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http://www.brakesindia.com/brakesdivision/sqamanual.pdf
Brakes India SQA Manual
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.
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
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
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.
3) PPAP: Approved supplier list reference given. PPAP categorization details & document
requirements specified.
4) APQP & Safe launch plan: Safe launch plan details were elaborated.
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.
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.
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
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
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.
Procedure
Flow Chart – Supplier Selection Process
Supplier Identification
Data receipt
`
Not OK
Judgment
OK
Gap analysis & closure at supplier end.
Supplier should have minimum valid ISO 9001 certification to be a supplier of BI.
8. The above audit can be waived if the supplier has been already audited / approved for
that part family.
2. EQUIPMENT / GAUGES 5
a) Calibration 4 Calibration done
b) Availability & maintenance
Average 4.5
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
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
Pre-PPAP audit
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.
Machining ,Casting, Forging, Sintering Pressed parts, Special process, Friction, Spring, Plastic, Rubber
Proprietary assembly parts
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
For all the above categories, if OEM customer asks for further documents, the same needs to be
submitted on case to case basis.
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”
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.
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.
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.
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.
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.
• 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.
Not Ok
Clear Approval by E, R&D Improvements
OK
• 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.
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.
σ = Σ (Xi - X )2
(n- 1) X
6σ
Pp -This is the process potential index, (short term) which is defined as the tolerance width divided by
the process performance, irrespective of centering.
Page No. 29 BI – SQAM Rev: 2 – Nov 09
Brakes India SQA Manual
Pp = USL – LSL
6σs
Ppk - This is the process performance index (short term), which accounts for process centering and is
Cp – Process potential index (Long term): Is defined as the tolerance width divided by the process
capability, irrespective of process centering.
Cp = USL – LSL
6σ
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.
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.
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
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.
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.
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.
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.
TAG SAMPLE
Pink color tag - Sample inspection part Orange color tag - New products
Quantity Quantity
Signature Signature
Quantity Quantity
Signature Signature
Revision 1
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.
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.
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.
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
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.
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.
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
Page No. 45 BI – SQAM Rev: 2 – Nov 09
Brakes India SQA Manual
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.
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.
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
• 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.
Information to supplier
Information from supplier
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
OK
PSW sign off Collect action plan
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.
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.
Audit at supplier end Review of action plan & Monitor & close the gap
Implementation within 6 months
Yes No
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.
Audit priority rating is calculated based on the formula given below. and calculated once in 3
years.
1. Process audit will be based on the following headers (As per check list) but not limited to the
following zones.
Process quality planning
Personnel & Qualification
Receiving stage & storing
Production and assembly stage
Packing, storage, handling, transporting and EMS requirements
Failure analysis, Corrections and Continual improvements
3. Dimensional, metallurgical and capability study will be carried out during product audit.
Mfg unit raise CAR request and Process capability monitoring, Standardization
Sends to Supplier / SQA of documents, tryouts wherever applicable
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.
Not OK
Check
Adequacy
No
• 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.
Format - index
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.
FINANCE
GENERAL
2 MANUFACTURING CAPABILITIES
3 CONTRACT REVIEW
5 PURCHASING
7 PROCESS CONTROL
15 TRAINING
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
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
Audited by:
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
Design tool
Build tool
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
Example:
# ØXXX Yes XX
Diameter
Notes
1.1 Free from burr, rust, damage and cracks Visual Every lot
1.2
4.1
5.1
5.2
6.1
7.1
Documents retention : All Quality documents shall be stored for a minimum period of years & should be traceable.
Operation:
Ref.
Feature Verification Method
1 No.
3
1
2 Proper seating of the
1 Visual
boot
No cut/puncture mark
2 Visual
on boot
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:
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
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
Part No : xxxx Issue No. Date of Checking: mm/dd/yy Start Time End Time
2 Operation 2 Yes * *
3 Operation 3 Yes * *
Signature Signature
Date: Date :
AREAS
Sub-supplier control
Interim containment
interim containment
Handling of parts &
Machine Condition
Rejection analysis
Responsibility for
Capability Study
Toolings,Jigs &
Completed on
completion of
Reason for conditional Approval
Raw material
Instruments
conditions
Measuring
Process
Fixtures
General
Layout
action
action
Sl.No
4 Material and its compatibility for Heat treatment / plating / painting / brake fluid
7 Is the SIR latest and has it been cleared without any issues
- Machine name
- Process parameters
- Jigs / Fixtures
21 Are the special process parameters qualified and are they specified
25 Capability studies shall be taken for dimensions which are prone to vary during the
process
26 Change management agreement addressed in quality plan.
SQA Engineer:
Date Format : PPAP A&B / 01
PPAP Checklist ( Category : C )
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
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
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
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)
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
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
Guidelines :
Atleast 2 tools to be used, 3 or more tools preferable.
Narrate briefly the QC tool used.(Provide attachments wherever necessary)
SUPPLIER
METHOD MACHINE
1 1
2 2
3 3
4 4
5 5
DEFECT CLASSIFICATION
OCCURRENCE
DETECTION
SUPPLIER
HORIZONTAL DEPLOYMENT ON SIMILAR PARTS / PROCESSES:
YES NO (Furnish details if YES)
YES NO
OYES NO
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)
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.
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
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
Auditor/s Signature & Date Reviewed by Signature & Date Approved by Signature & Date Auditee / Process Owner Signature & Date
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)
Quality Certifications
Certifying Body
Quality issues :-
Last 6 months PPM At BI : At Supplier end :
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
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
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
Rating
Failure Analysis, Corrections, Continual Achieved Reference
6 0, 4, 6, 8, % Score
improvements Score score
10
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 - - - -
FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process Audit
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
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
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
3) Control
#DIV/0!
Plan Does CP address corrective actions in case of non
1.3.07
conformities (Reaction plan)?
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
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
2.2.03 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 )
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
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
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
3.1.02 Availability of product drawing, Inspection plan, material history cards etc.
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?
3.1.12 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.)
3.2.07 Shelf life items storage ( Have the Shelf Life Items been identified and validation takes place periodically? )
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
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
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 ?)
4.1.09 Clear identification & separate locations for materials looking alike.
4.1.12 Marked containers for reject/ rework/ adj parts ( Eg. Red bin analysis for rejected parts)
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
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
Machine and process capability evidences for important characteristics and process
4) Production Stage
4.2.07
parameters
FM/SM/SA/01-Oct07
Brakes India Ltd., Chennai Audit rating check sheet Supplier Process 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
Consumption of Power 5.3.02 Monitoring consumption and action when they are abnormal.
Disposal of oiling
5.5.03 Dispose of the used oil only to Hazardous waste recyclers
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
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
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)
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
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
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
History cards
PM checklist
PM adherence
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
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.
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
attributes
Other
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
PSW Qualified Lab Doc PPAP Check Sheet Conditional Approval Sheet (if Any)
BI – SQA USE ONLY
SQA Engineer to communicate customer window engineer before change implementation if required.
FMEA Number___________________________
Page_____________________of______________
Core Team______________________________________________________________________________________________________________________
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
Plant Date :
Unit Reason : Tick applicable & fill appropriate column
Supplier D.C/ Inv. no. 5. Third party inspection charges (At actuals)
Cost working
1. GR Rejection
Debit note will be raised by finance dept. for all GR rejections.
2. Line Rejection
Administrative cost Total cost
Sign: (Unit Quality Module) Sign: (Unit Supply Module) Sign : (SQA) Sign :(SDI)
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