization following steps should be taken.
1. Process must be understood in terms of its relationship to other operations / users and in terms of
process elements (people, equipment, material, method and environment)
2. Determine the characteristic to be analyzed / managed depending upon the following
a) As defined in the drawings / process control standards (significant and critical characteristics)
b) The current and potential problem areas.
3. External cause of variation should be reduced before the study begins. This would mean that the
ensuring process is operated as intended i.e. m/c should be operating as specified with respect to
tool, speeds, feeds, setup, etc. The purpose is to avoid the obvious problem that could have been
corrected even without the use of control charts.
4. The current process setting / condition should be noted down e.g. m/c setting, operator, input
material, measuring system time etc. and keep noting all the relevant events such as tool change,
operator change, new raw material, shift change, m/c stops etc. These information will help in
subsequent control chart analysis and deciding the improvement / corrective action.
5. As data is basis for further analysis, it is absolutely essential that the reliability of data is ensured.
This may be ensured through the followings:
a) Using the precise measurement system (Least count 1/10 of the specified tolerance)
b) Using the qualified inspectors.

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Setting up of control charts
Chart Type Center Line LCL UCL
__ = = _ = _
X X X-A2R X+A2R
_ _ _
R R D3 R D4 R

Values of D4, D3, A4 are given in the table below:

n 2 3 4 5 6 7 8 9 10
A2 1.88 1.02 0.73 0.58 0.48 0.42 0.37 0.34 0.31
D4 3.27 2.57 2.28 2.11 2.00 1.92 1.86 1.82 1.78
D3 0 0 0 0 0 0.08 0.14 0.18 0.22
d2 1.13 1.69 2.06 2.33 2.53 2.70 2.85 2.97 3.08s

Data taken from these control charts are to be utilized for calculating the Cp, Cpk reports and
the same to be submitted to BI agreed in quality plan, as per the below guidelines.

Guidelines
• Take 25 subgroup data from past 3 months regular control charts; ensuring
uniform spread across all control charts.
• Plot an X bar R chart by using these data’s and calculate Cp & Cpk value
• Check whether the process is in control or not
• If the Cp & Cpk values are ok, send the process capability report to BI
• If the Cp & Cpk value is not ok take appropriate action to control this variation

Suppliers are expected to maintain X bar - R chart for all critical and significant
characteristics identified in drawing and short term capability data every year for other
parameters identified during PPAP.

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Section 4.4 – Receiving inspection at BIL


Purpose
To define supplier requirements for approval of regular supplies and inspection
methodology / acceptance criteria to be followed at Brakes India Ltd on receipt of material.
Scope
Applies to all production parts received that are not in skip / DOL category.
Supplier responsibility
• The supplier must submit along with part invoice a self-inspection report mentioning the drawing
issue no. for dimensional & metallurgical for all parts supplied to Brakes India Ltd.
• The supplier must adhere to the identification requirements specified on the part drawing,
inspection standard or applicable regulation
• For metallurgical inspection the supplier to submit test specimens as mutually agreed between B.I
and supplier. (Ex for text slabs, castings)
Procedure
1. Brakes India on receipt of material will check for delivery challans, inspection reports, packing
and quantity.
2. Lots delivered to B.I. will be cleared based on self-certification or sampling inspection as per the
discretion of B.I. The sampling plan followed is given below.
3. Items will be considered for skip inspection and the acceptance criteria are indicated.
4. Based on conformity to specification the component is accepted and the individual lots are rated
and the same will be reflected in Supplier quality rating
BI Sampling plan
BI Sampling Plan
Accept on ' 0 ' defect Reject on `1' defect

Dimensional inspection Material Inspection


Category ' A' : For all components Category A : Castings, Forgings, Springs & Sintered
(Other than Category ' B ' & ' C ') parts
Sample size Batch size Sample size
Lot size Visual Dimensional
Up to 50 10 Upto 100 3
51 - 150 20 100-500 8
151 - 500 25 501-2000 10
501 - 2000 30 2001-5000 13
>2001 50 Above 5001 20
Category ' B ' : For all Category B : Sheets, strips, coils, spring wires,etc
fasteners,castings,pressings,mouldings
Sample size Category Sample
Lot size Visual Dimensional
Up to 500 30 10 Sheets, strips 2 specimen for every 5 tons
501 - 2000 50 20 Coils & Spring wires 1 test piece from each coil
>2001 100 30
Category ' C ' : For bars, sheet materials and Category C : Bars, tubes, etc.
strips
Sample size Batch size (Weight Specimen
Lot (Weight in Tons) Visual Dimensional in Tons)
Up to 5 2 Up to 5 2
5 - 10 3 5 - 10 3
>10 4 >10 4

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Section 4.5 Quality rating & PPM calculation
Purpose
To explain the procedure on supplier performance evaluation & monitoring

Procedure
Every Goods receipt (GR) is rated for the quality of the supplied materials /
components. In addition to GR rejection, line rejections & customer returns will also be taken for
overall quality rating. The criteria for awarding scores for GR are listed below.

Quality rating calculation


Usage Decision Score
Status of lot based on Usage Decision (UD code)
code in SAP %
GR accepted based on DOL status with inspection report D1 100
GR accepted on skip lot basis with inspection report S1 98
GR inspected & straight accepted with inspection report A1 95
GR accepted on skip lot or DOL status without inspection report S2 90
GR inspected & straight accepted without inspection report A7 90
GR inspected & accepted with deviation with documented request from
A3 88
supplier.
GR inspected & accepted with deviation without documented request from
A2 85
supplier.
GR accepted based on inspection after segregation or rework. A4 , A5 50
GR rejected (Full lot rejected) R1 1
GR accepted Based on process scrap of supplier A6 --*
* Will not be considered for Q – rating calculation.

If there is any one instance of line rejection in the particular rating period, for the parts supplied
by the vendor, the quality rating of the part will get reduced by 10% (Absolute). If there is an instance of
OEM rejection in the rating period the rating will get further reduced by 50% (Absolute)

PPM calculation
Rejection PPM is calculated every month using the formula given below.

PPM = ((Tot. qty rej. at GR) + (Tot. qty rej. at line) + (Tot. qty rej. at OEM)) x 1000000

Tot qty received from supplier

First 10 lots from supplier for a part will not be taken into account.

Note:
• PPM & Quality rating details are available in vendor portal for previous 3 months.
• Selected suppliers scoring PPM > 500 will be called / visited & review will be
conducted.
• Suppliers appearing consistently in the high PPM list, in spite of reviews & support
from BI shall be considered for deletion.

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Section 4.6 – Control of non conforming part
Purpose
To define supplier requirements for control of non-conforming parts.

Scope
Applies to all parts when non-conforming items are identified.

Explanation
Non-conforming product means non-fulfillment of the drawing / specification requirements. The
procedure listed below describes the attention needed from the suppliers for dealing with non-
conformities both at their own facility, at his sub supplier end those in transit and at Brakes India.
Supplier responsibility
1. For non-conformance noticed after production, it should be isolated and kept in separate
identified locations. Supplier should record and review the nonconformities to take decision on
disposition. If decided to go for concession, supplier shall raise a concession request to B.I.
Products awaiting concession acceptance shall not be dispatched without the clearance from B.I.
2. If concession is rejected by B.I., supplier has to segregate / rework or scrap the lot depending
upon the condition. In case of segregation the supplier should ensure that all defective
components are screened out completely.
3. Where non-conformance is anticipated prior to production, the supplier should raise deviation
request to B.I. B.I. will accept or reject based on the criticality of the characteristics.
4. If the concession and deviation request raised for nonconformance is accepted by B.I, the supplier
shall indicate the quantity and its reference in the inspection report and identify the quantity
separately. The lot details should be provided to Vendor Quality of respective units and to
Supplier Quality Assurance (SQA).
5. If decided to rework, it shall be done as per the rework instructions and should be 100% re-
inspected. While reworking, supplier should ensure that other parameters of the product remains
unchanged (Both dimensional & Aesthetics). If any such conditions are witnessed, separate
concession request should be raised and 100% inspection should be introduced to the deviated
parameter.
6. Supplier should move the scrap materials immediately to scrap yard / scrap area. Where possible
they should mutilate them to prevent mix up. In case of material supplied by B.I. they should
return the same to B.I. at the earliest with proper identification.
7. Records of rework and scrap are to be maintained. It is auditable by BI at any time.
8. If required by B.I. the supplier has to give corrective action for the nonconformance’s noticed to
avoid further recurrence. Supplier should study their tooling, processes and inspection controls at
all stages or train the personnel if required to prevent the nonconformance.

Cost of Poor Quality (CoPQ): Suppliers are expected to monitor & reduce the CoPQ. The
CoPQ essentially comprises of `internal failure cost’ & `external failure cost’. This will include
all rejections / rework at inhouse, Brakes India Ltd & OEM.

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Hints to prevent mixup
1. Supplier should isolate the nonconforming materials to identified locations (Use separate
containers where practicable) at various stages like receiving, in process and final to prevent mix-
up with accepted material.
2. Supplier should reject the materials when a nonconformance is noticed during any stage of
manufacture even if the material is supplied by B.I.
3. Supplier should exercise great care to isolate materials, components that are identical in
appearance to one another.
4. Supplier should plan their production in such a manner that identical components, materials are
not manufactured during the same period.
5. Supplier should identify the accepted material after inspection with OK tags before dispatching to
B.I. This should contain part no., issue no., Quantity and inspectors signature.
6. .If supplier keeps any unidentified container with components in it, it should be treated as a
“Suspect product”. All the verification and correction processes applicable to a non-conforming
product is applicable to this.
7. Supplier should demonstrate the ability to identify the suspected parts to its raw material source if
required. Supplier should be able to demonstrate the ability to identify & trace the source / Heat
No / batch No. in case of a defect in the final part.
Hints to prevent non-conformity
1. Ensure usage of calibrated gauges, Instruments & Fixtures.
2. Deploy systems and train the personnel’s to scrap setting rejections immediately after first off
approval. Make a record of the setting rejection and dispose it accordingly. Proper identification /
mutilation of the setting rejection is mandatory.
3. First off reports should be recorded under these conditions.
4. a) Complete setting change over b) Tools & insert changeover.
c) Tool travel accidents
5. Always maintain a spare for critical tooling.
6. Tool life should be monitored on a day-to-day basis. Inserts, drills & other typlical tooling should
not be used more than its recommended life. After regrinding, tools should be inspected and
approved for tool-controlled dimensions.

7. Training should be provided to personnel’s for safe material handling of in-process and finished
parts.
8. Ensure proper storage of parts preventing it from environmental threats & accidents.
9. Rework of parts should be carried in a separate location adhering the rework instruction. Rework
of parts should be carried out under strict supervision.
Tips in eliminating Rust / Mixup / Damage
Do’s
• Use red and yellow bins in each & every machine/ station. Ensure that the scraps are
put into red bins & rework parts are put into yellow bins. Ensure operators are
educated & adhering to this practice.
• Ensure threaded parts are handled carefully. Wherever possible use partitioned trays.
Don’t s
• Don’t keep raw materials in open space.
• Don’t keep material without applying rust preventive oil.
• While doing a 100 % inspection take only one part at a time. If not OK, keep it in its
red bin before picking up next part
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Brakes India SQA Manual

Section 4.7 – Skip lot & DOL Implementation


Purpose
To define the minimum requirements for Skip Lot inspection of supplier parts.

Procedure
Step 1. Consideration for Skip Lot:
Supplier Parts will be considered for skip lot inspection if parts quality under any one of the
following group conditions are met.
Conditions for GROUP A
A1. Supplier with valid ISO / TS 16949 Certificate for the part supplied
A2. Minimum 95% Quality rating for that part for last 3 rating months.
A3. Dimensional and / or material test reports for the part supplied as per agreed quality plan /
control plan
A4. There should not be any rejection for the minimum of last 3 months / 25 lots.
Conditions for GROUP B
B1. Supplier with valid ISO 9001 Certificate for the part supplied
B2. Minimum 95% Quality rating for that part for last 6 rating months.
B3. Dimensional and / or material test reports for the part supplied as per agreed quality plan /
control plan
B4. There should not be any rejection for the minimum of last 3 months / 25 lots.
Conditions for GROUP C
C1. PSW approval and / or PPAP Documents as per SQA manual latest edition
C2. Supplier with valid ISO 9001 / ISO TS 16949 Certificate for the part supplied
C3. Minimum 95% quality rating for that part for last 3 rating months.
C4. Dimensional and / or material test reports for the part supplied as per agreed quality plan /
control plan
C5. There should not be any rejection for the minimum of last 3 months / 25 lots.
Once the parts satisfy any one of the above group conditions the part recommended for skip lot.
The list of such parts/suppliers and method of approval (Group A or B or C) will to be maintained by
Unit QC
Step 2: Requirements for sustenance for all the groups in Skip lot.
On receipt of material the part under skip lot, the part has to be cleared at receiving inspection
based on the verification of the Dimensional inspection reports and or Material test reports received from
the supplier as per agreed quality plan / control plan.
The part under Skip lot will be subjected to inspection once in 3 rating months / 25 lots which
ever is earlier (3 rating months / 25 lots which ever is earlier is treated as one cycle) and if found OK skip
lot status will be continued. If Not OK communicate to Supplier and follow step 3
Note: If there is no supply for a part number during a month, the part is not considered for rating
purpose.
Step 3: Procedure for taking corrective actions in case of line rejection / skip
inspection rejection
The part will be brought under normal inspection as per BI single sampling plan. Corrective
action will be raised for the part and the same has to be closed. To bring this part gain under skip lot
follow above step 1 and step 2 of above procedure.

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Direct On Line (DOL) Procedure:
Step 1: Consideration for DOL:
DOL: These pre-requisites are applicable for all direct materials except protective plugs,
protection sleeves, etc. For DOL parts, inspection will be done once in 500 lots or once in 6 months
whichever is earlier if parts qualify under the following group conditions are met:

Pre requisites:-
• PPAP / Change Management completed up to latest level.
• FFF Matrix completion with respective units.
• Already under skip lot and have completed minimum one cycle.
• No CAR should be pending.
• Process & Product audit grade should be at least B grade.

Step 2: Requirements for sustenance of DOL.


On receipt of DOL part the lot will be cleared at receiving inspection based on the verification of
the Dimensional inspection reports and or material test reports received from the supplier as per agreed
quality plan. A DOL tag has to be put (or) the regular OK tag to contain “DOL PART” rubber stamp.
The parts will be removed from DOL for non receipt of dimension inspection reports /
metallurgical report for each lot and lay out inspection report form supplier once in a year.

The parts will be removed from DOL in case of any Line rejections / OEM customer complaint
and the same will be communicated by Unit QC to supplier / SDI / SQA and follow step 3

Step 3: Procedure for taking corrective actions for DOL.


• The part has to be brought under normal inspection.
• The Corrective action report request will be raised by unit for the part and the same has to be
closed.
• The bring this part again under DOL it has to be again monitored & promoted to skip lot
inspection and then to DOL status

• BI plans to stop all regular receiving inspection with effect from Jan 2011.
Suppliers are expected to implement DOL before this deadline.
In case of failure to do so, inspection & administrative charges will be recovered
from suppliers as applicable.

• Any new part development will be taken up only with DOL supplier.

• Apart from the above DOL requirements, Brakes India Production System (BPS)
requires KANBAN requirements, usage of standard bin sizes, rationalization of
despatch quantity, logistics arrangements, etc. The individual part wise
requirements will be sent to supplier by respective unit supply module. Suppliers
are expected to adhere to these requirements.

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Section 4.8 – Change management


Purpose
For re-qualification of parts that are already under supply where changes are made to
design, agreed process, tooling, measurement method, location and approved sub-suppliers.
Scope
This procedure is applicable to all existing part suppliers.
Procedure
Unit/SDI to communicate the Change information
design change to supplier

Design changes , Alteration note, Sub supplier change, Location


etc change, Process change, RM change

Information to supplier
Information from supplier

Supplier to submit Supplier’s change


request form duly filled to SQA

SQA registers the request Location changes

No technical changes No
Re PPAP NO Verification
No required required
Receipt of
Samples from Yes
supplier Receipt of sample, Verification
Documents at supplier end

Not OK

SIR / ISLR
Capability Check for dimensions & Material Result evaluation
(SIR / ISLR) of samples
as required
OK OK Not OK

Adequacy & Implementation Adequacy

OK
PSW sign off Collect action plan

Send required documents to unit / supplier Implementation check

Update the documents & close the check list

Details
1. If any of the below mentioned conditions change, the change management process is required after
mutual discussion with supplier & customer.
2. Following situations leads to change management approval process.
3. Any technical changes, PSW approval required.

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Re-PPAP is done for the changes mentioned below


a. Change in dimensions or tolerances or raw material.
b. Tooling change.
c. Process change
Physical verification is done for the changes mentioned below
a. Sub supplier change
b. Location change
c. Management change.
d. Acquisition / takeover

Note: On site verification is based on SQA’s discretion.

4. For design change if design authority of component is with Brakes India, unit will inform to
concerned supplier for respective design changes.
5. For tooling, sub – supplier, process change & location change situations, the respective part supplier
has to inform SQA/SDI/Unit before any one of above changes are initiated
6. Final decision for further process requirements will be arrived after discussion with supplier.
7. The Supplier is to submit “supplier’s change request” with indication of changes to SQA. SQA will
send back the request with requirements to approve the change.
• BIL will audit the new location / sub-supplier along with the supplier as required. The results of
the findings are evaluated and the adequacy of the changes is checked. If result is found ok,
decision is taken for approval.
• If the adequacy is not ok, action plan to be submitted & implemented.
• If the implementation adequacy is not ok, the supplier is re audited and results are again
evaluated.

Any change in raw material source, process sequences, major tool changes, etc. must be
approved by BI. BI may notify the QMS registrar of the supplier, if a supplier violates this
system. Certifying body may revoke the certification if found non compliance to the ISO 9001/
TS 16949 procedures.

Page No. 49 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual
SECTION 4.9 – PROCESS AND PRODUCT AUDIT
PURPOSE
Product and process audit is a method to evaluate the supplier performance in terms of
quality systems, in-process controls, and adherence to agreed practices along with conformance
of part to drawing requirements. The result of a Product and Process Audit will show the
supplier’s performance and identifies potential areas for continual improvement. Product and
Process audit must be done for the actual process chain at the supplier’s / Sub supplier’s
manufacturing plant.
SCOPE
Applies to all production part suppliers, based on BI’s discretion.
SUPPLIER RESPONSIBILITY
The supplier is responsible to develop and maintain his product and process quality in a
way that audit score of 90% or above is guaranteed.
PROCEDURE
Supplier Selection Supplier to commit an action Supplier identified as “C”
& audit schedule plan (AB & B)
preparation

Audit at supplier end Review of action plan & Monitor & close the gap
Implementation within 6 months

Satisfactory No Yes Satisfactory &


(A Grade) improved quality
status

Yes No

Audit report closed Status projected to


management and supplier
considered for deletion

If audit rank is “C”, the supplier needs to come & present the actions planned to
BI. If no improvement is seen even after 6 months of report release, in spite of
support from BI, supplier shall be considered for deletion.

Page No. 50 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual
EXPLANATION
1. Supplier will be identified for the audit based on the following criteria.
• Parts criticality.
• High PPM rejections & CAR ratings
• Volume of part.
• Change Management
• Routine schedule – Suppliers not covered in previous audit schedules.
2. BI. SQA will issue a written notification of the audit to the supplier prior to the scheduled
time of the audit. The supplier must issue an acknowledgement of this request within 3 days
of receiving it. It is expected from supplier, that he does a self audit before this.
3. For product audit, a part with quality issues will be selected. The audit may extend to high
volume parts also.
4. On the closing day of the audit, B.I auditor will prepare a summary report and then meet with
the supplier to discuss the results and countermeasure plan activities.
5. A detailed report on audit findings with actual scores will be sent to the supplier. For the audit
findings, the supplier to give the counter measure plan for all the observations within five (5)
working days.
Note: The countermeasures plan must be signed by the supplier’s top management
6. After the issue of counter measures plan, the supplier is required to present the plan and
actions implemented, to SQA at B.I., for the current status of the non-conformances found
during the audit. This has to be initiated by supplier and completed within 30 days from the
date of issue of audit report.
7. After the review, based on the status, a suitable date will be fixed for conducting the
verification audit.
8. If improvements carried out are found to be satisfactory, the audit report will be closed. If no
improvement is seen, supplier will be considered for deletion.

Audit frequency fixing criteria


Audit frequency is fixed based on the priority rating given below
Rating % Audit priority rating Audit frequency
>70 % I Once in 1 year
40- 70 % II Once in 2 year
<40 % III Once in 3 year

Audit priority rating is calculated based on the formula given below. and calculated once in 3
years.

(Parts criticality rankx0.35)+(PPM rankx0.15)+(Volume rankx0.2)+(CAR rankx0.3) X 100


5

Wherein the ranking guidelines are in given in the table.

Ranking guidelines for fixing frequencies – Data period per annum


Rank Part criticality PPM Volume (Qty.) p.a CAR
5 Most critical >1000 >200001 >5
4 Critical 501-1000 100001-200000 4
3 Medium critical 251 - 500 40000-10000 3
2 Low critical 100 to 250 10000-40000 2
1 Not critical <100 <10000 1

Page No. 51 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Sections of Process and product audit

1. Process audit will be based on the following headers (As per check list) but not limited to the
following zones.
ƒ Process quality planning
ƒ Personnel & Qualification
ƒ Receiving stage & storing
ƒ Production and assembly stage
ƒ Packing, storage, handling, transporting and EMS requirements
ƒ Failure analysis, Corrections and Continual improvements

2. Product Audit will be based on the following headers


ƒ Dimensional Analysis
ƒ Capability & Endurance
ƒ In-house rejection trend
ƒ Other product specific attributes

3. Dimensional, metallurgical and capability study will be carried out during product audit.

Page No. 52 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual
Section 4.10 – Corrective and preventive actions
Purpose
The purpose of Corrective Action Report (CAR) is to ensure that supplier follows a
systematic problem solving approach to avoid the chances of recurrence.
Scope
Applies to all production parts when a non-conformance is identified.
Procedure
Flow Chart: Corrective action process
Non-conformity of part

Mfg unit raise CAR request and Process capability monitoring, Standardization
Sends to Supplier / SQA of documents, tryouts wherever applicable

SQA receives CAR and records it Corrected samples / Lots supply

Supplier has to initiate containment Horizontal deployment of corrective action on similar


action for parts within 24 hrs. Parts, if applicable

Supplier should analyze the root cause


Physical verification by SQA, if required

Corrective action Proposal to be sent


to SQA within 10 days. Adequacy CAR closure by SQA

Supplier should submit SQA forwards adequacy closed CAR to unit


Alternate proposal after
Re – analysis
Unit monitors the lots for effectiveness of corrective actions,
for 3 lots / 1 month based on unit’s discretion

If Inadequate SQA verifies


adequacy of Effectiveness of CAR – Verification by unit
corrective
action proposal Not OK OK
Return to SQA
With comments
Unit to forward the closed CAR copy to SQA

Closed CAR handed over to supplier

Page No. 53 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual
Details
1. The manufacturing unit will raise the request for corrective action report (CAR) if they observe
any non- conformance to drawing requirements including standards specified.
2. The copy of the report with details of problem statement, lot details, non-conforming quantity, old
CAR ref if repeated and other information specified will be sent to Supplier / SQA by the
receiving unit. (Refer CAR format)
3. CAR classified into 3 categories A.B.C. the details are given in CAR format.
4. SQA receives the CAR request from the unit and records it after verifying the completeness of all
details pertaining to the non-conformity. Sufficiency of the data for analysis is also ensured.

On receipt of CAR / information about quality issue, Supplier must initiate


containment action within twenty-four hours for the parts at BI, in transit, in-
house and at sub supplier end. Contained lots should be identified with details
of containment. OK parts to be identified & the details to be communicated to
SQA.
The supplier should analyze the non-conformance and provide the corrective
action proposal within 10 working days and implement the same within
proposed 30 days. Any relaxation to this will have to be authorized by BI-SQA.
Unauthorized delays may lead to cost recovery.

5. BI – SQA to clear the proposed corrective action for the adequacy. In case of inadequate
corrective actions, supplier should submit alternate proposal.
6. The parts supplied before implementation of corrective action should be subjected to 100%
inspection for the non-conformity raised.
7. Process capability simulation trials should be demonstrated to validate corrective action taken,
where ever applicable.
8. After implementation of corrective action, samples/lots should be monitored and the
implementation cut off date to be mentioned in CAR.
9. Support documents such as process flow diagram, inspection layout, control plan, PFMEA, WI
etc. are to be updated if there is any change and the same to be enclosed with CAR. Supplier
should get approval from BI-SQA in case of changes. Supplier should horizontally deploy the
corrective actions taken on similar parts produced, wherever applicable.
10. BI-SQA will verify the corrective action implementation at the supplier end based on requirement
& after approval, SQA will forward adequacy closed CAR copy to the unit.
11. Unit will monitor the effectiveness of corrective actions for 3 Lots / 1 month based on unit’s
discretion.
12. If effectiveness found satisfactory, the RI unit will close and send the CAR copy duly signed to
SQA for record purpose.
13. If effectiveness is not satisfactory, CAR copy will be return back to SQA for revisit.
14. Closed CAR copy will be handed over to supplier.

Every effort should be taken to prevent defects in complaint resolution. Limit 100 %
inspection for only containment.

Page No. 54 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Section 4.11 – Tool management


Purpose
To define requirements of tool management to the suppliers of production part.
Procedure
A typical tool management cycle is to be explained in the figure below. This applicable to the.
pressing, forging, die-casting and molding processes.
Flow chart: Tool Management Cycle
Tool drawing Release Preparation of

- Tool Id. No. tool history cards


Manufacturing of tool - Preventive maintenance check sheet
with inspection plan
- Define the tool life / regrinding norms

Tool trial run

Tool Stage and layout inspection of part


Correction

Not OK
Check
Adequacy

OK Send the tool for maintenance record


the tool maintenance activities
Issue the tool to production, along with the (Recording activity + replacement of
inspection report, limit samples. accessories in the history cards). Check
the adequacy of fixed regrinding norms.

Before starting production, approval the


Setup and record the same

No

Monitor the tool condition by patrol inspection


(as per control plan) and last off inspection. OK
Yes

Record the exact quantities produced and move the


tool back to the standardized location along
with the last off samples.

• Identify each jig / fixture with unique identification number. Each one should have a history card.
Whenever, a modification is carried out in jig / fixture, ensure the tool’s drawing is updated.
• For consumable tools, fix the frequency of replacement / reconditioning based on scientific
calculations. Please don’t wait for defect to occur to change the tool, rather once the no. of
specified parts completed, change it.
• Ensure that a robust system is established to track the no. of parts produced / cycle.
• Always have enough spares of tools / inserts for a trouble free run.
Page No. 55 BI – SQAM Rev: 2 – Nov 09
Brakes India SQA Manual
Section 4.12 – Cost recovery process
Purpose
To recover the administrative and other costs incurred by BI, because of non conforming parts
supplied by Supplier.

Scope
Applies to all production parts. The Cost Recovery Advice (CRA) applies to the line rejections,
GR rejections, every instance of OEM rejection and delay in CAR closure (beyond the target). etc as
specified in format.

Description
The recovery amount will vary depending upon the nature of complaint & no of occurrences. the
amount of recovery is specified in the attached format & based on the discretion of BI.

Procedure
1. Whenever the non-conformed part noticed at BI, the RI will raise the CRA and CAR to SQA
in concurrence with Unit supply module.
2. CAR should be raised against the Supplier related to the complaint along with CRA.
3. SQA will register and forward the CRA to SDI after verification. Once SDI signs it will be
forwarded to finance dept. for necessary recovery.
4. Finance dept. will recover the respective amount against the supplier’s account.

5. Supplier shall have to take proper corrective actions by closing the CAR and make sure the
complaint is not repeating again.

Amount of recovery is fixed for each category & the details are given in CRA format.
Apart from administrative cost, actual costs incurred by way of rework, transportation,
manpower, travel costs, etc will also be recovered.

Page No. 56 BI – SQAM Rev: 2 – Nov 09


Brakes India SQA Manual

Format - index

Sl. No Click on the Description to go to the page Revision No.


1 Evaluation of Supplier Quality system- ESQS 02
2 Tool Progress Report 01
3 Design Review 01
4 Quality Plan 04
5 Safe launch plan 01
6 Packaging Standard 02
7 Capacity verification 01
8 Compliance Audit Check sheet 01
9 Conditional Approval Format 02
10 PPAP Check sheet – A & B 01
11 PPAP Check sheet - C 01
12 Process capability calculation sheet 01
13 Corrective Action Report 03
14 Process and Product Audit format & report 02
15 FFF matrix 02
16 Supplier’s change request form 04
th
17 Process Failure Mode & Effect Analysis - 4 Rev. 01
18 Cost Recovery Advice (CRA) 02

The formats given in PDF file is for information only. Please contact your SQA window
engineer to get editable excel file with embedded formulae for your day to day use.

Page No. 57 BI – SQAM Rev: 2 – Nov 09


Brakes India Limited

EVALUATION OF SUPPLIER QUALITY SYSTEM (ESQS)


Date:

Supplier Name : Points


Elements & Questions Observations 0 1 2 3 4
MANAGEMENT

1 Does the Supplier has professionally


managed organisation structure ?

2 Does the Supplier has OEM's/Tier 1


suppliers of OEM's as their Customer
base ?

3 Does the Supplier fulfill/ monitor the


Customer satisfaction index interms of
QCD?

4 Does the Supplier has acumen to become


Global Player ?

1 Does the supplier possess required


infra-structure for BI parts ?

2 Status of the Machine capabilities


presently in operation ?

3 Does the Supplier has a good


manufacturing practices (like cell
concept, SMED, mistake proofing etc) ?

4 Does the Manufacturing process used


are adequate for BI requirements?

FINANCE

1 Does the Supplier's PBT is about 6%


(last fin.Year) with respect to Sales?

2 Does the Supplier has Year on Year


cost reduction plan & implementation
program ?

3 Debt equity ratio 1.5:1 max ?

GENERAL

1 Does the Supplier has Standard packing


system ?

2 Does the supplier keen to establish


Business relation with BI?

3 Does the Supplier has Adequate Controls


for Traceability

4 Are they using any poke yoke setup ?

5 Is Bar Coding Practiced?


Format : BI / ESQS / Rev.02 dated 1 Nov 09
Elements & Questions Observations Points
0 1 2 3 4
QUALITY SYSTEM
1 MANAGEMENT RESPONSIBILITY

a) Does the supplier have anyone responsible


for quality, reporting, directly to top
management ?

b) Is manufacturing primarily responsible for


product quality ?

2 MANUFACTURING CAPABILITIES

a) Does the supplier have the required manufacturing


facilities to meet the contractual requirement ?

3 CONTRACT REVIEW

a) Whether Purchase orders (including


amendments) received from the customers
are reviewed considering the feasibility
also ?
b) Suppliers preparedness for submitting APQP &
PPAP ?
c) Does the suppliers have evident of PPAP document
for similar products ?
d) Are they having adequate knowledge in preparing &
using control plan & FMEA ?
e) Are they having adequate Experience in preparing
and handling FMEA documents?
4 DOCUMENTS AND DATA CONTROL

a) Is there a method of controlling the documents


for revision status, user location and updation
including customer supplied documents like
drawings, quality/control plans ?

5 PURCHASING

a) Does the purchase document (or equivalent


document) specify all the necessary quality
requirements like drawing/ issue no., spec.qty/wt
price etc.., and whether the quality records
of sub-contractors kept up to date ?

6 PRODUCT IDENTIFICATION & TRACEABILITY

a) Are the raw material and products identified


at all production stages including delivery
(I.e. from receipt to delivery)

7 PROCESS CONTROL

a) Are the products manufactured as per


documented work instruction (operations/
inspections) like manufacturing layout/ process
sheet, drawing / specification, quality/ control
plan ?
Poka Yoke works properly throughout the process
and are checked for effectiveness periodically.

Format : BI / ESQS / Rev.02 dated 1 Nov 09


Elements & Questions Observations Points
0 1 2 3 4
b) Is special process qualified (design of
experiments may be used) and whether
trained/ qualified presonnel employed
for special process operation ?

c) Is the preventive maintenance carried out


with checklist as per plan on machines/
equipments and whether the Machine
capability indices are satisfactory (for
products having special characteristics) ?
d) Does the supplier comply to all applicable
Government safety & enviornmental
regulations including those concerning
handling, recycling, eliminaiton / disposal
of hazardous & toxic substances and
possessing appropriate Government
certificate ?

e) Is the working environment clean & well


maintained ?

8 INSPECTION AND TESTING

a) Are receiving inspection activities carried


out including customer supplied matierals/
products ?
All incoming parts are clearly identified and
demarked separately until quality is assured.

b) Is inspection carried out between stages as


per quality plan / control plan / work
instructions and are they displayed near work
area and updated periodically?

c) Is gauging/ measuring are avilable and done at


setup and periodically for each process as per
work instruction / quality / control plan and
whether the special process monitored as
per work instruction / process sheet ?
Are Gauges / Fixtures maintained well?
Sampling check is sufficient. NC procedure is
clear and countermeasure carried out.

d) Does the supplier carry out final inspection &


testing as per the work instruction/ quality /
control plan ?
Sub suppliers QC activities has been reviewed
in detail and every concern have been solved

9 CONTROL OF INSPECTION, MEASURING

a) Whether the gauges, inspection, measuring


& test equipments calibrated periodically
and suitably identifed (including MSA) ?

b) Are all measuring equipments properly


handled and stored ?
10 INSPECTION AND TESTING STATUS
a) Is inspection and /or test status suitably
identified from receipt to delivery ?

Format : BI / ESQS / Rev 02 dated 1 Nov 09


Elements & Questions Observations Points
0 1 2 3 4
11 CONTROL OF NONCONFORMING
PRODUCT

a) Are the rejected & reworked materials kept


separately identified and the analysis
carried out ?

12 CORRECTIVE AND PREVENTIVE ACTION

a) Are the customer complaints and the


internal nonconformities (rejected/reworks)
effectively handled for initiating corrective
and preventive actions ?

13 HANDLING, STORAGE, PACKAGING


PRESERVATION AND DELIVERY

a) Does the supplier handle, store, pack


preserve & deliver items in the proper
method or in the method specified by the
customer to avoid damage or deterioration
of the product?

14 CONTROL OF QUALITY RECORDS

a) Are the quality records maintained properly


(I.e) identification, collection, indexing
access, filing, storage, disposition and is
it legible, readily retrievable and kept for the
specified retention period ?

15 TRAINING

a) Whether the training needs identified and


provided for all presonnel performing
activities affecting quality and effectiveness
to Training monitored?
16 STATISTICAL TECHNIQUES

a) Whether the supplier follow statistical


techniques for controlling process and
product characteristics and relevant records
maintained (atleast products having
special characteristics) ?
b) Does the supplier have any CP/CPK trend
monitoring program?

17 PPM LEVEL/SELF CERTIFICATION

a) Does the supplier maintain its quality level


in PPM ?
If Yes, Present PPM Level

b) Does the supplier operate under 'Self


certication' of parts with the existing
Customers ?

c) Supplier schedule adherence with the


existing customers ?

d) Does the Supplier supplies in JIT / or keep


consigement stocks ?

e) Does the suppier has Internal system to


evaluate Suppliers/sub-supplier selection ?

f) Does the Supplier has infrastructure for


Raw material inspection, receiving in process
and final inspection?
Format : BI / ESQS / Rev 02 dated 1 Nov 09
Elements & Questions
OBSERVATIONS
ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

1 Air Act
a) Does the Supplier possess the valid consent to operate under latest
prevailing Air Act.
b) If yes , specify the validity date
c) Does the supplier comply / plan to comply to the consent condition
stipulated by the concerned SPCB

Water act
2
a) Does the Supplier possess the valid consent to operate under the latest
prevailing Water Act.
b) If yes specify the validity date

c) Does the supplier plan to comply to the consent condition stipulated by


the concerned SPCB

3
Hazardous Waste Management & handling Rules
a) Does the Supplier possess the valid authorization under the latest
prevailing HW management and Handling rules.
b) If yes , specify the validity date

c) Does the supplier comply to the conditions stipulated in the authorization


given by the concerned SPCB
d) Does the supplier has an adequate Trade Effluent Treatment Plant

If yes a)provide details of TETP & Disposal of TETP sludges

e) Does the Organisation have adequate Sewage handling facility?

Any other legal / Regulatory requirements applicable to the nature of the


process and is the supplier comply to them
Acceptance Criteria : Min score 70% and not more than 3 zero scores Total marks:
Supplier should have valid ISO 9000 certification as minimum requiremen Percentage:
No.of Zero scores:
Recommendation :

Audited by:

Format : BI / ESQS / Rev 02 dated 1 Nov 09


TOOL PROGRESS REPORT
PART NUMBER: XXXXXXX PART NAME: YYYYYYY
TOOLING SOURCE: Inhouse SUPPLIER: Supangita Engineers Ltd
TOOLING / EQUIPMENT Press tools SUPPLIER CODE: S999 TOOL COMPLETIONN DATE: 12/6/2003

WEEK ENDING 1/3 8/3 15/3 22/3 29/3 5/4 12/4 19/4 26/4 3/5 10/5 17/5 24/5 31/5 7/6 14/6
STAGE

Receive component drawing

Design tool

Build tool

Tryout and fine tune

PLAN ACTUAL SUPPLIER SIGNATURES


APPROVED APPROVED CHECKED ORIGINATOR
TITLE

SIGN &
DATE / / / / / / / /
Format : BI / TP Rev-01
DESIGN REVIEW OF CHILD PART Date :

Note : Design review has to be done before child part sample development.
Part No. / Issue No. Unit Model

Description: Supplier

Change & Way of


Dimension / Spec. (as given in Grid E, R&D
# Parameter SC/CC parameter dimn if required Reason for change Remarks
drawing) ref comment
(Otherwise write OK)

Example:
# ØXXX Yes XX
Diameter

Notes

Note: All drawing dimension, material, finish & Notes to be covered.


Consider both dimensional requirement & process capability requirement if any during discussion.
Supplier representative: E, R&D representative BI - SQA representative : SDI Rep. Unit rep (If reqd)
Name: Name: Name: Name Name
Sign Sign : Sign : Sign. Sign.
Format : BI / DR Rev- 01
Brakes India Limited
Quality Plan Agreement
Supplier Name:
Part Name:
Part number / Issue number:
Customer / Model
Unit:
# Characteristics Grid Ref. Method of inspection Safe launch plan Calibration freq& Normal Sampling /
parameter & verification of the Frequency
checking freq. date

1.0 Visual parameters:

1.1 Free from burr, rust, damage and cracks Visual Every lot

1.2

2.0 Dimensional parameters

3.0 Metallurgical parameters (covering RM, HT & Finishes):

4.0 Capability report (SC/CC Characteristics identified in draiwng) * #

4.1

5.0 Capability report (Identified during PPAP) * #

5.1

5.2

6.0 Layout inspection

6.1

7.0 Rejection reports*

7.1
Documents retention : All Quality documents shall be stored for a minimum period of years & should be traceable.

Unit: SQA Supplier:

Name: Name: Name:

Signature/Date : Signature/Date : Signature/ Date :


Notes:
* Parameters marked thus to be retained at supplier end. The same shall be subject to verification during visit of BI Personnel.
# Parameters under 4 & 5 has to be checked 100 % if there is no prevention fail safe, during initial 3 months of buld supply (safe launch)
a) Supplier shall provide test certificate in accordance with the above agreement for lots as applicable.
b) Capability report shall be computed from data taken across production lots over a period of time mentioned. Capability studies
shall be repeated in case of change of RM, Machine, location etc.,
c) Suppliers will be reviewed monthly, based on their PPM rejections and Quality issues & called for quality reviews as required.
d) In case of CAR raised on any SC/CC parameter, the respective parameter to be inspected 100 % for next 1 year to avoid repeat issue.
Format No. BI / QP Rev-04 dated 3rd Nov '09
Safe Launch Plan
Brakes India
Ltd. Special Work Instruction
Customer/Project: Part/Process Description: Part No. Issue date
NISSAN D21 Safe launch checking item for Wheel
TRUCK cylinder Assembly viewing

Operation:

Ref.
Feature Verification Method
1 No.
3

1 Check for feed thread Visual

Check for mounting


2 Gage
thread and pitch
Finish on feed port
2 3 Visual
surface

1
2 Proper seating of the
1 Visual
boot
No cut/puncture mark
2 Visual
on boot

2 1 Presence of piston slot Visual


Plunging action to check
2 Visual
for spring
1

2
1 Presence of caps Visual
1
Proper passivation of
2 Visual
the bleed screw

1
1 Test Punch Mark Visual

1
Proper fine grain
1 phospating of piston & Visual
any damage on piston

1
1 Date code stamping Visual

The part should be marked with Yellow paint after qualification of the above points
Comments:

Supervisor Signature: Date:


Packaging specification sheet
Part Name: Model L Disc Pad. Supplier code: R017
Part description: Model L DiscPad Supplier name: RANE BRAKE LININGS LIMITED
Revision No.: 1 Supplier address:
Plot #30, Industrial estate,
Ambattur, Chennai - 600 058
Packing illustration:
(Attach photograph of packing arrangment)

Details of packing:
Dimension (mm) Wt. / part Qty. of Total part Total wt. (part wt. &
parts wt. packaging wt.) in Kgs
Length Breadth Height Thick
340 195 200 4 0.36kg 20 7.2kg 8.39kg

Description: carton reference M635


Mode of despatch:
1 Through TVS logistics (by road)
2 By suppliers arrangement (by road)
3 By suppliers arrangement (by train)
4 By suppliers arrangement (by road and air sometimes)
Necessary details along with dispatch:
1. Invoice
2. Dimensional results (as per quality plan)
3. Material test results / Mill TC
4. Capability reports, whenever applicable (as per quality plan)
APPROVED BY:
UNIT : SUPPLIER :
NAME : NAME :
SIGNATURE : SIGNATURE :
CAPACITY ASSESSMENT SHEET (for all BI part families with supplier)
Supplier Name : M/s. XXX

Window Engineer : ---

Traub CNC machining Gridning


Sl# Part Name Part No AMD
C.T (sec) Hrs. Reqd. C.T (sec) Hrs. Reqd. C.T (sec) Hrs. Reqd.

1 Input rod 0.00 0.00 0.00

2 Output rod 0.00 0.00 0.00

3 Bracket 0.00 0.00 0.00

Total Qty 0
Total Hrs Required : 0.00 0.00 0.00

Number of machine 5 3 3

Available Hrs per Month (assumed for 2 shifts (18 hrs max.) & 25 days) 2000.0 1200.0 1056.0
Machine down time [ % Avail Hrs] (10% assumed) (includes setting, breakdown, PM etc.,) 200.0 120.0 105.6

Loss due to OPR EFF % Avail Hrs (5% assumed) (operator change, untrained operator etc.,) 100.0 60.0 52.8

Machine Hrs dedicated to BI % 100 100 50

Net available Hrs 1700.0 1020.0 448.8

% Utilization 0 0.000 0.000

% Utilization for other customers 0 0 50

% Capacity free (Spare capacity) 100 100 50

1)avg peak demand for past 6 months


2) Plan to ach o/p for the above qty
COMPLIANCE AUDIT CHECK SHEET

Part No : xxxx Issue No. Date of Checking: mm/dd/yy Start Time End Time

Controls on Cycle Setting Quantity


S.No Operation Time in time in
Control Plan W.I sec Min. Produced Ok R/W Rejected FTC % yield
1 Operation 1 Yes * *

2 Operation 2 Yes * *

3 Operation 3 Yes * *

FTC shall be Minimum 90 % (may vary based on customer requirement)

Supplier: SQA Representative :

Signature Signature

Date: Date :

Format : BI / Comp Audit Rev-01


To : Unit
Kind attention.:
The following part is conditionally approved for the reasons given below. Please introduce double sampling for the related
parameters till the PPAP is converted to straight approval by SQA. This will be informed to you as & when the PPAP is converted to straight.
Reference No. :
REASON FOR CONDITIONAL APPROVAL
Part no: PSW No. :
Part name: Conditionally Approved on. :
Supplier Name:

AREAS

Sub-supplier control

Interim containment

interim containment
Handling of parts &
Machine Condition

Rejection analysis

Responsibility for
Capability Study
Toolings,Jigs &

Target Date for


Responsibility
Improvements

Completed on
completion of
Reason for conditional Approval
Raw material

Instruments

conditions
Measuring
Process

Fixtures

General
Layout

action

action
Sl.No

Conditional Status Completion Status


BI Representative : BI Representative :

Supplier Representative : Supplier Representative : Format:BI/Cond Rev 02


PPAP Checklist – (A&B category)
Part No. Supplier
Part Name : Project :
# Check Point Yes No Remarks
Is there a design review conducted (before sample submission) or supplier has given
1
assurance that he will meet all drawing./ Cp, Cpk requirements.
2 Does the process flow address raw material & S/C sources

3 Material specification and its availability

4 Material and its compatibility for Heat treatment / plating / painting / brake fluid

5 Are the tool sketches available

6 Is the component manufacturing location clearly defined

7 Is the SIR latest and has it been cleared without any issues

8 Does the control plan address the following:

- Machine name

- Process parameters

- Jigs / Fixtures

- Measuring instruments used

9 Is mode of packing and transportation addressed

10 Is between stages handling addressed

11 Does PFMEA address all requirements as per process flow

12 Co-relation of process capability and MSA

13 Is Poka – Yoke addressed for significant characteristics (force sensor in forging


machines temp sorter in hot forging etc)
14 Are all characteristics of drawing addressed in control plan

15 Adequacy of the quality plan

16 Is the FTC report filled properly

17 Is the PTR samples available with supplier with necessary tag

18 Check method uniformity between BI and supplier

19 Supplier’s awareness on mating component and function

20 Is reason for conditional approval stated clearly

21 Are the special process parameters qualified and are they specified

22 Is there a list of process instruments coming under calibration

23 If capability is not achieved, Have we addressed 100 % inspection

24 Ensure SIR (layout inspection) taken after completing all processes

25 Capability studies shall be taken for dimensions which are prone to vary during the
process
26 Change management agreement addressed in quality plan.

27 Study of process capability in case of RM change shall be addressed in quality plan

28 PTR and PSW capacity shall match as far as possible

SQA Engineer:
Date Format : PPAP A&B / 01
PPAP Checklist ( Category : C )

Part No : Supplier : M/s

Part Name : Project :

Sl Not
Check Point Yes No Remarks
No applicable
1 Is the SIR latest and has it been cleared without any
issues
2* Does the control plan address the following:
- Machine name
- Process parameters
- Jigs / Fixtures
- Measuring instruments used
3* Are all characteristics of drawing addressed in
control plan
4* Adequacy of the quality plan
5 Is reason for conditional approval stated clearly
6* Capacity meeting the specified volume

7* Review of Fit, Form, Function

Note : Items marked * not mandatory for customer specified sources & collaborator’s
sources.

SQA Engineer :
Date :

Format: BI / PPAP C / 01
PROCESS CAPABILITY STUDY REPORT
Supplier : Ref. No.
M/S. XXXXX

Customer : PERIOD ( Month ):


Brakes India Ltd Nov '07
Part No.: 29666743 Part Name : XXXXXXX
Characteristic Specification Tolerance
OUTER DIA LSL 4.74 USL 4.77 0.03
Operation No : 10 Opn. Description : VMC
Instrument Used MICROMETER Least Count : 0.001
CAPABLE PROCESS OBSERVED :
Cp > = 1.67 CAPABLE Cp = 2.27
Cpk > = 1.33 CpK = 1.63
HISTOGRAM n = 42

30 200

180
25
160

140
20
120

15 100

80
10
60

40
5
20

0 0
2.37

4.75

4.75

4.76

4.76

4.76

4.77

4.77

4.77

4.78

4.78
Observation : - No. of Class : 4
1-5 6 - 10 11 - 15 16 - 20 21 - 25 26 - 30 31 - 35 36 - 40 41 - 45 46 -50
4.760 4.763 4.755 4.759 4.761 4.761 4.758 4.760 4.757
4.756 4.760 4.757 4.758 4.756 4.757 4.758 4.758 4.758
4.760 4.758 4.758 4.761 4.765 4.756 4.759 4.760
4.761 4.760 4.760 4.762 4.761 4.762 4.758 4.757
4.761 4.758 4.757 4.760 4.763 4.760 4.762 4.758

Observed beyond Specification : Target Nominal :


0.00% 4.755
Estimated beyond Specification : Average (X): 4.759
0.00% Std.Dev. (O):
(sigma) 0.0022
ACTION PLAN FOR IMPROVEMENT(IF NOT CAPABLE) Prepared by :

Sign & Date


Approved by :

Sign & Date

1
CORRECTIVE ACTION REPORT (CAR)
Part name: C.A.R.No. / Unit
BRAKES INDIA LTD Part number: CAR raised date :
Drg Issue no: Reported by:
Supplier / Vendor code : Customer: Authorised by :
Product model : CAR sent to supplier on date:
Supplier Plant/Location :
CONCERN RANK A B C
Supplier DC / Invoice no: DC date: Lot reference:-
Qty Received :- BI GR no:- GR Date:-
Complaint Identified at
Receipt stage Assy stage Product Audit
Customer End Assy testing Others specify:
Complaint details
Fitment Functional Packing / Labelling
Dimensional Aesthetics / Visual Material
Others specify
Complaint history
New Skip Part PPAP approved
Repeated Non -skip part Yes No

UNIT
Non conformance description
Sl.No. PROBLEM Defect Photo/Sketch (Attach
separate sheets if necessary)

Non conforming quantity:

Specify other details wherever necessary

Defective sample retained with unit Sample given to supplier Sample / photo shown to supplier

Quantity available at Brakes India for disposition: CRA ref No. (if any)
Unit Recommendation
Segregate Rework Concession by BI Reject to supplier

SUPPLIER TO SEND CORRECTIVE ACTION PROPOSAL WITHIN 10 DAYS FROM RECEIPT OF CAR

Guidelines for ranking of CAR

Customer Complaint/Repeat CAR in same part number after closure of original CAR by unit /OE fitment dimensions A
Line stoppage due to quality issue/Dimensional issue in significant & critical characteristics B
Others(Dimensional deviation not affecting fit & function/Aesthetics/Handling damage/Mix up/Rust,etc) C
Format : BI / CAR Rev- 03 - May 09 Page : 1 OF 3
CONTAINMENT ACTION
NG
Identification
Parts checked at Date OK Remarks
Reject Rework mark on OK part

Brakes India

In Transit

Supplier Inhouse

Sub - Supplier

ANALYSIS TOOLS

C&E DIAGRAM (4M) 5 WHY ANALYSIS SCATTER DIAGRAM CHECKSHEET

STRATIFICATION HISTOGRAM PARETO ANALYSIS CONTROL CHART

Guidelines :
Atleast 2 tools to be used, 3 or more tools preferable.
Narrate briefly the QC tool used.(Provide attachments wherever necessary)

CAUSE & EFFECT DIAGRAM


MAN MATERIAL

SUPPLIER
METHOD MACHINE

WHY - WHY ANALYSIS


Why it occurred Why it was not detected

1 1

2 2

3 3

4 4

5 5

DEFECT CLASSIFICATION

Process Tooling Gauging Packing / Labelling

System Machine Handling Operator

Maintenance Training Rework

Format : BI / CAR Rev- 03 - May 09 Page : 2 OF 3


CORRECTIVE ACTION
IDENTIFIED ROOT CAUSE CORRECTIVE ACTION RESP TGT DATE

OCCURRENCE

DETECTION

SUPPLIER
HORIZONTAL DEPLOYMENT ON SIMILAR PARTS / PROCESSES:
YES NO (Furnish details if YES)

STANDARDISATION OF CONTROL DOCUMENTS

PFC CONTROL PLAN DRAWINGS

PM CHECKLIST QUALITY PLAN TOOL DRAWING

GAUGE DRAWING FIXTURE DRAWING SOP

PFMEA UPDATED PACKING INSTRUCTION

Note : Attach supporting details / documents where ever necessary

CORRECTIVE ACTIONS WITH EFFECT FROM:

Cut off DC / Invoice no & Date :

Supplier Representative Name: Sign: Date:

PHYSICAL VERIFICATION OF CORRECTIVE ACTION IMPLEMENTATION (IF REQUIRED )

YES NO

SQA Engineer: Date: SQA

CORRECTIVE ACTION ADEQUACY

OYES NO

Approved by: Date :


CORRECTIVE ACTION CLOSURE (BY ORIGINATING UNIT) :

Signature: Date:
UNIT

Note: Unit to monitor the effectiveness of corrective actions (for 3 lots or 1 month, based on unit's discretion), sign and forward this copy to
SQA for updating the database.(SQA Repository)
Format : BI / CAR Rev- 03 - May 09 Page : 3 OF 3
Fit, Form & Function Matrix
To: Mr.

Unit no:

The below mentioned FFF activities were implemented with effect from supplies dated: _______________. Please monitor the lots after this & arrange for skip introduction as per usual skip inspection procedure (if not already implemented)

Supplier Name : Customer : Date : No. of cavities


Part No : Issue no Part Name : PPAP Completed: Yes / No
Fit, form, function Characteristics
Present process controls available Checking method Past complaints (Last 1 year)
( including SC/CC )
Sl used in Remarks / action plan for DOL stage Dock audit &
Inhouse Resp. Target
No. Category of Machine Process 100% manufacturing OEM BI - Line Incoming improvement inspection details inspection Report.
Characteristics Specification Fail Safe line rejections@
FFF name / type capability inspection complaint Rejections Rejections
sup end.
1

10

11

12

Note : 100% inspection required if there is no fail safe for OEM customer fitment characteristics. Recommended process capability for all FFF characteristics is Cpk > 1.67. All FFF characteristics should be covered in Final inspection report. For all
OEM customer fitments 100 % insp. is required either in line or final insp. or DOL station when Poka-yoke is not there.
Sampling plan
a) n=as per BI sampling plan, c=0
b) n=5, c=0
If there is any rejection in sampling inspection, 100 % inspection should be done for that characteristic.

Unit Representative Supplier representative


Window Engineer name :
name: name :
Sign : Sign Sign :

Fit : The ability of item item to physically interface or interconnect with or become an integral part of another item.
Form : The shape, size, dimensions, mass, weight, and other visual parameters which uniquely characterize an item. For software, form denotes the language and media.
Function : The action or actions which an item is designed to perform.
Format : BI / FFF Matrix Rev 2
Brakes India Ltd., Chennai
Process And Product Audit Report
Supplier / Sub - supplier / Satellite unit audited Reason for the Audit Audit No.:

Date
High CAR / Routine /
Change Mangement
Overall Audit Critical Suppliers left
( Location / Auditor:
Priority Rating Supplier of the our in prev.
Subsupplier)
Month plans

Part No. / Name Application Degree of


Audit Score (%)
Conformity
1
Process 0
Process Owners Product 0
Process
Previous audit
Product
Machining Pressing Moulding Protective finishing Casting Springs Bar rolling
Assembly, Subassembly /
Inhouse processes audited Forging Heat treatment Welding Lining / Bonding Packaging
Testing

Complete Process Sequence Others ( please mention):

Machining Pressing Moulding Protective finishing Casting Springs Bar rolling


Sub-supplier process audited Assembly, Subassembly /
Forging Heat treatment Welding Lining / Bonding Packaging
(if any) Testing
Complete Process Sequence Others :

Process Audit Product Audit


Main Elements Main Elements Achieved Reference
Achieved Score Reference Score Result % Result %
(Process) (Product) Score Score
I Process Quality Planning 0 30 0 Dim adherence 0 10 0

II Personnel Qualification 0 20 0 Capability 0 10 0

III Receiving Stage and storing 0 20 0 In house rejection 0 10 0

IV Production Stage 0 70 0 Endurance - - -

Packaging, Storage, Handling,


V Transporting, EMS & OHSAS 0 30 0 Other attributes - - -
requirements
Failure Analysis, Corrective
VI Actions and Continual 0 30 0
Improvements.

Overall Score
Over all Score (I+II+III+IV+V+VI) 0 200 0 0 30 0
(I+II+III+IV+V)

Grading
Overall Degree of Conformity % Grading of the Process Grading Remarks

90% to 100% Full Compliance A


If any of the above elements in Process audit is
80% to 89% Predominant Compliance AB
less than 60%, Grading is downgraded by one
step.
60% to 79% Partial Compliance B
i.e., A to AB or AB to B or B to C
Less than 60% No compliance C

Auditor/s Signature & Date Reviewed by Signature & Date Approved by Signature & Date Auditee / Process Owner Signature & Date

Copies for Circulation to : SDI Units

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Supplier Process Audit
General Information
Name :

Location:
Other manufacturing sites:
(if any)
Established in:
Total Employee strength :
(Permanent employees)
Regular Working norms :
(shifts x hrs)

Annual Turn over

Tie-ups (if any)

Core Manufacturing Competance:

Manufacturing , testing and


validation facilities available

Quality Certifications

Certificate ISO 9001:2000 ISO TS 16949 ISO 14001 Others

Certifying Body

Obtained in (Year) / Date of Cert : Date of Cert : Date of Cert :


target dt. (if planned) Date of Expiry : Date of Expiry : Date of Expiry :

Quality issues :-
Last 6 months PPM At BI : At Supplier end :

Last One year CAR's raised

Total No.of Parts supplied to BIL

No.of New parts added


PPAP Status
Business relationship with Brakes India Ltd.
Business with BIL: (Since)

Major parts supplied to BIL

Business share of BIL:

Future Plans

FM/SM/SA/01-Oct07
Audit Score Sheet

Process Audit

Rating
Achieved Reference
1 Process Quality Planning 0, 4, 6, 8, % Score
Score score
10
1 Process Flow Chart 0
2 PFMEA 0 0 30 0
3 Control plan 0

Rating
Achieved Reference
2 Personal Qualification 0, 4, 6, 8, % Score
Score score
10
1 Responsibiilty and Authority 0
0 20 0
Qualification, training and suitability of
2 0
personnel

Rating
Achieved Reference
3 Receiving Inspection & Stores 0, 4, 6, 8, % Score
Score score
10

1 Receiving inspection and Subsupplier control 0


0 20 0
2 Stores 0

Rating
Achieved Reference
4 Production Stage 0, 4, 6, 8, % Score
Score score
10
Appropriateness of work and inspection stations
1 0
to the needs.
Approval for production starts and recording of
2 0
adjustment details / deviations.

3 Quality Monitoring. 0

0 70 0
4 Adhrence and adequacy of process parameters 0

5 Machine management 0

6 Tool management 0

7 Instruments and Gauges management 0

FM/SM/SA/01-Oct07
Audit Score Sheet

Process Audit

Rating
Packaging, Storage, Handling , Transporting Achieved Reference
5 0, 4, 6, 8, % Score
EMS and OHSAS 18001 requirements Score score
10

In-house material handling. Tracebility and


1 security against mix-up / exchanges by mistakes 0
of parts and material flow.
Tuning of transport materials & packing to the 0 30 0
2 0
special properties of the product.

3 EMS & OHSAS 18001 Requirements 0

Rating
Failure Analysis, Corrections, Continual Achieved Reference
6 0, 4, 6, 8, % Score
improvements Score score
10

Availability of Target parameters for product


1 0
and process & monitoring of compliance.

Continual improvements of product and


2 0 0 30 0
process.

Carrying out corrective actions on time and


3 0
check for effectiveness in the process.

Product Audit
Rating
Achieved Reference
7 Product Audit 0, 4, 6, 8, % Score
Score score
10
1 Dimensional Adherence 0 0 10 0
2 Capability 0 0 10 0
3 Internal rejections 0 0 10 0
4 Endurance / Other Attributes - - - -
5 Other Attributes - - - -

Evaluation of Compliance with individual requirements:


Full compliance with the requirements 10 Points
Predominant compliance with the requirements with minor nonconformity 8 Points
Partial compliance with the requirements with more severe nonconformity 6 Points
Unsatisfactory compliance with the requirements with major nonconformity 4 Points
No compliance with the requirements 0 Point

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive
Main Check Rating Avg. Rating Observations / Points for improvement along with objective Responsi
Sub Element Look for (Check list) compliance / Areas needing Action Plan Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 evidence bility
improvement

PFC No.: Issue No.:

1.1.01 Adequacy of sequences from receiving up to shipping.

Are the latest copies of Drawings / Specifications


1.1.02
available with supplier?

Any significant change in the process flow in the past


1) Process 1.1.03 12 months due to process improvement or customer #DIV/0!
Flow concern ? If yes, look for process validation .

1.1.04 Availability of Raw materials supplier details in PFC

1.1.05 Identification of CC & SC stages


1) Process Quality Planning

1.1.06 Availability of sub-supplier details in PFC

PFMEA No.: Issue No.:

1.2.01 Adequacy of sequences in line with process flow.

1.2.02 Considerations & identifications on CC& SC

Any method exists for updating PFMEA on ongoing


2) Process 1.2.03
basis #DIV/0!
FMEA
Reviews based on RPN, severity, excess scrap /
1.2.04
rework, customer concerns, etc.

Are actions based on PFMEA reviews completed on


1.2.05
targets?

1.2.06 Are Poka Yoke’s included in PFMEA?

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)
Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever
possible,audit by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive
Main Check Rating Avg. Rating Observations / Points for improvement along with objective Responsi
Sub Element Look for (Check list) compliance / Areas needing Action Plan Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 evidence bility
improvement

CP No.: Issue No.:

1.3.01 Is CP in line with Process Flow & FMEA?

1.3.02 Are all S.C’s & C.C’s identified in CP?

1.3.03 Are PFMEA changes & concerns identified in CP?

Is CP adequate covering all tests / checked fixtures /


1.3.04 gauges / frequencies / responsibilities / historic
concern?

1.3.05 Does CP address all dimensions as per drawings?


1) Process Quality Planning

1.3.06 Does CP address process characteristics?

3) Control
#DIV/0!
Plan Does CP address corrective actions in case of non
1.3.07
conformities (Reaction plan)?

Does CP cover agreed standards / practices not


1.3.08 specifically addressed in the drawing (like burr free,
flash free, surface finish, acceptance limits, etc) ?

Does CP cover layout inspection and functional


1.3.09
testing?

1.3.10 Does CP cover packaging and despatch standards?

Does CP address each stage’s process validation &


1.3.11
frequency?

Are Poka-Yoke devices uniquely identified in CPand


1.3.12
their shift wise qualification / validation?

Does PFC , PFMEA , CP address actions based on


1.3.13
findings of the previous audit?

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever
possible,audit by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive
Main Check Rating Avg. Rating Observations / Points for improvement along with objective Action Responsibi
Sub Element Look for (Check list) complaince / Areas needing Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 evidence Plan lity
improvement

2.1.01 Do they have a clearly defined organization structure?


1) Organization
structure
2.1.02 Is there a Customer Contact Persons identified for Quality Issues

2.2.01 For management of modifications & NCs

2.2.02 For operating & work instructions ( Design / Engg / QC )

2.2.03 Adequate resource for Inspection activity covering all the shifts (QC / QA / Manufacturing)
2) Roles ,
Responsibility & 2.2.04 For process approval and release ( QC / QA / Manufacturing )
authority
(Competency of 2.2.05 For set-up approval (First-off & Last-off) ( QC / QA ) #DIV/0!
employees, required
to perform their 2.2.06 For interpretation of control charts ( Prod / QC / QA / Manufacturing )
role)
2.2.07 To stop production on NCs ( QC / QA )

2.2.08 For rework approval ( QC / QA )

2.2.09 For environmental safety ( Personnel / HR )

2.3.01 Qualification / Skill matrix availability


2) Personnel & Qualification

2.3.02 Training calendar and adherence

2.3.03 Product knowledge

2.3.04 Knowledge of consequences to customer in case of N.C products / processes

2.3.05 Health and safety at work awareness.(OHSAS)

Availability of skilled personal ( At receiving inspection, Line inspectors, Final inspection,


2.3.06
Production, Maintenance, Tool design/ maintenance, QA, Calibration, etc)

2.3.07 House keeping training.


3) Qualification,
training &
2.3.08 Training on problem solving methods pertaining to their jobs. #DIV/0!
suitability of
personnel
2.3.09 Skills on process capability studies & M/c capability studies

Qualification records (Welding certificate, driving license for industrial trucks, eye sight test for
2.3.10
viewers, etc.)

2.3.11 Carrying out & ordering the installation & calibration of inspection, measuring & test equipments

2.3.12 Knowledge on MSA

2.3.13 Training on handling of parts, equipments at each stage.


Carrying out continual improvements - Waste elimination, cost reduction, cycle time reduction,
2.3.14
setup times

2.3.15 Knowledge on error proofing / Poka-Yoke

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive
Main Check Rating Avg. Rating Observations / Points for improvement along with objective Action Responsi
Sub Element Look for (Check list) complaince / Areas Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 evidence Plan bility
needing improvement

3.1.01 Are incoming packages appropriate (as per purchase order)

3.1.02 Availability of product drawing, Inspection plan, material history cards etc.

3.1.03 Sampling plan – Is zero defect policy evidenced?

3.1.04 Availability of suitable TD/TS

Is RM procured from approved source as per Specefication ( TD 1-30-07 ) & for Rubber items ( Check validation
3.1.05
done by Supplier )

1) Receiving 3.1.06 Are RM test parameters verified at defined interval as per CP / QP?
#DIV/0!
3) Purchase, Receiving stage, storage and sub-supplier management

stage
3.1.07 Are calibrated / adequate inspection/test facilities available?

3.1.08 Is self inspection reports received from suppliers

3.1.09 Supplier rating availability

3.1.10 Supplier audit schedule and adherence

3.1.11 Source audit approval record

3.1.12 CAR on vendor rejections & adequacy of corrective actions and how the system is effective?

3.2.01 Tidiness

3.2.02 Clear identification & separate locations for materials looking alike.

Roofed area / Area available to total R/M handled and any Rust preventive method adopted if any ? and Raw materia
3.2.03
stored properly to avoid deterioration?

Availability of identification cards / colour codings (Status card - Accepted / Rejected / Under inspection, RM Heat
3.2.04
code etc.)

2) Storing 3.2.05 Any chances of mix-up? #DIV/0!

3.2.06 Is quarantine area clearly isolated and adequate?

3.2.07 Shelf life items storage ( Have the Shelf Life Items been identified and validation takes place periodically? )

3.2.08 FIFO controls and stack records

3.2.09 Lighting / Safety / Easy access

3.2.10 Traceability

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)
Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive
Main Check Rating Avg. Rating Observations / Points for improvement along Action Responsibi
Sub Element Look for (Check list) complaince/ Areas needing Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 with objective evidence Plan lity
improvement

4.1.01 Work instructions adequacy & compliance

4.1.02 Stage drawings adequacy & compliance

Process parameter display at relevant stages (E.g. Pr, Temp, time, speed, feed, Location
4.1.03
of resting & butting, etc) & Are SOP's displayed near the Machine/cell

Inspection instructions adequacy & compliance (Does the Inspection Plan / Control
4.1.04
Plan bears Customer designated Critical & Significant Characteristics ?)

Rework / Scrap instructions / procedures ( Do they have a system of handling rework /


4.1.05
scrapped parts ? )
4) Production Stage

1) 4.1.06 Quarantined & ear-marked WIP area


Appropriaten
ess of work 4.1.07 Availability of quarantined final inspection area #DIV/0!
& inspection
station to the
needs 4.1.08 Tidiness , cleanliness ,ergonomics, lighting etc

4.1.09 Clear identification & separate locations for materials looking alike.

4.1.10 Availability of inspection table, work table etc

4.1.11 Availability of in & out bins

4.1.12 Marked containers for reject/ rework/ adj parts ( Eg. Red bin analysis for rejected parts)

4.1.13 Defined rework station

4.1.14 Health and safety at work (OHSAS)

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit
by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive
Main Check Rating Avg. Rating Observations / Points for improvement along Action Responsibi
Sub Element Look for (Check list) complaince/ Areas needing Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 with objective evidence Plan lity
improvement

4.2.01 Set up & last off approvals (With samples)

4.2.02 1st principle method of 1st OFF approval

4.2.03 Stage inspection adherence as per schedule


2) Approval
for Control and regulation of important parameters, process qualification (DOE etc) & Is
production 4.2.04 application of Statistical Tools evident in Shop Floor ?
starts and (Process Monitoring Chart / X bar - R Chart, Run Charts etc.)
#DIV/0!
recording of
adjustment 4.2.05 Changed Production parameters
details and
Availability of instruments, gauges and adequacy (Like profile projector, surf tester,
deviations 4.2.06
height gauge,hardness tester crack detection etc)

Machine and process capability evidences for important characteristics and process
4) Production Stage

4.2.07
parameters

4.2.08 Recording of rejections / rework

4.3.01 Is there a Master list of Gauges / Instruments / Jigs & Fixtures ?

4.3.02 Triggering mechanism for calibration of instruments / gauges / jigs& fixtures?

4.3.03 MSA/ R&R


3) Quality
monitoring 4.3.04 Relaibiltity, function and corrosion resistance tests (if applicable).
#DIV/0!
4.3.05 Layout inspection schedule and adherence

4.3.06 Adherence to submission of reports as per Quality Plan

4.3.07 Availability of SQA Manual, awareness and deployment in shopfloor


4) Adequacy and Adherence to process parameters Refer Annexure 1
5) Machine management Refer Annexure 2
6) Tool Management Refer Annexure 2
7) Instruments / gauges / fixture management Refer Annexure 2
Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)
Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit
by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive Observations / Points for improvement


Main Check Rating Avg. Rating Responsib
Sub Element Look for (Check list) complaince / Areas needing along Action Plan Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 ility
improvement with objective evidence

5.1.01 Suitable transporting means

5.1.02 Availabiltiy of bins (Inhouse & movement to subcontractors)

Protection against damage (Inhouse & movement to


5.1.03
subcontractors)

5.1.04 Environmental influences and air conditioning


5) Packing, storage , Handling transporting and ISO 14001 Requirements

5.1.05 Expiry dates


1) Inhouse material
handling & storage / 5.1.06 Kanban / JIT
Traceability and severity
5.1.07 Defined storage area (WIP) #DIV/0!
against mix up/ exchanges
by mistake for parts and
material flow 5.1.08 Marked containers / locations

5.1.09 Identification & marking of parts

5.1.10 Identification & marking of operation

5.1.11 Inspection & test application status

5.1.12 Route cards with Traceability

5.1.13 Batch and heat numbering

5.1.14 Protection against damage

No. of quantities per package / Parts Positioning in package /


5.1.15
Work Instruction
2) Tuning of transport
materials and Packing to the 5.1.16 FIFO controls
#DIV/0!
special properties of the
product 5.1.17 Tidiness, cleanliness & overstocking

5.1.18 Packaging- Transport worthiness (Look for drop test)

5.1.19 Work documentations (Final inspection report)

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit
by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive Observations / Points for improvement


Main Check Rating Avg. Rating Responsib
Sub Element Look for (Check list) complaince / Areas needing along Action Plan Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 ility
improvement with objective evidence

3) ISO 14001 / 5.3.01 Is your organization IS0 14001 certified?

Consumption of Power 5.3.02 Monitoring consumption and action when they are abnormal.

4) Generation of Noise 5.4.01 Any action If Noise level exceeds 90 dB(A) ?

5.5.01 Any action If Polythene cover thickness less than 20 micron ?


5) Spillage / Leakage /
Movement / Storage and 5.5.02 Usage of trays for keeping barrel and containers
5) Packing, storage , Handling transporting and ISO 14001 Requirements

Disposal of oiling
5.5.03 Dispose of the used oil only to Hazardous waste recyclers

5.6.01 Identify High risk Fire prone areas

6) General Maintenance Ensure availability of adequate different type of fire extinguishers


5.6.02
activities / Fire Hydrants
Identify key personnel and provide adequate training for fire
5.6.03
fighting
#DIV/0!
7) Where applicable : 5.7.01 Monitor stack emission once in a year and ensure SPM

Emission Control 5.7.02 Ensure availability of pollution control certificate.

5.7.03 Safety and health policy available?

Do you have facilty to address safety concerns raised by


5.7.04
Employees
Identification of risk potential areas and keeping it away from
5.7.05
main area.

5.7.06 Availability of first aid boxes at prominent areas.


OHSAS 18001 requirement
5.7.07 Availability of procedure to report accidents

5.7.08 Availability of inhouse / outsourced medical facility

Availability of control system in work place which are risk


5.7.09
potential.

5.7.10 Availability of Risk management plan on emergency systems

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever possible,audit
by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Highlights of positive Observations / Points for improvement along


Main Check Rating Avg. Rating with objective evidence Action Responsibili
Sub Element Look for (Check list) complaince / Areas needing Target
Element List No. 0,4,6,8,10 Rating 0,4,6,8,10 Plan ty
improvement

6.1.01 Presence and absence of personnel

1) Availability
6.1.02 Quality indices / failure rates, audit results etc
of Target
parameters for
Non conformities cost / Cost of poor Quality - Records / Trend
Product, 6.1.03 #DIV/0!
charts.Non conformity costs
process &
Monitoring 6.1.04 Process characterictic values (Cp, Cpk)
compliance
Are Customer survey & Quality Rating Reports received from
6.1.05
customer
6) Fault analysis and continual improvements

Recording of break down times, setting time, downtimes etc, OEE


6.2.01
(Any Kaizens)

6.2.02 Availability of cycle times / thro put times (Any Kaizens)


2) Contiual
improvement on
6.2.03 Cost optimisation #DIV/0!
product and
process
6.2.04 Reducing stock level

6.2.05 No of production pieces produced per hour

Recording of rejections / rework and Analysis - 7 QC Tools. (Is


6.3.01 the Corrective and Preventive Actions initiated for In-house
rejections / rework ?)

3) Carrying out
6.3.02 Implementation / Sustenance of improvements
corrective
actions on time
#DIV/0!
and check for 6.3.03 CAR - Analysis status ( Look for all CAR's raised last one year)
effectiveness in
the process Operator awareness of customer complaint (Both internal &
6.3.04
external)

6.3.05 Improvement program from various B.I. Audits

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed rating average is 5.5 - Subelement rating to be 4)

Rating: Full Compliance with requirements: 10; Predominant Compliance with minor NC-8; Partial with more severe NC-6; Unsatisfactory with major NC-4; No Compliance with requirement - 0. Audit Notes / Guidelines (Important Note: Where ever
possible,audit by observing the actual process)

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0 Part No. 0

Adequacy and Adherence to Process Parameters in Production stage - Annexure 1


Significant Observations / Points for
Machine, Devices, Doc ref. / Process
Op. No. Operation Description
Tools, Jigs & Fixtures
Process Characteristics Product Characteristics Spec Characteristi Method of insp.
Characteristics
Actual improvement along with objective
cs evidence

Rating 0,4,6,8,9

Reference score 9

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0

Process audit report - Annex 2


Observations / Points for
Action Responsibi
Main Highlights of positive complaince / Rating Rating improvement along with Target
Sub Element Avg. Rating Plan lity
Element Areas needing improvement 0,4,6,8,10 0,4,6,8,10 objective evidence

Bed flatness

Scribing of bed

Horizontal parallelism

Ram repeatability

Spindle run-out

Chuck face-out

Slide repeatability

Safety sensors
Machine Management

Warning devices

Temperature
#DIV/0!
Timer

Poka-yokes

Periodic validation of Poka Yokes

Daily qualification of Poka Yoke with NG Parts

History cards
PM checklist

PM adherence

Recording of break down times, setting time, downtimes etc, OEE

Identification of accessories

Stacking of accessories

Critical spares

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0

Process audit report - Annex 2


Observations / Points for
Action Responsibi
Main Highlights of positive complaince / Rating Rating improvement along with Target
Sub Element Avg. Rating Plan lity
Element Areas needing improvement 0,4,6,8,10 0,4,6,8,10 objective evidence

Tool ID
Tool drawing
Tool stacking
Spare tool availability
Tool Management

RI of tool
Tool service life
#DIV/0!
Tool life
History cards
PM checklist
PM adherence
Poka-yokes
Tooling plan
Jig/fixture ID
Jig/fixture drawing
Jigs/fixtures

Jig/fixture stacking
Jig/fixture calibration
Maintenance frequency of wear parts
History card
Instrument ID with LC
Instrument

Stacking #DIV/0!
Calibration
History card
Gauge ID
Gauge drawing
Gauges

Stacking
Calibration
History card

FM/SM/SA/01-Oct07
Process audit report - Annex 2 (i)

Machine Ave.

Bed flatness #DIV/0!


Scribing of bed #DIV/0!
Horizontal parallelism #DIV/0!
Ram repeatability #DIV/0!
Spindle run-out #DIV/0!
Chuck face-out #DIV/0!
Slide repeatability #DIV/0!
Safety sensors #DIV/0!
Machine Management

Warning devices #DIV/0!


Temperature
Timer
#DIV/0!
Poka-yokes #DIV/0!
Periodic validation of Poka Yokes #DIV/0!
Daily qualification of Poka Yoke with NG
#DIV/0!
Parts
History cards #DIV/0!
PM checklist #DIV/0!
PM adherence #DIV/0!
Recording of break down times, setting time,
#DIV/0!
downtimes etc, OEE
Identification of accessories #DIV/0!
Stacking of accessories #DIV/0!
Critical spares #DIV/0!
Tool ID #DIV/0!
Tool drawing #DIV/0!
Tool stacking #DIV/0!
Spare tool availability #DIV/0!
Tool Management

RI of tool #DIV/0!
Tool service life #DIV/0!
#DIV/0!
Tool life #DIV/0!
History cards #DIV/0!
PM checklist #DIV/0!
PM adherence #DIV/0!
Poka-yokes #DIV/0!
Tooling plan #DIV/0!
N/A - Not Applicable
Score Status Denoted as
0 No compliance with requirement Not Avail.- Not available
4 Unsatisfactory with major NC 4
6 Partial compliance with minor NC 6
8 Predominant compliance with minor NC 8
10 Full compliance with requirement Available

FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit

Supplier : 0

Product Audit Report


Critical / Rating
Main Rating 0,4,6, Highlights of positive complaince / Responsib
Part No. / Part Name Significant Spec. 0, 4 , 6 8, Avg. Rating Action Plan Target
Element 8, 10 Areas needing improvement ility
Dimension 10
Dimensional
Adherence
Capability
Endurance /

attributes
Other

Overall Inhouse process rejections ( For all BI parts put together):

Guideline for Subelement rating - Average of rating of individual check points to be computed and in case the average falls between two rating the lower rating to be adopted. ( For example if computed
rating average is 5.5 - Subelement rating to be 4)
Rating: Both dimensional and visual characteristics are adequate: 10; Minor deviations in the visual charcteristics but dimensionally adequate - 8;Minor dimensional deviations -6; Major and critical
dimensional deviation -4; No Compliance with requirement - 0.
Capability Rating:For Ppk > 2.0 - 10 ; For 2.<Ppk > 1.67 - 8 ; 1.67 < Ppk > 1.33 -6 ; 1.33 < Ppk > 1.00 - 4 ; Ppk< 1.00 - 0.
Note: For tool dominant processes like Moulding, Pressing etc. Cp will be considered instead of Cpk (Min. sample size 25 successive nos.)

Inhouse process rejections Rating: PPM < 100 - 10 ; 100 > PPM < 1000 - 8; 1000 > PPM < 10000 -6; 10000 > PPM - 4; No PPM monitoring - 0.

In house process rejections Rating (for tool dominant process like Moulding) : PPM < 5000 - 10 ; 5000 > PPM < 10000 - 8; 10000 > PPM < 50000 -6; 50000 > PPM<100000 - 4; No PPM monitoring -
0.

FM/SM/SA/01-Oct07
BI Tracking no.
Brakes India – Corp. QA

Supplier’s Change Request (SCR)


Supplier Name : SCR Tracking No:

Part No/ Name : Issue No.: Original BI PSW No.


Nature of change (Tick applicable) Alternation Note Ref (If BI initiated) .
TO BE FILLED IN BY SUPPLIER

Process Tooling Location Sub Supplier Design Material source

Change Initiated By: Supplier BIL


Change Description:

Sl. Characteristics Affected due to change


Impact of Change Remarks
No (Use additional sheet if required)

For Non Technical changes PSW revision need not be required.


Supplier rep. name : Sign: Date :

* Re-PPAP Required : Yes No * Verification Required: Yes No


Documents :
PFD MSA Ppk reports FFF matrix

PFMEA Master sample Inspection report Quality plan


Control plan Lay out report Validation test results Compliance audit

Design FMEA SIR/ISLR Capacity Assessment Packing Spec Sheet

PSW Qualified Lab Doc PPAP Check Sheet Conditional Approval Sheet (if Any)
BI – SQA USE ONLY

* Subject to the discretion of SQA.


If Physical Verification is required planned
Verified on : Action plan for non-conformance (if any)
Verified by :

Reviewed by: Approved by:


Signature & Date: Signature & Date:

SCR closure details:


New PSW No.:
Date:

Date of Change Implementation / Identification (If any) :

SQA Engineer to communicate customer window engineer before change implementation if required.

Format U52 / SCR Rev. 4 dated 17 April 09


POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA) – (As per FMEA Manual Rev. 4)

FMEA Number___________________________

Page_____________________of______________

Item:________________________ ___________ Process Responsibility__________________ Prepared By______________________________

Model year(s)/Program(s)__________________ Key Date ____________________________ FMEA Date (Orig)_________________________

Core Team______________________________________________________________________________________________________________________

Process Action Results

Occurrence
Classification

Detection
Severity
Step Potential Potential Potential Current Current Responsibility

Occurrence
RPN
Requirements Failure Effect(s) Cause(s) Process Process Recommended & Target Actions Taken

Detection
Severity

RPN
Mode of Failure of Failure Controls Controls Action Completion & Effective
Function Prevention Detection Date Date

Format : U52 / PFMEA Rev. 1


Brakes India Limited - Brakes Division
CRA - Cost Recovery Advice - For vendor parts
To: Finance Department CRA No:

Plant Date :
Unit Reason : Tick applicable & fill appropriate column

Customer if applicable Administrative costs given in brackets for each category.

Part No. 1. Rejection at receiving inspection (Debit Rs.2000/each lot rejection)

Part Name 2. Line rejection (Debit Rs.10,000 / Occurence)

Supplier code 3. Seggregation / Rework at BI - (Rs.5000 / Occurence+Actual cost)

Supplier name 4. Repeat seggregation / Rework at BI - (Rs.10,000 / Occurence+Actual cost)

Supplier D.C/ Inv. no. 5. Third party inspection charges (At actuals)

GR No. 6. OEM Customer complaint (Rs.10,000 / Occurence+Actual cost)

CAR No./ Date 7. Delayed CAR closure (Rs.5000 / Occurence)

8. Premium freight due to Quality problem / Delivery failure (At actuals)

9. Non adherance to change management commitment.(Rs.5000/+actuals if any)

Total cost to be recovered (Rs) 10. Other charges. Pl. mention………………..

Brief description of problem :

Cost working
1. GR Rejection
Debit note will be raised by finance dept. for all GR rejections.
2. Line Rejection
Administrative cost Total cost

3, Segregation / Rework costs 4. Repeat seggregation / Rework costs


Segg / Rework cost for labor Consumables/Tools cost Administrative cost Total cost

5. Third Party Inspection


Third Party Inspection agency / Type of Cost of 3rd party inspection Transportation charges
Total cost
work

6. Cost to Brakes India because of OEM customer complaint


Cost at brakes India including
charge debited by OEM
Description Quantity customer's to Brakes India Total amount

7. Delayed CAR closure


CAR No. CAR sent to supplier on Brief description of problem Total cost

8. Premium Freight charges


Details Date Freight cost Total cost

9. Violation of change management commitment


Nature of violation Details of violation Cost Total cost

10. Other charges


Details Date Cost Total cost

Total cost to be recovered

Sign: (Unit Quality Module) Sign: (Unit Supply Module) Sign : (SQA) Sign :(SDI)

Recovery details (To be filled by Finance dept.)


Details Cost recovered Signature

Note : After all the above 4 approvals are completed, CRA will be forwarded to finance dept with a copy to unit & SQA Format : BI / CRA Rev. 2

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